TEG has been selected by Youngstown Thermal (YT) to provide engineering services for the design, engineering and construction administration for a new gas turbine co-generation system at their downtown Youngstown, OH DHC facility. The project is being developed in partnership with EPRI, Energy Industries of Ohio and DOE to host the AUSC Com Test of experimental materials and turbine technology designed to operate at 1,400°F. TEG will be responsible for infrastructure upgrades, design and engineering for modifications needed for the existing DHC plant to serve as the host facility including interface with the Com Test systems. The services include design, engineering and construction administration for the new co-generation system including 15 MW combustion turbine, HRSG to provide HP steam to a 20 MW steam turbine generator and for the Com Test superheater and turbine. High temperature steam from the Com Test turbine will be available to be inducted into the steam turbine generator and supplement the 150 psig DHC system. Equipment procurement and construction is anticipated to begin in the fourth quarter of 2016.
Estimated Value of Construction - $50,000,000
TEG has again been selected by GSA to upgrade the combined heat and power (CHP) system originally designed by TEG. TEG served as the lead engineer and designer for the expansion of GSA's DHC system in Washington, D.C. and introduced CHP into their operations to include 11 MW of co-generation and modification of an existing coal-fired boiler to operate as heat recovery steam generator. The most recent project involves developing modifications to the chilled water control system to optimize the chiller plant operation. The optimization program will include monitoring remote usage and pumping pressures, realtime chiller performance, realtime steam production cost and realtime electric power cost. The key to achieving operating cost savings is to switch from electric to steam driven chillers based on realtime production cost and divert electric power produced by the co-generation system to the electric power grid for sale.
Estimated Value of Construction - $200,000
TEG performed the initial development stages for introducing CHP to the Metro Nashville District Energy System (MNDES) to significantly reduce overall operating cost while providing reliable back-up electrical energy to Metro's proposed downtown flood protection system. The new co-generation system will provide emergency electrical power to a river water pumping system proposed to protect the First Avenue and the lower SoBro area from flooding as was experienced in the spring of 2010. During normal operation, the new co-generation system will produce up to 7 MW of electric power and reduce both the electrical demand and energy currently being purchased from Nashville Electric Service (NES), the local TVA power distributor. Heat recovered will produce up to 150,000 lbs/hr (with supplemental firing) of steam for distribution to MNDES customers. TEG analyzed appropriate alternative technical configurations to satisfy the MNDES heat cycle while meeting the energy requirements of the flood-water pumping system as well as the Energy Generating Facility's electric demands. TEG defined the optional equipment selections and prepare the conceptual design. TEG prepared the requisite probable project construction, operation and maintenance cost analysis and develop the LCCA to determine the project will satisfy an acceptable ROI. The economic overview is extremely favorable and the project is expected to be operational in the second quarter of 2017.
Estimated Value of Construction - $25,000,000
TEG was awarded the design and project administration services contract for constructing a steam and condensate pipeline to serve the General Motors (GM) Assembly Plant in Hamtramck, MI. The new services, consisting of a 20" high pressure steam main and 6"condensate return line, extend approximately 7,200 feet from the municipal solid waste-fueled co-generation facility to the Hamtramck facility's powerhouse. The design included modification to three separate boiler plants. The steam is primarily supplied from extraction steam from the co-gen facility. To achieve the desired steam export, significant modifications were required to the co-gen systems controls, process extraction, desuperheating and condensate systems. The GM facility receiving the services required modification to facilitate delivery of externally generated steam, manage return of condensate and lay-up the existing coal and gas-fired boilers with hot stand-by provisions. A third boiler plant which provides back-up steam service to the waste-to-energy (WTE) facility required re-rating of two large package boilers to a higher operating pressure required to enable these boilers to provide the high pressure backup steam to the GM facility. In addition to boiler modifications, new steam export piping was installed, along with feedwater system modification to facilitate the higher pressure, control system modification to enable dual-pressure operation of the re-rated boilers and replacement of economizers of both boilers to facilitate the required capacity.
Estimated Value of Construction - $12,000,000
TEG was selected as the lead design engineer and project administrator for the development of a wood-fired co-generation facility in Ontario, Canada. The facility consists of a wood-fired circulating fluidized-bed boiler capable of producing 187,393 pph of steam at 1,421 psia and 1,005°F, one 10 MWe condensing extraction steam turbine (TG1), one 5 MWe back-pressure steam turbine (TG2), a 150 mmBTU/hr steam re-boiler, 80 mmBTU/hr steam to hot water heat exchanger and corresponding distribution systems, a carbon-dioxide capture and recovery system and a flue gas capture and recovery system along with all necessary ancillaries.
Estimated Value of Construction - $45,000,000
TEG provided design and project site surveillance for the installation of an 11 MW combined heat and power project that began commercial operation in 2004. An existing coal-fired boiler was modified into a waste heat recovery boiler that would receive exhaust gas from two new combustion turbines. Tube surface was added to the boiler's convection section and the air heater was replaced by an economizer. The modifications also included the installation of a natural gas-fired burner within the bottom portion of the boiler's furnace to take advantage of the hot oxygen-rich turbine exhaust, increasing efficiency of the combined cycle boiler operation.
The modified boiler recovers sufficient heat from the exhaust of the two combustion turbines to produce 50,000 lbs/hr of saturated steam at 250 psig without supplemental firing. The burner system installed in the bottom of the boiler's furnace section can fire another 195 mmBTU/hr. The modified boiler has a capacity of 242,000 lb/hr, yielding a total system efficiency that exceeds 84% (BTU's fuel in on a HHV basis to BTU's of electric and thermal output).
This boiler is one of six in the facility that supplies steam to a district energy steam system. The facility also includes a chilled water plant that was modified as part of the project. The modified chiller plant includes eight new 2,200 ton chillers, two of which are steam turbine-driven. At peak electrical periods, the two steam turbine-driven chillers can utilize steam produced by the combustion turbine waste heat recovery system, giving operators the ability to shed over 3 MW of electrical consumption, thus increasing the amount of electric power available for sale back to the local Utility.
Although the boiler capacity was increased by 22,000 lb/hr and the chiller plant capacity was increased by over 6,000 tons, the new equipment and systems were designed to fit within the space confines of the existing facility. Additionally, all modifications to the boiler and chiller plants were performed while the facility remained in full production.
Estimated Value of Construction - $60,000,000