UW‐Madison
September 13, 2012
Wisconsin Public Utility Institute
Gas: What’s in the Pipeline?
Making the Switch to Gas: Utility Infrastructure Needs and a Case Study of a Coal‐to‐Gas Plant Conversion
Jeff Pollei, UW‐Madison
Agenda
 Campus Overview and Utility Summary
 Evolution of Heating Plants
 CSHP Plant History
 CSHP Legal History
 CSHP Rebuild Project
 Plant Dispatching
CSHP Rebuild Project and Campus Utility Infrastructure Requirements
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UW‐Madison
September 13, 2012
University of Wisconsin Overview
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Founded in 1848
12 Schools/Colleges
Enrollment of 42,099
>18,500 Employees and Faculty
 20.6 Million GSF on 935 Acre Main Campus (>27.0 Million Total)
Campus Overview (Before March 2012)
West Campus Cogeneration Facility (WCCF)
• 400,000 PPH Steam
• 20,000 Tons Chilled Water (Electric)
• 100 MW Combustion T/G (Nat. Gas)
• 68 MW Extraction/Condensing T/G
Walnut Street Heating Plant (WSHP)
• 600,000 PPH Steam (Nat. Gas)
• 11,000 Tons Chilled Water (Electric) • 9,000 Tons Chilled Water (Steam)
CSHP Rebuild Project and Campus Utility Infrastructure Requirements
Charter Street Heating Plant (CSHP)
• 500,000 PPH Steam (Coal)
• 300,000 PPH Steam (Nat. Gas)
• 26,000 Tons Chilled Water (Steam)
• 9.7 MW Back Pressure T/G 2
UW‐Madison
September 13, 2012
Campus Overview
Campus Overview (January 2015)
West Campus Cogeneration Facility (WCCF)
• 400,000 PPH Steam
• 30,000 Tons Chilled Water (Electric)
• 100 MW Combustion T/G (Nat. Gas)
• 68 MW Extraction/Condensing T/G
Walnut Street Heating Plant (WSHP)
• 600,000 PPH Steam (Nat. Gas)
• 11,000 Tons Chilled Water (Electric) • 9,000 Tons Chilled Water (Steam)
CSHP Rebuild Project and Campus Utility Infrastructure Requirements
Charter Street Heating Plant (CSHP)
• 900,000 PPH Steam (Nat. Gas‐New)
• 300,000 PPH Steam (Nat. Gas‐Existing)
• 26,000 Tons Chilled Water (Steam)
• 9.7 MW Back Pressure T/G 3
UW‐Madison
September 13, 2012
Campus Utility Summary
 Steam Summary
• 2,100,000 PPH Total (2014)
• 1,800,000 PPH Firm
• 1,316,000 PPH Peak
 Chilled Water Summary
• 76,000 Tons Total (2015)
• 67,500 Tons Firm
• 64,000+ Tons Peak
 Electrical Summary
• 71 MW Peak
Evolution of Heating Plants
 Radio Hall
1887 – 1908
 Ag Bulletin
1889 – 1908  Service Building Annex
1908 – 1958  Charter Street Heating Plant
1958 – Present  Walnut Street Heating Plant
1975 – Present  West Campus Cogeneration Plant
2005 – Present
CSHP Rebuild Project and Campus Utility Infrastructure Requirements
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UW‐Madison
September 13, 2012
Evolution of Heating Plants
 Main Campus
Radio Hall 1887 – 1908
Evolution of Heating Plants
 Agriculture Campus
Ag Bulletin 1889 – 1908
CSHP Rebuild Project and Campus Utility Infrastructure Requirements
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UW‐Madison
September 13, 2012
Evolution of Heating Plants
 Campus Aerial, ca. 1900
Evolution of Heating Plants
 Central Heating Plant
Service Building
