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Albany Medical Center Cogeneration Plant

• • •Massachusetts Energy Efficiency Partnership

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Let Cogen Power Your Future!

We specialize in:• Providing Comprehensive

Cogeneration Services

• Cogeneration Feasibility Studies

• Development of CHP Project Budgets

• Design-Build/EPC Turnkey Power Solutions

• Engaging Third-Party Financing

• Offering Plant Operations Services to Customers

Projects include:• BurrstoneenergyCenterMiCrogrid,utiCa,ny

• gusCenergyBioMassPlant,roMe,ny

• st.JosePh’shosPitalCogenPlant,syraCuse,ny

• avilaretireMentCenter,alBany,ny

• alBanyMediCalCenterCogenerationPlant,alBany,ny

About Cogen Power Technologies

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About Albany Medical Center

• Albany Medical Center Hospital

- 651-bed

- level-itraumaCenter• Albany Medical College

- MdProgram-567students

- graduatestudies-227students• Capital District Psychiatric Center

Northeastern NY’s only academic health sciences center

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Expansion

Phase I • New $360 Million,

350,000 SF Patient Pavilion expansion

- 20operatingroomsuites

- 60Med/surgicalBeds

- 56neonataliCuBeds

- 30adultiCuBeds

Phase II• Future 150,000 SF

expansion plannedEstimatEd

annual stEam usagE

(mlbs)

EstimatEd annual stEam

Cost ($)

Est. annual ElECtriCal

Consumption (kWh)

Est. annual ElECtriCal

Cost pEr kWh ($)

annual pEak ElECtriC

dEmand (kW)

total Est. ElECtriCal

dEmand Cost ($)

Existing Campus 185,403 $2,781,039 52,103,740 $5,731,411 9,257 $805,504phasE i addition 22,618 $339,268 8,838,713 $972,258 1,103 $113,506phasE ii addition 9,694 $145,416 3,788,019 $416,682 473 $48,217

total 217,715 $3,265,723 64,730,472 $7,120,351 10,833 $966,277

EstimatEd annual stEam Cost

$3.3 M

EstimatEd annual ElECtriC Cost

$8.1 M

EstimatEd total Costs for nEW Campus

$11.4M

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Feasibility Study

Identified objectives• Flexibility in how energy needs – electric and steam - are met

• Firmer control over costs and budgets

• Reduced carbon footprint

• Opportunities for further expansion in the long term

Total Estimated Plant Cost $24,000,000M

Estimated Annual Savings $2,790,044

Simple Payback 9years

Internal Rate of return 10%

NYSERDA GRANT (CHP Incentive) $2,000,000

RecommendationPrime Mover

• Mercury 50 Gas Turbine Generator

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Project Site

• Dense urban location

• Hilly site

• Surrounded by delivery truck driveway

• No laydown area

• Existing daycare center

• Steam pipes, running from the boiler plant to the hospital, crossing overhead on concrete piers

• Must phase work around active uses

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Construction

• Construction began while daycare was still in use

• Built into the side of the hill, the plant was constructed one half at a time

• First, a tunnel for new steam lines was dug into the hill

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• Once the lines were connected, the old lines were dismantled, and the foundation and the new building were constructed in phases over the tunnel

• New two-story 23,000 SF facility

• Structural steel frame

• Brick-colored precast insulated panels (sound deadening, R-value, and ease of assembly)

• Building was completed under schedule and under budget

Construction

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Project Overview• New 25,000 SF Building

• $23 Million Contract Value

• $500,000 in Value Engineering Reductions

• 8 year Simple Payback

• Generating Electrical Power & Steam

• Natural Gas Fired

• Operations in Unison with Utility

• Automated Load Shed System

• Broke Ground - March 2011

• Operational - March 2013

Albany Medical Center Cogeneration PlantAlbAny, ny

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First Floor Plan

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Technology

• 4.6MW Solar Mercury 50 Gas Turbine (Expandable to 9.2 MW)

• Rentech HRSG - 60,000 lbs/hr of Steam (Expandable to 75,000 lbs/hr) Diverter Damper

• 2 - 530 ton York Absorption Chillers (Expandable to 2,500 tons)

• Industrial Steam Condensate Tank & D/A (De-aerator) Tank

• Rockwell Load Management System

• JJ Crewe Gas Compressor

• 750 kw Caterpillar Black Start Generator

• Designed for Expansion for: - 2nd Mercury 50 Turbine - 2nd HRSG - 13,000 lbs/hr - Steam Absorption Chillers - 1500 tons

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Turbine

Solar Mercury 50 - 4.6 MW• 10 Stage Axial Compressor

• 2 Stage Recuperated Turbine

• Recuperation - Low NOx (Nitrogen Oxide)

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HRSG (Heat Recovery Steam Generator)

Rentech Boiler Systems • 13,000 lbs/hr of Steam - Unfired

• 60,000 lbs/hr of Steam - Fired

• Diverter Damper

• Peabody - Coen Burner

• Steam produced in HRSG delivered to hospital steam header

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Gas Compressor

JJ Crewe• 1000 scfm at 225 psi

• 60,000 lbs/hr of Steam - Fired

• Aerzen screw compressor

• Slide valve/recycle valve capacity control

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Chillers

York YK• (2) 530 Tons

• R134-A Refrigerant

• Full Load .587 kw/ton NPLV = .362 kw/ton

• VFD

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Controls

Rovisis SCADA System• Distributed PLC Control

- Allen Bradley - Monitor Only

• BOP Controls & Chiller Plant - Johnson Metasys

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Black Start Generator

Caterpillar• 750 kw

• Diesel

• Synch to 480v Bus and Turbine

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Load Management System

Rockwell• Control the import of real and reactive

power from the utility by controlling the turbine output

• Automatically calculates the number of breakers (12 controlled) that need to be shed to maintain the turbine (with a response time of 78 msec or less) upon loss of the utility.

• Provide manually initiated, automatic synchronization across both utility breakers and/or tie breaker

• Allow operators to remotely trip both utility breakers, tie breaker, or 12 feeder breakers

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Electrical Interconnection

• Identified milestone schedule early in project

• Worked with National Grid to finalize schedule

• Held coordination meetings every 2 to 4 weeks

• Existing services (2) were @ 34.5 kV

• Uncovered coordination issue with hospital breakers

• Completed all necessary design and obtained National Grid authorization to synchronize 14 months after first coordination meeting

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Environmental Benefits

Gas Hog!

3,478 Cars

REDUCES EMISSIONS OF CARBON DIOxIDE (CO2) BY 20,000 TONS PER YEAR

Taking 3,478 Cars off the RoadEqUAL TO:

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Challenges

1. Construction site

- a.Borderednumerousresidentialhomes

- b.Borderedtheonlydeliverytruckentrance

- c.existingsteamlines

- d.daycarelocatedonconstructionsite

- e.Coordinationwiththe$360Mexpansionprojectongoingatsametime

2. Electrical Infrastructure

- a.as-Builddwgsnot100%accurate

- b.existinghospitalbreakerswerenotcoordinatedwithutilitybreakersettings

- c.oneoftwo15MWmain34.5kvto13.2kvtransformershadfailed“C”phasewinding

solution=ChP/Cogeneration- d.temporaryreplacementwasonly5MWanddelayed“synchronization”by6months

- e.the15MWreplacementhadasixmonthleadtime3. Hospital Steam Load

- a.turbine/hrsgsteamproduction&existingboilerhouse

- b.excessivecyclingofhrsgductburner4. Hospital Staff Training

- a.trainingprovidedduringprojectconstructionandprojectcommissioning

- b.KeyhospitalFacilitydirectorleftonemonthprior toPlantturnover

- c.hospitalstaffstillacclimatingtohavingPrimePoweronsite

- d.Followuptrainingtobeprovidedat6monthmark

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Questions?

Contact:

John Moynihan

(518)213-1090

jmoynihan@powerbycogen.com