PI-93010 - Temiskaming Hospital Cogen 01 - Power …powergenysys.com/.../08/PI_09-93010-Temiskaming-Hospital-Cogen.pdfPOWER GENySYS P ROJECT E XPERIENCE I NFORMATION - D ISTRIBUTED

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File: PI-93010 - Temiskaming Hospital Cogen 01.DOC 93010 - Page 1 of 10

Above: Aerial view of the Temiskaming Hospital, New Liskeard, Ontario. Project Description: 1st Hospital Cogeneration System in Ontario (1993)

In 1993 Marsh Energy Inc. was awarded a turnkey contract by the Temiskaming Hospital in New Liskeard to design, build, operate and maintain the 1st hospital cogeneration system in Ontario utilizing a natural gas reciprocating engine-generator.

The system prime-mover is a Caterpillar Model 3406 natural gas fuelled reciprocating engine-generator set, producing 225 kWe of load displacement electricity (no export), approximately 360 lbs/hr of steam at 125 psig from the exhaust heat recovery steam generator, and about 250 kWth of hot water from the oil cooler and jacket water cooling circuits. Heat recovery was not incorporated for the aftercooler circuit.

Under normal operation the plant is unmanned.

A lack of space inside the existing boiler plant facility required the engine-generator set to be located at ground level just outside and adjacent the boiler plant wall (see photos: right & below/left), in an outdoor acoustically treated enclosure, (see next page).

The fire-tube heat recovery steam generator (HRSG) was installed inside the boiler plant on a steel stand directly above large condenser water pumps. Engine exhaust was piped to the HRSG through openings in the boiler room exterior wall, (see photos below).

Temiskaming Hospital New Liskeard, Ontario Service Provider: Marsh Energy Inc., Burlington, Ontario.

Services: ( Provided by: Vito Mike Casola, P.Eng., Engineering Manager, Marsh Energy Inc. ) • Verification of Project Feasibility / Economic Analysis, • Detailed Engineering Design and Drafting, • Equipment Procurement for all Major and Auxiliary Equipment, • Preparation of Contract Documents and Contract Administration, • Project Management and Construction Supervision, • Startup / Commissioning and Operation / Maintenance, • Monthly Operational Reports.

Above: View of Caterpillar 3406 engine-generator set on concrete pad.

Above: View of genset and exhaust piping to/from HRSG in boiler room.

Above: View of HRSG inside boiler room, mounted above condenser pumps.

CAT 3406

GENSET 225 kWe

HRSG (125 psig)

Boiler Plant

Boiler Plant

Temiskaming Hospital

Typ. exhaust piping support bracket Wall opening for JW piping to HX-1

Wall opening for electrical conduits

Vibration Isolation Springs

Concrete Inertia

Pad

Exhaust Outlet

Steel Stand

Wall opening for exhaust piping to HRSG



View of outdoor enclosure, muffler, heat dump radiator, and piping.

Project Description: 1st Hospital Cogeneration System in Ontario (1993), cont… Outdoor Acoustic Enclosure

Due to a lack of space in the boiler plant the engine-generator and other auxiliary equipment had to be installed in an outdoor acoustically treated enclosure adjacent the boiler room.

Engine exhaust was treated with a muffler/silencer mounted on the roof of the enclosure, piped to the HRSG in the boiler room and exhausted to

Temiskaming Hospital New Liskeard, Ontario Service Provider: Marsh Energy Inc., Burlington, Ontario.

atmosphere several feet above the building roof level. The piping was anchored at the wall opening and allowed to expand on wall mounted support brackets equipped with slide guides. A universal tied expansion joint connected to the muffler compensated for all expansion during operation. The stack, supported near the top of the building, was able to expand at the lower 90° elbow. All piping was sloped back to the HRSG where any condensate automatically drains via a float trap.

The jacket water (JW) cooling circuit was connected (smaller pipes) to a plate-frame heat exchanger installed on the outside wall inside the boiler room and to the heat dump radiator on the enclosure roof.

Outdoor acoustic enclosure, radiator, muffler, and piping: Center-Right: Muffler and heat dump radiator mounted on roof of enclosure. Center-Left: Exhaust to HRSG / atmosphere; JW circuit to HX-1 in boiler room.

Outdoor acoustic enclosure, radiator, muffler, and piping: Center: Heat dump radiator mounted on roof of enclosure. Center-Left: Natural gas supply line and regulator; Ventilation air inlet hood.

Acoustic Enclosure

Heat Dump Radiator

Muffler

Exhaust Stack to Atmosphere

Ventilation Air Inlet Hood /

Silencer

Heat Dump Radiator

JW Circuit Coil Aftercooler Circuit Coil

Acoustic Enclosure



Heat Dump Radiator

Acoustic Enclosure

JW piping to Heat Exchanger

Exhaust piping (genset to HRSG)

Supplemental Muffler / Silencer

Universal tied expansion joint

Ventilation Air Outlet Hood /

Silencer

Exhaust piping to HRSG JW

to HX

Exhaust piping (HRSG to stack)

Muffler / Silencer

Concrete Inertia Pad

Gas Supply / Regulator

Universal tied expansion joint in exhaust piping (engine to HRSG)

Elec. conduits (enclosure to boiler room)Typ. wall mounted pipe support bracket

Jacket Water piping (Genset to HX)



Temiskaming Hospital New Liskeard, Ontario

Service Provider: Marsh Energy Inc., Burlington, Ontario.

Project Description: 1st Hospital Cogeneration System in Ontario (1993), cont…

Outdoor Acoustic Enclosure - Inside

The outdoor acoustic enclosure houses the prime-mover (Caterpillar 3406 genset) and other auxiliary equipment.

Mounted on the enclosure roof is the heat dump radiator, and muffler connected to a universal tied expansion joint, which compensates for all expansion of the exhaust piping to the HRSG during operation (photo, right).

The auxiliary equipment inside the enclosure includes the electrical control panel and utility interface / sensing panel, a genset battery charger, the neutral grounding resistor and electrical unit heater, a ventilation air fan, dampers and silencers, lube oil filter, jacket water (JW) cooling circuit circulation pump, JW thermostatic 3-way mixing valve and balance valves, and the JW and aftercooler circuit piping from the genset to the radiator, (photos, below left and right).

View of acoustic enclosure entrance and genset / auxiliary equipment inside

View inside outdoor acoustic enclosure. Left: Insulated turbocharger and exhaust pipe through enclosure roof. Center-Right: JW thermostatic mixing valve, ventilation fan & motorized damper.

View inside outdoor acoustic enclosure. Center-top: Ventilation air fan and motorized damper, JW balance valves. Center-bottom: Lube oil filter, JW circulation pump.

Engine Exhaust Utility Interface / Sensing Panel Caterpillar 3406 Genset

Jacket Water Coil

Aftercooler Coil

Universal Tied Expansion Joint Muffler

Expansion Tanks

Acoustic Enclosure Entrance Door

Engine Exhaust

Ventilation Air FanMotorized Damper Utility Interface

/ Sensing Panel

Battery Charger

Lube Oil Filter

Thermostatic Mixing Valve

Genset

Ventilation Air Fan

JW Circ. Pump

Genset




Project Description:

1st Hospital Cogeneration System in Ontario (1993), cont…

Outdoor Acoustic Enclosure - Inside, cont…


Inside enclosure: JW thermostatic 3-way mixing valve, ventilation fan.

Inside enclosure: Ventilation fan, JW circuit balance valves, electrical cables.

Inside enclosure: Jacket Water Circulation Pump. Inside enclosure: Startup & Commissioning - Balancing JW cooling circuit.

Inside enclosure: Utility interface/sensing panel, genset power and control panel. Inside enclosure: Neutral grounding resistor, ventilation inlet damper, gas train.

JW Thermostatic 3-Way Mixing Valve

Motorized Damper

Utility Interface / Sensing Panel

Natural Gas Train

Genset

Variable Speed

VentilationFan

JW Circuit Balance Valves

JW Circ. Pump

Neutral GroundingResistor

Neutral Grounding Resistor

Acoustic Enclosure Entrance

Door

JW Circuit Balance Valves

Power cables & control wiring

to building

Power Disconnect Switches

Aftercooler circuit piping

Power cables in cable tray from control panel to electrical room

Ventilation Inlet Air Motorized Damper

Normally Closed Manual Bypass

JW from HX-1 JW from Rad

Genset

Genset Power & Control Panel

Electric Unit

Heater

Power cables from generator to control panel

JW to

HX-1

JW to

Rad

JW from Rad

Variable Speed

VentilationFan

Power Disconnect Switches

JW from HX-1

Strainer

JW to

Rad

JW to

HX-1






Outdoor Acoustic Enclosure - Inside, cont…

Electrical equipment located inside the enclosure includes the generator power and control panel (see photos right), the utility interface / sensing panel (UIP), neutral grounding resistor and genset battery charger (see photos bottom-left and bottom-right). The UIP includes double (redundant) utility grade protection relays.

The generator power and control panel includes annunciation lights to indicate trouble and warnings. Also included is a generator control switch and control dials / buttons (see photo right-middle). The genset control switch allows for manual and auto operation. Other dials and buttons (left to right in photo) include a voltage adjust dial, an alarm accept button, an emergency stop button, a lamp test button, a frequency adjust dial, and a load set dial.

Genset Power & Control Panel Generator Motorized Breaker: 52-G

Inside enclosure: Utility interface/sensing panel, Battery charger

Inside enclosure: Battery charger

Battery Charger

Battery Charger

Genset Power & Control Panel

Generator Breaker

Annunciation Lights

Genset Synchronization

Annunciation lights

Engine control switches and buttons

Utility Interface / Sensing Panel






Jacket Water / Oil Cooler Circuit Heat Recovery: Boiler Room

The prime-mover (Caterpillar 3406 genset) Jacket Water (JW) and Oil Cooler are combined in a single cooling circuit. This JW cooling circuit was connected to a plate and frame heat exchanger (HX-1), inside the boiler room on the outdoor wall adjacent to the outdoor enclosure, to recover this thermal energy in the form of hot water (photos, right).

The JW cooling circuit was also connected in parallel with the heat dump radiator, mounted on the roof of the enclosure. The radiator was sized for 100% cooling of the both JW and Aftercooler circuits.

The other side of HX-1 is connected to the building’s hot water heating (HWH) system. A circulation pump draws HWH from a branch line connected to the HWH main return line (upstream of the heating boilers) to HX-1 where it is heated by the JW circuit and returns it back to the same heating return line (downstream of the extraction point).

JW Heat Recovery: Heat Exchanger (HX-1), HWH to/from HX-1/Boiler Return.

HWH Circulation Pump, Turbine Flow Meter with normally closed bypass.

Cogeneration system hot water heat recovery tie-in to hot water boiler return.

JW HX-1, JW to/from genset, HWH to/from HX-1, BTU meter.

Genset

JW from HX-1 to genset JW from genset to HX-1

Strainer

JW Cooling Circuit

Heat Exchanger

HX-1

Circ. Pump

Normally Closed Manual Bypass

Hot Water Heating (HWH) Boiler Return Line to HX-1 HX-1 to Boiler Return Line Flow Meter to be installed

Auto Air Vent (AAV)

Turbine Flow Meter

HWH: HX-1 to

Boiler Return

HWH: Boiler Return to HX-1

HWH Circ.

Pump

JW: HX-1 to gensetJW: genset to HX-1

Heat Exchanger

HX-1

Manual Bypass

RTD

RTD

BTU Meter

HWH:Boiler Return to HX

HWH:HX to Boiler Return

Circ. Pump

Strainer

BoilerFeedwaterto HRSG

Temp. Gauge

HWH:from HX-1

HWH:Boiler Return to HX-1

HWH: HX-2 to Boiler Return

HWH:HX-1

to HX-2

HWH Boiler Return

Manual Bypass

Hot Water Heating Boiler

B-1

JW: HX-1 to genset

JW: genset

to HX-1

BlowdownLine

TurbineFlow Meter






JW thermal energy transferred to Domestic Hot Water: Boiler Room

The previous page outlines how thermal energy recovered from the cogeneration system JW circuit is transferred to the building’s hot water heating (HWH) system via HX-1.

Part of this thermal energy is diverted to a secondary shell-and-tube heat exchanger (HX-2) (photos, middle left/right), via a branch HWH circuit (photos, bottom-left, middle-right) where it is transferred to heat domestic water, stored in a new primary storage tank (photos, top-right, middle-left).

A new circulation pump (photo, bottom-right), circulates domestic water between an existing domestic hot water storage tank (not shown) and the new primary DHW storage tank, with domestic water being heated by the thermal energy recovered from the cogen JW circuit via HX-2/HX-1.

Domestic Hot Water Storage Tank heated by cogen via JW HX-1 HX-2.

Domestic Hot Water Storage Tank heated by cogen via JW HX-1 HX-2.

Branch HWH circuit from HX-1 to HX-2 for heating DHW.

Cogeneration system hot water heat recovery tie-in to boiler return & HX-2.

Domestic Hot Water Circ. Pump: Existing DHW storage tank to new storage tank.

New Primary DHW Storage Tank

heated by cogen system: JW HX-1 HX-2

HX-2 to be installed on metal stand

DWH

DWH

HX-2

Thermostatic 3-way mixing valve

New PrimaryDHW Storage Tank heated by cogen:

JW HX-1 HX-2

HX-2

Thermostatic3-way mixing valve

Circuit Balance

Valve

Circuit Balance

Valve

HWH branch circuit:HX-1 HX-2 Boiler Return

Circulating Pump:Circulates domestic water between an existing DHW storage tank and the new DHW storage tank with DHW heated via HX-2.

HWH:from HX-1

HWH:Boiler Return

to HX-1

HWH Boiler Return

Hot Water Heating Boiler B-1

HWH branch: HX-2 Boiler Return

HWH branch: HX-1 HX-2

CircuitBalance

Valve

DWH

DWH





Project Description: 1st Hospital Cogeneration System in Ontario (1993), cont…Engine Exhaust Heat Recovery via Heat Recovery Steam Generator: Thermal energy is recovered from the engine exhaust as high pressure steam. Approximately 360 lbs/hr of steam at 125 psig is generated by a Heat Recovery Steam Generator (HRSG) located inside the boiler room.

Engine Exhaust Heat Recovery Steam Generator (HRSG).

Engine Exhaust Heat Recovery Steam Generator (HRSG).

HRSG: Boiler Feedwater Line, Feedwater Valve, and Chemical Feed Line.

Foreground: HRSG Boiler Feedwater Pumps. Background: HX-1 & JW/HWH piping.

HRSG, Boiler Feedwater Line and Metering, and Blowdown Line.

HRSG Steam Supply, Backpressure Valve, and Excess Steam Blowoff.

HRSG steam supply tie-in to main steam header, HWH to/from boiler return/HX-1.

Engine Exhaust Heat Recovery

Steam Generator ( HRSG )

360 lbs/hr Steam @ 125 psig

HX-1

Feedwater Meter

Steam Boiler Feedwater Pumps

Clorius Boiler FeedwaterMagnetic Flow Meter

ExhaustINLET

ExhaustOUTLET

Engine exhaust condensate (drained through float trap)

HRSG drain

ChemicalFeed Line

HRSG 360 lbs/hr

@ 125 psig

ExhaustOUTLET

Boiler Feedwater Line to pneumatic

Feedwater Valve

Feedwater Manual Bypass

ChemicalManual Bypass

Chemical Feed Line

Water Level Control Station

Pneumatic Feedwater

Valve

Feedwater connection

To blowdown tank

Combimeter 3 VPD

Blowdown

Meter

Feedwater


(B-3)

To blowdown tank

Feedwater

Bypass


(B-3)

JW to HX-1

HWH: HX-1 toBoiler Return

Blowdown


HRSG


HWH: HX-1 to Boiler Return

125 psig HRSG steam tie-in to steam header Steam Header

Isolation Valve

HRSG Steam Supply

125 psig HRSG steam

supply to main steam header

Backpressure Steam Valve

(Set at 125 psig) Excess Steam Blowoff Valve

(Set at 135 psig)

Excess Steam Blowoff Outlet to atmosphere

Condensate to float trap

HRSG Steam Supply

P O W E R G E N y S Y S - P R O J E C T E X P E R I E N C E I N F O R M A T I O N - D I S T R I B U T E D G E N E R A T I O N




Project Description: 1st Hospital Cogeneration System in Ontario (1993), cont… Drawing M-4: Outdoor Enclosure – PLAN Layout: Plan View of Outdoor Enclosure, Radiator, Exhaust Piping, HRSG, HX-1 and JW Piping.





Project Description: 1st Hospital Cogeneration System in Ontario (1993), cont… Drawing M-5: Outdoor Enclosure - South Elevation: Elevation View of Outdoor Enclosure, Radiator, Exhaust Piping, JW Piping and Gas Supply.





Project Description: 1st Hospital Cogeneration System in Ontario (1993), cont… Drawing M-6: Outdoor Enclosure – West Elevation: West Elev. of Outdoor Enclosure, Radiator, Exhaust & JW Piping, HRSG, HX-1 & Gas Line.





Project Description: 1st Hospital Cogeneration System in Ontario (1993), cont… Drawing M-7: Inside of Outdoor Enclosure – Layout & Elevation: Views inside enclosure: Genset, Gas Train, Circ. Pump & Piping, Vent Fan, & Elec. Panels.





Project Description: 1st Hospital Cogeneration System in Ontario (1993), cont… Drawing M-8: Inside of Outdoor Enclosure – Ceiling Plan & Inside Wall Elevations: Views inside enclosure: Cooling Circuit Piping & Pump, Vent Fan, & Elec. Panels & Cables.





Project Description: 1st Hospital Cogeneration System in Ontario (1993), cont… Drawing M-9: Inside Boiler Room – North Wall Elevation: View of HRSG, Level Control Station, Boiler Feedwater, Energy Meters, HX-1 & JW Piping.