Annex
1908 – 1958
CSHP Rebuild Project and Campus Utility Infrastructure Requirements
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UW‐Madison
September 13, 2012
Evolution of Heating Plants
 Present Configuration
West Campus Cogeneration Facility (WCCF)
Walnut Street Heating Plant (WSHP)
Charter Street Heating Plant (CSHP)
Evolution of Heating Plants
 Present Configuration
West Campus Cogeneration Facility (WCCF)
3.5 + Miles Walkable Tunnel
190 + Steam Pits
? Miles of Inaccessible Box Conduits
Walnut Street Heating Plant (WSHP)
CSHP Rebuild Project and Campus Utility Infrastructure Requirements
Charter Street Heating Plant (CSHP)
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UW‐Madison
September 13, 2012
CSHP Plant History
 Constructed in 1958
 Three 100,000 PPH Spreader Stoker Boilers Manufactured in 1953, Purchased Second Hand From Hudson Motors
 One 200,000 PPH Spreader Stoker Boiler Installed in 1964
 One 300,000 PPH Gas/Oil Boiler Installed in 1970
 Baghouse Constructed in 1985
 Chilled Water Plant Building Additions in 1965 & 1973
 9.7 MW Back Pressure Steam T/G Installed in 1995
CSHP Legal History
 Sierra Club Files Open Records Request in 2006
 Sierra Club Indicates Filing of Lawsuit in December 2006
 Sierra Club Files Lawsuit in May 2007
 On November 7, 2007, the US District Court for Western District of Wisconsin Issued a Decision Finding That Three of Five Projects Between 1996 and 2004 Violated the Clean Air Act’s NSR Provisions
CSHP Rebuild Project and Campus Utility Infrastructure Requirements
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UW‐Madison
September 13, 2012
CSHP Legal History
 US District Court for Western District of Wisconsin Findings
Routine Maintenance, Repair or Replacement (RMRR)
Nature and Extent
Duration
(Days)
Project
Description
1
Boiler 4 Rear Wall
Replacement (73 Waterwall
Tubes and Casing)
45
2
Boiler 4 Side Wall
Replacement (67 Waterwall
Tubes and Casing)
3
Findings
Like-Kind Applicable
CAA
RMRR Replacement
Test
Modification
Purpose
Frequency
Cost
Maintain
Pressure
Integrity
One or Two
Times in
Boiler Life,
Not Routine
$97,300
Yes
N/A
N/A
No
<45
Two or Three
Increase
Times in
Availability and
$77,000
Boiler Life,
Reliability
Not Routine
No
Yes
Actual to
Projected
Actual
No
Boiler 1, 2 and 3 Economizer
Replacement
183
Two Times in
Increase
Availability and Boiler Life, $788,899
Reliability
Not Routine
No
No
Actual to
Potential
Yes
(1)
4
Boiler 1 Stoker Feeder
Replacement
81
Increase Boiler
Two Times in
Efficiency,
Boiler Life,
$90,700
Availability and
Not Routine
Reliability
No
No
Actual to
Potential
Yes
(1)
5
Boiler 4 Stoker Feeder
Replacement and Boiler 1, 2
and 3 Generating Bank/
Superheater Replacement
274
(9 mo.)
Increase Boiler
Efficiency,
Two Times in
Productivity,
Boiler Life, $1,712,348
Availability and Not Routine
Reliability
No
No
Actual to
Potential
Yes
(1)
Modified without preconstruction PSD permit so CSHP is subject to best available control technology (BACT) and must apply for
revised operating permit.
(1)
CSHP Legal History
 Sierra Club Files Open Records Request in 2006
 Sierra Club Indicates Filing of Lawsuit in December 2006
 Sierra Club Files Lawsuit in May 2007
 On November 7, 2007, the US District Court for Western District of Wisconsin Issued a Decision Finding That Three of Five Projects Between 1996 and 2004 Violated the Clean Air Act’s NSR Provisions
 On November 21, 2007, Sierra Club and State of Wisconsin Announce a Consent Decree to Transition Charter Street and 12 Other Coal‐
Burning Facilities
• 15% Coal Reduction at CSHP Beginning 1/1/08
• Feasibility Study for CSHP and CHPP By 7/2008
• Lookback Study for 12 Other Coal‐Burning Facilities By 12/2008 (Eight Univ. of Wisconsin Institutions)
CSHP Rebuild Project and Campus Utility Infrastructure Requirements
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UW‐Madison
September 13, 2012
CSHP Comprehensive Heating Plant Study, July 2008
 Four Options Analyzed
• Option 1 – BACT on Existing Coal Boilers, New Gas Boiler
• Option 2 – Integrated Gasification Combined Cycle Including Six Gasifiers and Two 350,000 PPH Syngas Fired Boilers
• Option 3 – Two 350,000 PPH Gas/Oil Boilers
• Option 4 – Two 350,000 PPH Hybrid Biomass CFB Boilers
Notes:
-
Options 2, 3 and 4 Retire Existing Coal Boilers and Include Back Pressure
Steam Turbine Cogeneration
Options 2 and 4 Capable of Burning Biomass and Fossil Fuels
CSHP Rebuild Project and Campus Utility Infrastructure Requirements
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UW‐Madison
September 13, 2012
CSHP Rebuild Project
 Original Project Scope
• Two 225,000 PPH Packaged Gas/Oil Boilers
• One 350,000 PPH Biomass Boiler w/AQCS and Solid Fuel Handling • Offsite Rail and Bike Path
• 20 MW Back Pressure Steam Turbine Cogeneration
• Balance of Plant Upgrades
• Decommissioning of All Four Coal Fired Boilers
• $250.6 Million Project Cost
CSHP Rebuild Project and Campus Utility Infrastructure Requirements
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UW‐Madison
September 13, 2012
CSHP Rebuild Project
 Concept Diagrams
2010
Conceptual
CSHP Rebuild Project
 Concept Diagrams
CSHP Rebuild Project and Campus Utility Infrastructure Requirements
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UW‐Madison
September 13, 2012
CSHP Rebuild Project
 Project Budget (Enumerated at $250,600,000)
Phase A – Packaged Boilers
$ 20,000,000
Phase B – Biomass Boiler, AQCS and Solid Fuel Handling
111,600,000
Phase C – Offsite Rail and Bike Path
4,400,000
Phase D – Steam Turbine Generator
12,200,000
Phase E – Balance of Plant
36,000,000
Overhead and Contractor Fee
16,000,000
Owners Costs
Total Project Cost
CSHP Rebuild Project and Campus Utility Infrastructure Requirements
200,200,000
50,400,000
250,600,000
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UW‐Madison
September 13, 2012
CSHP Rebuild Project
 Original Project Scope
• Two 225,000 PPH Packaged Gas/Oil Boilers
• One 350,000 PPH Biomass Boiler w/AQCS and Solid Fuel Handling • Offsite Rail and Bike Path
• 20 MW Back Pressure Steam Turbine Cogeneration
• Balance of Plant Upgrades
• Decommissioning of All Four Coal Fired Boilers
• $250.6 Million Project Cost
CSHP Rebuild Project and Campus Utility Infrastructure Requirements
 Revised Project Scope
• Four Two 225,000 PPH Packaged Gas/Oil Boilers
• One 350,000 PPH Biomass Boiler w/AQCS and Solid Fuel w/AQCS and Solid Fuel Handling • Offsite Rail and Bike Path
• 20 MW Back Pressure Steam Turbine Cogeneration
• Balance of Plant Upgrades
• Decommissioning of All Four Decommissioning of All Four Coal Fired Boilers
• $188.3250.6 Million Project Cost
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UW‐Madison
September 13, 2012
CSHP Rebuild Project
November 2010
CSHP Rebuild Project
February 2011
CSHP Rebuild Project and Campus Utility Infrastructure Requirements
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UW‐Madison
September 13, 2012
CSHP Rebuild Project
May 2011
CSHP Rebuild Project
July 2011
CSHP Rebuild Project and Campus Utility Infrastructure Requirements
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UW‐Madison
September 13, 2012
CSHP Rebuild Project
July 2011
CSHP Rebuild Project
October 2011
CSHP Rebuild Project and Campus Utility Infrastructure Requirements
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UW‐Madison
September 13, 2012
CSHP Rebuild Project
January 2012
CSHP Rebuild Project
February 2012
CSHP Rebuild Project and Campus Utility Infrastructure Requirements
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UW‐Madison
September 13, 2012
CSHP Rebuild Project
March 2012
CSHP Rebuild Project
April 2012
CSHP Rebuild Project and Campus Utility Infrastructure Requirements
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UW‐Madison
September 13, 2012
CSHP Rebuild Project
May 2012
CSHP Rebuild Project
May 2012
CSHP Rebuild Project and Campus Utility Infrastructure Requirements
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UW‐Madison
September 13, 2012
CSHP Rebuild Project
May 2012
CSHP Rebuild Project
August 2012
CSHP Rebuild Project and Campus Utility Infrastructure Requirements
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UW‐Madison
September 13, 2012
CSHP Rebuild Project
September 2012
Plant Dispatching
 MG&E Sp‐3
CSHP Rebuild Project and Campus Utility Infrastructure Requirements
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UW‐Madison
September 13, 2012
Plant Dispatching
 MG&E Sp‐3 • Generation Credit
• $0.12329 per kW per Day
• Special Terms & Provisions
• UW Owns a Share of WCCF (100% Chilled Water, 25% Thermal)
• WCCF Generators are Operating, Chillers Receive Station Service, No Demand
• WCCF Off (Available), On‐Peak, 8,500 Btu/kWh Heat Rate (Daily or FOM Gas)
• WCCF Off (Available), Off‐Peak, Sp‐3, No Demand
• WCCF Off (Not Available), Real‐Time LMP Plus 10%
Plant Dispatching
 MG&E LS‐1
CSHP Rebuild Project and Campus Utility Infrastructure Requirements
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UW‐Madison
September 13, 2012
Plant Dispatching
 MG&E LS‐1 + IGD‐1 Distribution ($0.0343/Therm)
Plant Dispatching
 Cooling Season Dispatch Order (Current)
Notes:
• WCCF (1)
20,000 Tons (Electric)
• CSHP
26,000 Tons (Steam) + Cogeneration
• WSHP
9,000 Tons (Steam)
• WSHP
11,000 Tons (Electric)
(1)
No Demand
Plus Demand
In 2015, an additional 10,000 tons will be available at WCCF. This capacity is subject to demand charges.
CSHP Rebuild Project and Campus Utility Infrastructure Requirements
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UW‐Madison
September 13, 2012
Plant Dispatching
 Heating Season Dispatch Order (Current)
• Firm Capacity (Unaffected by Electric “Blips”)
• CSHP
(1) 300,000 PPH + Cogeneration
• WCCF (2)
200,000 PPH (15% Dispatch Benefit)
• WCCF (3) 200,000 PPH (15% Dispatch Benefit)
• Non‐Firm Capacity (Electric “Blips” Can Cause Boiler Trips)
• WSHP/CSHP Notes:
(1)
(2)
(3)
1,050,000 PPH
In 2014, an additional 450,000 PPH of firm capacity will be available at CSHP UW is responsible for uneconomic dispatch costs when WCCF is not selected by MISO (<25 MW)
UW takes additional steam when WCCF is selected by MISO
Plant Dispatching
 MG&E Sp‐3
MG&E Proposed
2013 Rate Case
Current
CSHP Rebuild Project and Campus Utility Infrastructure Requirements
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UW‐Madison
September 13, 2012
Plant Dispatching
 Cooling Season Dispatch Order (Future?)
• WCCF (1)
20,000 Tons (Electric)
No Demand
• WCCF
10,000 Tons (Electric)
Plus Demand
• WSHP
11,000 Tons (Electric)
Plus Demand
• CSHP
26,000 Tons (Steam) + Cogeneration ?
• WSHP
9,000 Tons (Steam)
 Heating Season Dispatch Order (Future?)
• Same as Previous
Questions
CSHP Rebuild Project and Campus Utility Infrastructure Requirements
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