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ERDC/CERL TR-04-23Central Heating and Power PlantConversion at Fort Wainwright, AKHeating Only with Backup Generation OptionConstruction EngineeringResearch LaboratoryJohn L. Vavrin, Noel L. Potts, John Westerman,Robert Lorand, Charles Schmidt, Raymond Heintel,and Michael R. KemmeApproved for public release; distribution is unlimited.November 2004
ERDC/CERL TR-04-23November 2004Central Heating and Power Plant Conversion atFort Wainwright, AK: Heating Only with BackupGeneration OptionJohn L. Vavrin, Noel L. Potts, and Michael R. KemmeConstruction Engineering Research LaboratoryPO Box 9005Champaign, IL 61826-9005Charles Schmidt and Raymond HeintelCharles Schmidt & AssociatesJohn Westerman and Robert LorandScience Applications International Corporation, Germantown, MDFinal ReportApproved for public release; distribution is unlimited.Prepared forU.S. Army Corps of EngineersWashington, DC 20314-1000UnderWork Unit No. CFM; Task GB22
iiERDC/CERL TR-04-23ABSTRACT: The Fort Wainwright (FWA) military community has a critical need to establish its power and heatingrequirements to successfully complete a series of planned capital improvements. The CHPP upgrade coincides with anexpansion of FWA’s mission within the next 5 years. To help the installation successfully complete these changes withinthe specified time frame, the Construction Engineering Research Laboratory (CERL) conducted an independent technicalassessment of the FWA CHPP. This follow-on study, which was completed in April 2003, expanded on the recommendation of previous work to convert the installation CHPP to heating only, and to purchase all electricity from the local electric utility.DISCLAIMER: The contents of this report are not to be used for advertising, publication, or promotional purposes.Citation of trade names does not constitute an official endorsement or approval of the use of such commercial products.All product names and trademarks cited are the property of their respective owners. The findings of this report are not to beconstrued as an official Department of the Army position unless so designated by other authorized documents.DESTROY THIS REPORT WHEN IT IS NO LONGER NEEDED. DO NOT RETURN IT TO THE ORIGINATOR.
ERDC/CERL TR-04-23ContentsList of Figures and Tables . viiConversion Factors . xPreface. xi1Introduction . 1Background. 1Objective . 2Approach . 2Scope. 2Mode of Technology Transfer . 32Plant Overview . 4Summary of Existing Mechanical Systems. 4Summary of Existing Electrical Systems . 5Summary of Existing Control System . 5Summary of Existing Projects. 6Summary of Planned Projects . 6Reliability . 6FWA Mechanical Systems . 6FWA Electrical Infrastructure . 63GVEA Power System Reliability . 10Historical Outages . 10Power Outage Prevention. 10GVEA Backup Power Generation. 14Supply and Transmission Issues . 14Conclusions on GVEA Reliability. 15Conclusion . 154FWA Existing Loads . 16Electrical . 16Heating. 165FWA Load Growth. 21Planned Projects. 21iii
ivERDC/CERL TR-04-23Electrical . 21Heating. 226Project Options . 27Option 1 Overview . 28Option 2 Overview . 297Conversion to Heating Only Design Considerations . 31Required Control System Modifications . 31Option 1: System Modification . 31Option 2: Total Replacement . 32Option 3: Upgrade to the “Ovation” System. 32Recommended Approach . 32Cost Comparison. 33Steam System Modifications . 33Conversion to 100 psig at 470 F . 33Pressure Reducing Stations . 33Required Modifications . 34Optional Modifications Considered . 34Recommended Approach . 34Mothball Steam Turbines . 35Required Changes to the Steam Turbines . 35Options Considered. 35Recommended Approach . 36Electrical Switchgear . 37Required Modifications . 37Options Considered. 37Recommended Approach . 38Electrical Substations . 38Existing Substations . 38New Substations. 39Substation Size. 39Substation Location . 40Recommended Approach . 41Budgetary Costs . 42Explanation of Approach. 43Heat Plant Backup Electrical Generation . 44Minimum Requirements. 44Options Considered. 45Recommended Approach . 45Installation Critical Electrical Loads . 46Existing Backup Generators . 46
ERDC/CERL TR-04-23Heating System . 46Critical Equipment . 46Critical Buildings . 47Load Shedding and Load Shaving. 47Options Considered. 49Option 1— Total Installation Backup . 49Option 2— Backup for Critical Loads Only (Distributed Generation) . 50Option 3— Backup for Critical Loads Only (Centralized Generation) . 51Recommendation . 528Cost Estimate Details . 53Construction Costs . 53Controls . 54Steam Conversion . 55Mothball Turbines . 56Switchgear . 56Substations . 57CHP Backup Generators . 58Critical Load Backup Generators. 59Operational and Maintenance Costs . 61Diesel Fuel Costs . 61Generator Routine Maintenance Costs . 61PRV Maintenance. 619Lifecycle Cost Analysis. 65Key Assumptions of the Analysis. 65Life Cycle Cost Summary . 6510 Environmental Considerations . 69Introduction . 69CHPP Boiler Impacts on Emissions of Air Pollutants . 70Potential Environmental Impacts of New Substations . 76Stormwater Runoff Management During Construction and Operation. 76Possible Adverse Health Impacts on Nearby Residents During the Operational Phase ofthe Project . 76Noise Impacts . 77Cumulative Environmental Impacts . 77Conclusions . 77Potential Environmental Impacts of Backup Power Generators. 78Air Quality Impacts. 78Noise Impacts . 85Stormwater Runoff Management During Construction and Operation. 86Odors. 86v
viERDC/CERL TR-04-23Flood Hazards and Encroachment on Wetlands . 86Protection of Historic Properties . 86Summary/Conclusion. 8611 Anti-Terrorism/Force Protection. 89Location of New Infrastructure. 89New Electrical Substations . 89Backup Generator Housing . 9012 Summary and Recommendations. 91Control System . 91Requirement . 91Option Selected . 91Steam System Modifications . 91Requirement . 91Option Selected . 92Mothball Steam Turbines . 92Requirement . 92Option Selected . 92Electrical Switchgear . 92Requirement . 92Option Selected . 92Electrical Substations . 92Requirement . 92Option Selected . 93Heat Plant Backup and Electrical Generation . 93Requirement . 93Option Selected .
ERDC/CERL TR-04-23 November 2004 Central Heating and Power Plant Conversion at Fort Wainwright, AK:
