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Calista Region Energy Needs Study Part 1 Final Report Vol. 4 (Appendix C) 2002
CALISTA REGION ENERGY NEEDS STUDY PARTI NUVISTA LIGHT & POWER , INC. 301 Calista Court Anchorage, Alaska FINAL REPORT VOLUME 4 (APPENDIX C) July 1, 2002 Frank J. Bettine, P.E., Esq. 1120 E. Huffman Road, PMB 343 Anchorage, AK 99515 (907) 336-2335 Cl C.2 C3 C.4 C.5 C.6 C.7 C8 C9 APPENDIX C INFORMATION ON NOVAGOLD COAL PLANT DESIGN AND COST INFORMATION 5 MW & 15 MW ° 80MW SWGR TRANSMISSION SYSTEM 1. SWGR Minimum Cost Transmission System 2. Optical Phase and Guy Wires 138 KV & 230 KV TRANSMISSION SYSTEM SINGLE & COMBINED CYCLE COMBUSTION TURBINE MICROTURBINES FUEL CELLS WIND GENERATION GENERAL PERMITTING REQUIREMENTS INFORMATION ON NOVA GOLD NovaGold Resources Inc,. - Fri Aug 10, 2001 Subscribe to our Email List frour Email ' Subscribe” | NovaGold Resources Inc. (NRI: TSE; NVGLF:OTC) Is a diversified natural resource company with strong operating revenues and excellent near term exploration upside. NovaGold is focused on the discovery, acquisition, and development of high-quality gold, platinum/palladium and aggregate properties in North America. This strategy is focused in highly prospective regions that have demonstrated significant production. Over the past three years the new Management Team has used this strategy to acquire exceptional mineral properties in Alaska and the Yukon with 17 million ounces in total gold resources (13.4 million ounces to NovaGold's credit). This is the largest resource base of any junior mining company in the world - with over an ounce of gold for every two issued shares of the company. With the acquisition of the 13 million ounce Donlin Creek Deposit, NovaGold is now advancing four multi-million ounce gold deposits. NovaGold continues to advance its early stage properties through strategic joint venture partnerships with Placer Dome, Newmont, Kennecott (Rio Tinto), Cominco and others. NovaGold's strength lies in the Management Team's strong background in exploration, all with experience from discovery through mine development. With this experience the company is positioned to profit from its existing resources and to capitalize on the favorable acquisition market for high-quality exploration properties. This should significantly increase shareholder value as the price of gold returns to long-term equilibrium levels and above. http://www. novagold.net/s/Home.asp Page 1 of 2 Latest Updates Fri Aug 10, 2001 : News Releases : Novagold Completes Financing To Accelerate Donlin ... (more...) Tue Jul 31, 2001 : News Releases : NovaGold Initiates Metallurgical Testwork At Doni... (more...) Mon Jul 30, 2001 : Related Articles : NovaGold Resources Special Report (more...) Mon Jul 16, 2001 : News Releases : NovaGold Finalizes Donlin Creek Deal with Placer D... (more...) Ticker Symbol: T.NRI Last: 0.83 $ Chg: +0.03 % Chg: +3.75 Volume: 81500 Day High: 0.87 Day Low: 0.81 . 08-10- Date: 2001 Time: 09:38 08/10/2001 NovaGold Resources Inc,. - Projects - Fri Aug 10, 2001 Page | of 5 Donlin Creek NovaGold Resources recently signed the final formal agreements with Placer Dome U.S. Inc. (PDG) to acquire a 70% interest in the world-class 13 million ounce Donlin Creek deposit located in southwestern Alaska. Donlin Creek is one of the largest undeveloped gold resources in the world and is located on part of Calista Corporation's 6.5 million acres of private patented land. Calista Corporation's Board of Directors unanimously approved the assignment to NovaGold of the underlying Mining Lease Agreement with Placer Dome during a recently held board meeting. The Measured and Indicated Resource at Donlin Creek is estimated to be 6.9 million ounces of gold grading 3.06 g/t with an additional Inferred Resource of 6.0 million ounces of gold grading 2.83 at a 1.5 Meese g/t Au cut-off grade (see Table 1). This resource remains open both at depth and along strike with BO DS hc ao potential to define a resource of over 13 million ounces through higher density drilling which would elevate m= the current Inferred Resources to the higher Measured and Indicated Categories. The current total seme POtential high-grade resource Is estimated at 5.5 million ounces of gold with an average gold grade of 5.1 g/t using a 3.5 g/t cut-off . This total potential resource is comprised of a Measured and Indicated Resource of 3.1 million ounces of gold grading 5.20 g/t with an additional Inferred Resource of RT 2.4 million ounces grading 4.96 g/t Au.(see footnote 1,2). Table 1, Donlin Creek Project - Resource Estimate 1.5 g/t Au Cut-off Grade | 3.5 g/t Au Cut-off Grade Subscribe to our Email List Resource Tonnes Grade Au Contained Resource Tonnes Grade Au Contained frour Email Category (millions) g/t Ounces Category (millions) g/t Ounces subsea] [Hemme [sa] o13[ _2aavmwo] [remus | co] sao] _so1s000| Fnsenws | ___ a] __ oa P[insenes | ze sas http://www.novagold.net/s/Projects.asp?PropertyInfolD=804 08/10/2001 NovaGold Resources Inc,. - Projects - Fri Aug 10, 2001 Page 2 of 5 lotal Meu 6,895,UUU total M&t 3,142,0UU Notes: Tonnes are rounded to the nearest 100,000 tonnes and ounces o! of gold are rounded to the nearest 1,000 ounces. Apparent errors In the addition of tonnage are due to rounding of decimal places. i Search our Web Site [keyword(s) Search | Donlin Creek Location Map 13 Million Ounce Resource Area The Donlin Creek project is located in southwest Alaska approximately 480 kilometers (300 miles) west of Anchorage and 19 kilometers (12 miles) from barge access on the Kuskokwim River. A state designated winter road provides access from the barge site. The 109 square kilometer property (42 sq. miles) is owned by Calista Corporation and Kuskokwim Corporation, the regional and village Native Corporations of the lower Kuskokwim region. The project has a 75 person all-season camp and an adjacent high quality 1,500 meter (5000 ft) long airstrip that is capable of handling large commercial aircraft (up to C-130 Hercules) for efficient shipment of personnel, large equipment and supplies. NovaGold's exploration program at Donlin commenced in early June. NovaGold personnel have begun on- site work including geologic mapping, sampling and trenching with a focus on defining the higher-grade http://www. novagold.net/s/Projects.asp?PropertyInfoID=804 08/10/2001 NovaGold Resources Inc,. - Projects - Fri Aug 10, 2001 Page 3 of 5 SLUULLUIG! CUIIIUUIDSD WILIE! Gite USpUsIL. GUIU TIM aizauull at Yuli ids SUlULLUT aly CUlIuiUtcU alu intrusive-related. The mineralization occurs over a 6 km trend along north-south and northeast-trending structural zones associated with disseminated and veinlet controlled gold-bearing fine-grained sulfides. A majority of the gold occurs within intrusive dikes and sills, but also as high-grade stockwork-vein zones In the surrounding sedimentary rocks along through-going structures. The Donlin Creek property has been advanced through a total of US$37-million dollars in exploration expenditures, Including over 110,000 meters of drilling, and 25,800 meters of trenching, as well as comprehensive surface and airborne geophysics. The exploration work completed by NovaGold in June and July has been integrated with the extensive exploration database collected on the property by previous workers to further refine the new structurally focused 3D geologic model. Final preparations are underway for the next phase of delineation and offset drilling on the high-grade targets. The drill program Is anticipated to begin In August with the objective to Increase the drill definition of the high-grade resource In preparation for detailed engineering and feasibility studies. The program will focus on refining the structural corridors controlling the higher-grade mineralization using a combination of oriented drill core and detailed structural mapping from trenching, as well as multi- element geochemistry and geophysics. Within the 308 diamond core holes completed by Placer Dome between 1995 and 2000 there are a total of 528 separate intercepts of greater than 5 g/t Au over a 4 meter Intercept yielding a grade times thickness value of 20 gram x meters or more. Within those intercepts, 232 Intervals exceed 10 meters of over 5 g/t Au (50 gram x meters) and an additional 86 exceeded 20 meters of over 5 g/t Au (100 gram x meters). Table 1 outlines 23 Individual Intercepts from the current resource area that exceed a grade times thickness of 40 meters of 5 g/t Au (200 gram x meters). Additional high-grade intercepts of >5 g/t over significant widths occur on several other targets on the property outside of the currently defined resource area. Table 1. Drill highlights with grade times thickness of greater than 200 gram x meters. Drill Interval Length Grade Gram Length Grade Foot Hole (meters) (meters) (g/t) meters (feet) (oz/t) Ounces 96-244 75.8-102 26.2 26.1 684.0 86.0 0.76 65.5 96-244 160-180 20.0 22.4 447.6 65.6 0.65 42.8 96-262 248-258 10.0 21.3 212.7 32.8 0.62 20.4 96-282 266.9-280 L3s1 20.3 266.0 43.0 0.59 25.5 97-397 12.7-38 25.3 10.7 271.9 83.1 0.31 26.0 97-401 13.7-40 26.3 10.1 266.3 86.3 0.30 25.5 97-421 178.3-202 23.8 10.7 254.1 77.9 0.31 24.3 http://www.novagold.net/s/Projects.asp?PropertyInfoID=804 08/10/2001 NovaGold Resources Inc,. - Projects - Fri Aug 10, 2001 Page 4 of 5 98-459 188-212 24.0 12.8 307.7 78.7 0.37 29.4 98-463 335-354 19.0 13.1 248.3 62.3 0.38 23.8 98-489 264-297 33.0 10.4 343.1 108.2 0.30 32.8 98-492 130-164 34.0 7035) 253.4 111.5 0.22 24.2 98-502 264-286 22.0 18.8 413.2 72.2 0.55 39.5 Incl. 274-283.6 9.6 38.1 366.0 31.5 init 35.0 98-503 191-214 23.0 9.2 211.6 715.5 0.27 20.3 98-519 254-282.9 28.9 8.8 253.2 94.8 0.26 24.2 98-534 223-254 31.0 9.8 303.1 101.7 0.29 29.0 98-538 48-86 38.0 6.4 241.5 124.7 0.19 Zao 99-553 216-228 12.0 19.3 231.8 39.4 0.56 22.2 99-555 0-29.8 29.8 20.2 601.3 97.7 0.59 oie o 99-555 47-78 31.0 7.7 238.9 101.8 0.22 22.9 99-555 240-276 36.0 6.7 242.0 118.1 0.20 23.2 99-557 73-87 14.0 14.4 202.1 45.9 0.42 19.3 The above drill results are from the high-grade sections of the southern part of the property that hosts the current 13 million ounce gold resource. This resource remains open at both ends and at depth. Select the following link to view a complete list of all of the significant intercepts that are greater than 5 g/t gold over 10 meters (>50 gram x meters) in the main resource area. Table of significant >50 gram x meter grade thickness intercepts. Seven additional potential resource areas occur on the property, all of which have significant high-grade drill results that are not included in the above current resource estimate. Additional exploration upside exists on NovaGold's adjacent Donlin North Property, where the geology and mineralization indicate the potential for bonanza-grade mineralization at depth. A preliminary economic analysis indicates that a higher- grade operation at would have strong economics even at today’s historically low gold prices. Using an 8% discount rate the discounted net present value per fully diluted share for the smaller high-grade resource only results in C$2.54 per share at $275 per gold ounce and C$5.48 per share at $300 gold. The objective of this year's Donlin Creek Project looking north at the main resource area. http://www.novagold.net/s/Projects.asp?PropertyInfoID=804 08/10/2001 NovaGold Resources Inc,. - Projects - Fri Aug 10, 2001 Page 5 of 5 program will be to increase the arill derinition or tne nigner- grade resource in preparation for detailed engineering and feasibility studies. NovaGold will continue to work closely with Placer Dome throughout the development of this project. Footnote:(1) The Measured, Indicated and Inferred resource estimate was calculated in year 2000 by qualified person, Marc Jutras, Senior Mining Engineer with Placer Dome Inc. using data from 308 core holes drilled from 1995 through 1999. The measured and indicated resources from this estimation were disclosed by Placer Dome on January 23, 2001. (2) Total Gold Resources(MI&I) are potential gold resources that will require additional exploration to elevate the Inferred Resource components to the higher level Measured and Indicated (M&I) Resource categories. Corporate Profile | Investment Hightlights | News & Reports | Projects | Gold Resources | Stock Quote & Chart | Related Information | Contact Us | QwikReport | Home Copyright © 2001 NovaGold Resources Inc. All Rights Reserved, http://www.novagold.net/s/Projects.asp?PropertyInfoID=804 ‘ 08/10/2001 COAL PLANT DESIGN AND COST INFORMATION SMW & 1SMW COAL PLANT DE PRECISION ENERGY SERVICES INC. L INTRODUCTION This report has been prepared to be used as an element of a feasibility study for a power generating plant intended to be developed for the supply of electric power and district heating energy to the City of Bethel, Alaska and surrounding communities. The objective of this report is to provide the project developers adequate information to identify the most feasible, long-term power generation options. Environmental permitting standards and expected performance related to the operation of the power plant have been noted in Section III to make the developer aware of the possible requirements. The costing information provided herein is based on the application of the Atmospheric Fluidized Bed (AFB) technology for generating steam in an integrated boiler. The recommendation to apply the AFB technology has been derived from previous experience also taking into account the performance capabilities of this technology. Two AFB combustors with integrated boilers will be fired with coal imported most likely from Canada. This report is based on medium volatile coal supplied from the Quinsam Coal Corporation coal mine near Campbell River on the Vancouver Island, British Columbia, Canada. This coal represents an average thermal coal mined in Western Canada or Alaska. For the purpose of this Study, Alaskan coal has not been included due to lack of developed coal deposits in the vicinity of the plant. However, the AFB technology proposed for this power plant is so versatile that it enables combustion of various, even low-grade fuels without modifying the combustion system or any systems downstream of the combustor. AFB combustion is a modern technology that is characterized by high combustion efficiency (low loss on ignition), extremely high availability, low-cost coal preparation and low-cost emission controls. The technology exceeds the performance of such leading edge technologies as the Clean Coal Plant at Healy, AK. The technology has become an industry standard for coal and alternate fuel-based, small power generation. The evaluations include provision for extracting, in an efficient way, heat energy that would be used for district heating of the City of Bethel. This feasibility study had not evaluated the cost of implementing the district heating system beyond the base power plant scope. Cost of supplying the heat energy to the City of Bethel, distribution within the City and installation of suitable heat exchangers and heaters should be a subject of a separate study. Two options are being evaluated: L Power plant generating 5 MW with heat extraction for district heating. 2s Power plant generating 15 MW with heat extraction for district heating. The power plant specifications are provided on the following page. Bethel Feasibility Study June 2001-Final Page 1 of 16 RES PRECISION EMERSY SERVICES INC. I. DESIGN INPUT DATA AND ASSUMPTIONS Two Plant sizes are considered in this Feasibility Evaluation: - 5 MW electric output - 15 MW electric output Both plants shall produce sufficient heat to provide for District Heating (DH) of the City of Bethel and surrounding communities. The DH system energy demand has been established based on data regarding usage of heating oil in Bethel. The data is compiled in the following table. Table 1. Heating Fuel Usage in Bethel, Alaska. Heating Fuel Usage ie Gallons per ct roe en usage cco 135,000 Btu/gal Btu/hbr January 11% 385,000 69,860,000 February 9% 315,000 63,280,000 March 8% 280,000 50,810,000 April 8% 280,000 52,500,000 May 7™% 245,000 44,460,000 June 7% 245,000 45,940,000 July 7™% 245,000 44,460,000 August 7™% 245,000 44,460,000 September 8% 280,000 52,500,000 October 8% 280,000 50,810,000 November 9% 315,000 59,060,000 December 11% 385,000 69,860,000 Totals 100% 3,500,000 Averaged for year 54,000,000 LHV -— lower (net) heating value In addition to the energy demand for the DH system, the Power Plant will need fuel supply for the generation of 5 or 15 MW. The energy demand for DH remains constant for either option. A portion of the steam generated in the Plant will be expanded in condensing turbines; a proportional volume of steam will be extracted from the turbine at 40 psig and delivered to the Central Heat Exchanger Station where it will be condensed. The latent heat of condensation will be transferred to water circulating in the City District Heating circuit. Bethel Feasibility Study June 2001-Final Page 2 of 16 PES =, EMERG Y SERVICES INC. Remark: In generating plants, the main energy loss component is that of the heat of condensation, which is removed in the condenser and dissipated to the atmosphere in the cooling towers. This waste amounts to in excess of 72% in small (below 100 MW), medium pressure and temperature range power plants. Only 24 to 28% of input energy is actually converted to electric power. In the case of the Bethel Cogeneration facility the energy utilization will increase to 62.7% for the 5 MW plant and 40.6% for the 15 MW plant. Fuel for the Cogeneration Power Plant For the purpose of this study it is assumed that the Fuel for the Cogeneration Power Plant will be Quinsam coal. The properties of this coal are compiled in Table 2 and 3 below. The Quinsam coal can be considered as typical for Western USA and Canadian coals. The sulfur content of Quinsam coal is relatively low (~0.70%), which has a great impact on the cost of emission control, primarily control of SO2. The coal contains also relatively high percentage of oxygen, ash and moisture (combined ~30%), which renders some advantages for NOx control but increases the complexity of particulate emission control and ash handling. Supply of Quinsam coal seems to be, at the time of preparation of this Study, the most feasible. There are coal resources in Alaska that may be considered for the supply to the Plant. These resources are: Seward Peninsula, Nelson Island (Kuskokwin), Chignik Bay (Alaskan peninsula) (Source: Combustion Fossil Power, Appendix, Coals of the World; ABB Combustion Engineering). The combustion technology proposed for the Bethel Plant will be able to burn those coals, with little or no modifications (primarily in the feeding system). These coal sources should be further investigated. Table 2. Quinsam Coal Properties Component oon im analysis Carbon 63.79% Hydrogen 4.19% Nitrogen 0.82% Sulfur 0.71% Oxygen (by difference) 9.21%! Ash Content 12.29% Moisture __ | 9.00%) 100.00%| Combustible Heating Value} Btu/Ib Gross (dry) 12,240} Heating value at 0% moisture Heating value at 3% moisture (residual moisture Gross (air dry) 11,680) that cannot be removed by ordinary drying) Gross (as received) 11,160) | Heating value with subtracted heat for moisture Net (as received) 10,620! evaporation Bethel Feasibility Study June 2001-Final Page 3 of 16 PRES == Lg SER’ VICES INC. Table 3. Ash Properties of Quinsam Coal SiO 38.0% Al,O3 27.3% Fe203 8.5% CaO 15.9% MgO 0.3% Na,O 0.2% K,0 0.1% TiO, 1.6% P203 0.6% SO3 4.1% Undetermined 3.4% 100.0% Bethel Feasibility Study June 2001-Final Page 4 of 16 DE PRECISION EMERGY SERVICES INC. Il. BETHEL, ALASKA POWER PLANT PROJECT SPECIFICATIONS Units 5 MW 15 MW No. Specification 1 Power plant total electric output Net output for sale Parasitic power (for internal plant use) 2 Steam parameters 3 Condensing at 4a Turbine efficiency (mechanical) 4b Generator efficiency 4 Generating efficiency (4a x 4b) 5 Extraction steam for DA and DHH 6a Steam flow, condensing cycle 6b Steam flow, extraction cycle 6c Total steam flow to turbine 6d Boiler blow-down 6 Steam generation in boiler 7a Power generation, condensing cycle 7b Power generation in extraction cycle 7 Total generation 8 COAL DEMAND Coal heating value Maximal coal demand at max. DH demand (Jan, Dec) Minimal coal demand at min. DH demand (May, Aug) Yearly coal demand @ 95% availability 9 Limestone demand at 95% availability 10 Hydrated Lime demand at 95% availability 11 Total ash flow from entire plant 11a Ash flow including CaSO3/, 12 District heating Heat supply to Central Heat Exchanger Station Heating water flow in DH system at 210°F Heating exchanged Ah Heating water return at 140°F; unit heat exchange Bethel Feasibility Study June 2001-Final kWe kWe kWe psia °F in. Hg (a) TE GE TGE psig Ib/hr Ib/hr Ib/hr Ib/hr Ib/hr kWe kWe kWe Btw/hr Ib/hr Btwhr Btu/lb 5,800 16,200 5,000 15,000 800 1,200 615 615 750 750 rz 2 85.0% 86.0% 95.0% 95.0% 80.8% 81.7% 40 40 13,900 120,300 80,000 80,000 93,900 200,300 2,473 5,276 96,373 205,576 2,360 12,082 3,440 4,118 5,800 16,200 11,160 11,672 26,454 10,666 24,568 50,300 115,400 1,845 3,836 403 862 6,179 14,177 9,096 20,374 Maximum Minimum 73,550,000 46,800,000 79,965 50,889 62,517,500 39,780,000 781.8 781.7 Page 5 of 16 IES PRECISION EMERG Y SERVICES INC. .__ DESCRIPTION OF THE BETHEL COGENERATION PLANT IV. A complete coal-fired power plant has been evaluated for the production of 5 MW and 15 MW of electrical power. Each plant option will include two separate boilers and turbine islands to provide the name plate capacity for power generation and supply of steam for the DH system. The minimal continuous output of the 5 MW plant is 3 MW or 10 MW of the 15 MW plant and simultaneous supply of steam to the DH system for at least 70% of the system demand. The main systems of each power plant option include: Pe YS The fuel and other input materials receiving, handling, storage and feeding system The power generation system The district heating exchanger station Emission control system Ash handling system Specifically, the Power Plant will include the following systems: oN 10. Mie 12: 13. 14. Coal receiving and unloading dock Coal storage area including stacking and retrieving equipment and crushers Furnace feeding system including conveyors and metering equipment Limestone and hydrated lime receiving, storage, retrieving and furnace feeding system; Limestone and hydrated lime will be used for controlling SO2 emissions. Hydrated ammonia receiving, storage, retrieving and furnace feeding system. Hydrated ammonia will be injected into the combustion gases ducting to reduce the NOx emissions. Two atmospheric fluidized bed combustors with integrated boiler, superheater, economizer and air heater. Two turbine and generator process lines including switch gear and one substation for the Plant. * Steam surface condensers with cooling towers and cooling water circulating pumps. Feed water demineralizer system with 100% redundancy, chemical treatment and deaerator. Boiler feedwater pumps with 100% redundancy. Air pollution control system including cyclones, baghouse, SNCR system, ducting and stack Fans and blowers for combustion air, flue gas induced draft and auxiliary. Instrumentation and controls, central control room and motor control center. Auxiliary equipment and installations such as loaders, diesel fuel storage tanks, compressed air system and other. Bethel Feasibility Study June 2001-Final Page 6 of 16 PES PRECISION SERVICES INC. 15. Stand by boiler for start up and supply of district heating energy during plant outage, as well as for auxiliary, intermittent steam demand. 16. Maintenance shop with tools. 17. The plant will be housed in appropriate buildings. The buildings will also include plant office and facilities for the plant personnel — locker rooms, lunchroom, etc. 18. District Heating Central Heat Exchanger Station with appropriate piping and connections to the City heating system. Fuel Receiving, Storage and Combustor Feeding System Coal will be shipped from the ocean port at Campbell Creek on Vancouver Island, Prince Ruppert or Westshore Terminal of the Port of Vancouver, all British Columbia, Canada on 10,000 ton, self- propelled barges directly to Bethel, to the Plant’s receiving and unloading dock. The plant will receive the entire coal supply during a 4 to 5 month summer window and stored in a coal storage area. For the 5 MW plant, 52,900 short tons will be delivered. At the end of the shipping season, approximately 35,500 tons of coal will be stored at the Plant site. This amount will be sufficient to operate the Plant until the start of the following shipping season. This amount provides also a contingency for the case of late start of the shipping season. The contingency is in the amount of 3,000 tons, which will last for approximately 20 days. The amount of coal to be delivered for the 15 MW plant is 117,600 tons. The amount of coal stored for the off-shipping season is approximately 78,000 tons, including a 20-day contingency. The contingency time can be extended by up to 2 weeks if the “spring” maintenance outage is planned to coincide with the beginning of the shipping season. The Fuel Receiving, Storage and Combustor Feeding System will be built as follows: I Coal receiving and unloading dock will be located at the riverfront and will include pilings in the river for one barge 400 feet long. River depth at these pilings must be 17 feet or greater. The dock will be attached to the pilings to hold one large coal-receiving hopper. 2s Excavation fill to support dock. It may be necessary to provide sufficient fill at river’s edge with a concrete quay to support heavy equipment. 3. Coal receiving office/building to house an office, lunchroom, and warehouse of disposable items coming in by barge. 4. Coal unloading equipment. A coal receiving hopper will be installed within reach of the slewing conveyor from barge. The hopper will be large enough for receiving maximum unloading tonnage per hour from barge. 3: Structural Support. It may be necessary to support receiving hopper on pilings if the ground is unable to support this large structure. 6. Coal conveyors to storage area and stacker. Receiving belt conveyor, 60” wide, from dockside hopper to coal storage. The conveyor will be elevated and equipped with a tripper. Bethel Feasibility Study June 2001-Final Page 7 of 16 IDES === eee SER VICES INC. 10. ale 12: 13) 14. Bridge conveyor stacker. This would be an elevated horizontal conveyor at right angle to the receiving conveyor, spanning over 150 - 200 feet, distributing coal on two piles 30 feet high and 160 feet long for the 5 MW plant and 260 feet long for the 15 MW plant. Coal Storage Pad. 5 MW. 15 MW Number of coal storage piles 2 2 Pile width 150 ft 200 ft Pile length 160 ft 260 ft Total storage capacity 35,500 ST 78,000 ST An area of 200 feet x 200 feet between piles for loader operation will be provided. The soil we be tested to determine the method of design, construction and stabilization of the ground pad. Three sides of each coal pile will be retained by concrete walls at least 10 feet high to control spillage. A fire prevention and suppression system will be installed at the coal storage area. Rubber tired loaders with a bucket capacity of 6 cubic yards will be used to move coal from either coal pile to the reclaim hopper at a rate consistent with that required to operate the plant. Reclaim hopper and supports to be located between the two coal piles. The loader will move the coal to the reclaim hopper that is located at ground level. Conveyor to crusher house. An incline belt conveyor from the reclaim hopper to a splitter chute will direct coal to either of two coal crushers. The conveyor will be covered to prevent dust blowing. Loader Maintenance Shop to provide safe and warm environment to service the two diesel bucket loaders, provide bridge crane and grease pits for both loaders, as well as storage of hydraulic fluids, engine oils and antifreeze. Diesel fuel to be stored above ground near the maintenance shop. Storage tanks will be furnished for an eight month or longer supply of fuel. Storage tanks can be filled by barge/ship to avoid handling and possible spills. All other mobile equipment would be diesel powered to avoid handling gasoline. Block heaters will be applied in all diesel-powered equipment with power hook-ups throughout the area. Breaker and grinding mill. A crusher house for two ring type single roll crushers will be provided. Reclaim conveyor will feed either crusher. The coal crusher’s capacity will be 80 tph/each. Each crusher will have the capacity to individually fill the coal bunkers. Permanent magnets will be installed before the crushers to remove tramp metal. The coal will be crushed to 1” minus size. Two crushed-coal conveyors will be provided to feed coal to the bunkers inside the boiler building. Each conveyor independently feeds coal to bunkers of each combustor. Conveyor redundancy allows coal conveyance to all bunkers regardless of which crusher is operating. Bethel Feasibility Study June 2001-Final Page 8 of 16 IDES 2 aaa SERVICES INC. 15. 16. 17. The loading system for furnace feed will include two bunkers to provide adequate and uninterrupted supply of fuel to the AFB combustors. The 15 MW plant will include double- chambered bunkers. The number of bunkers is based upon the AFB being equipped with two fuel metering feed screws on either side of each AFB combustor. Distribution conveyors with trippers. The bunkers for the AFB combustors will be fed at the top with a belt conveyor and tripper. The two conveyors from the two crushers feed individually the two distribution conveyors that service fuel bunkers. Diverter gate from the two crusher conveyors can feed either distribution conveyors independently or together. Flexibility of the system allows minimum loss of generating power. Gravity feed chutes to each of the four fuel feed metering screws. One bunker is dedicated to each metering screw. This avoids plugging of one bunker when shutting down a fuel feed screw. Coal Fired AFB Combustors with Integrated Boilers Two trains of the integrated AFB furnace - boiler system will be included in the Power Plant; each system will typically consist of: , Atmospheric fluidized bed combustor with internal bed recirculation, water walls and steam drum with connecting tubes and piping Backpass Tube Panels/Headers Superheater, attemperator and interconnecting steam piping Economizer with feedwater piping ASME Code Valves & piping as well as boiler trim valves; safety relief valves with vent piping and silencers Feedwater stop and check valves Tubular air heater Auxiliary start-up burners with lighters and flame detectors Burner Management System Primary and secondary combustion air blowers with motor drives Fuel and limestone feeders Bed drain system with ash screw coolers Integrated boiler, including piping, refractory, insulation and lagging/casing Boiler instrumentation Structural steel including platforms, grating, handrails The integrated AFB furnace, boiler and superheater system will produce superheated steam at 600 psig and 750°F to be used in the generating system. Bethel Feasibility Study June 2001-Final Page 9 of 16 IDES == Leia SER! VICES INC. Steam Turbine and Generator System Two trains of the Steam Turbine and Generator system will be included in the Power Plant; each system will typically consist of: - Turbine unit with condensing steam exhaust and one back pressure steam extraction outlet with non-return valves for district heating and de-aerator. - Required piping, insulation blankets, sheet metal lagging. - Generator, 13.8 kV, 60 Hz, 3600 rpm, 0.85 PF with brush-less excitation and coolers sized for water temperature 85°F. Generator shaft is monitored for vibrations. - Oil System on separate baseplate for lubrication and control oil with interconnecting piping and oil coolers sized for water temperature 85°F. Two main oil pumps and one emergency DC-motor driven pump. - Complete stand-alone digital control system handling all required turbine and generator controls (closed and open loop) and monitoring instrumentation (power output, pressures, temperatures, vibrations, etc.) of the steam turbine and generator unit. The control system includes a coordinating controller plus separate control units for the turbine governor function, steam turbine safety trip functions and generator voltage regulator functions. - Operator station with color monitor, keyboard, track ball and event and alarm printer. - Unit is built for indoor installation with noise attenuation to 85 dBA. Steam Surface Condenser With two feedwater circulating, liquid ring vacuum pumps. Each pump at 100% capacity. The condenser is built of 304L stainless steel tubing and tubesheets and coal tar epoxy coated water boxes. Cooling Tower One for both trains; fiberglass structure, stainless steel connecting hardware, heavy duty PVC film pack fill, two 28’ diameter fans with drive (200 hp), fire retardant FRP fan cylinders for velocity recovery and other. Feed Water Chemical Treatment and Deaerator A complete feedwater system would be supplied. Boiler feedwater and deaerator for each boiler would be included. Air Pollution Control System The air pollution control system will include in each AFB-boiler-turbine-generator line the following sub-systems: - Multiclone - Baghouse - Selective Non-Catalytic Reduction system for NOx control — engineered by PES - Limestone injection system for SO? reduction in the fluidized bed. The system will Bethel Feasibility Study June 2001-Final Page 10 of 16 PRECISION EMERGY SERVICES INC. include sufficient limestone storage capacity. - Induced draft fan - Ducting to the stack - Hydrated lime scrubber for additional SO, control The plant will have one multi-flue stack for discharging clean flue gases to the atmosphere. The stack may have to be equipped, depending on the environmental permit, with continuous emission monitoring (CEM) devices: - SO, monitor - Opacity monitor - NOx monitor - Oxygen monitor - Particulate concentration monitor The CEM devices, if required, will be supplied by AMETECH and/or AIM. Remarks regarding SO, and NOx Control The fluidized bed combustion technology is specifically attractive due to the ability to control SO2 emissions “in-situ” at the point where they are created, which is in the combustion chamber. Limestone (CaCO3) injected into the furnace calcinates, in the presence of the high combustion temperature, to CaO and CO2. CaO reacts with SO: producing anhydrate CaSO3. Further oxidation in the furnace, with the presence of oxygen, produces gypsum CaSO, -— an inert, harmless material that becomes a part of the ash. SO) sorption with limestone is about 65 to 85% effective; the reaction efficiency decreases with the lower sulfur content in the fuel. Depending on the environmental air quality permit that the Plant will be awarded, there may be a requirement to include an additional system for SO, control. The following table shows the results of SO2 control: Table 4. SO emission control requirements. Specification Units 5 MW |15MW Uncontrolled SO, production at max. fuel lb/hr 185 385 ton/year 767 | 1,594 ppm dry vol. 558 558 SO, emissions removed in FBC Ib/hr 129 269 Emissions with limestone control in fluidized bed, 70% efficiency nm = man Emissions at 345 working days / year ton/year 230 478 Target emissions * ton/year 100 100 Required reduction in additional scrubber ton/year 130 378 Bethel Feasibility Study June 2001-Final Page 11 of 16 RES PRECISION CRESS Y SERVICES INC. * Target emissions: SO2 emissions may be limited by the Authorities as follows: a. 100 ton/year (shown in the Table), then there will be a significant reduction required to be done in an additional system. b. % reduction of input sulfur converted to SO2; typical reduction requirement is 90%. If such a reduction requirement is issued, an additional scrubbing system will be needed. c. 30 percent of the potential combustion concentration (70 percent reduction), when emissions are less than 0.60 Ib/million Btu heat input. In this case, reduction in the AFB combustor produces 0.43 Ib/MM Btu and 0.39 Ib/MM Btu for the 5 and 15 MW option, respectively. If such a requirement is issued than no additional scrubbing would be required. The cost estimate of the project includes an additional SO scrubbing system. NOx emission standards are usually based on the emitted mass of NOx (as NO2) per unit thermal input into the furnace (Ib/MM Btu). The NOx emissions will be most likely set at a level of 0.160 — 0.250 Ib/MM Btu. These standards translate into the following numbers: Table 6. NOx Emissions Specification Units 5 MW | 15 MW _| Standard for NOx emissions, lower Ib/MM Btu 0.160 ton/year 87 197 Standard for NOx emissions, upper Ib/MM Btu 0.250 ton/year 136 307 Estimated NOx emissions : ppmvol 150 150 Ib/MM Btu 0.264 ton/year | 143 324 Required reduction at lower limit | ton/year 56| 128 Required reduction at upper limit * ton/year 8 17 Obtaining a standard of 0.264 Ib/MM Btu is also possible. In this case an additional system for the control of NOx would not be required. The cost estimated provided herein include a Selective, Non- Catalytic Reduction (SNCR) system. Bethel Feasibility Study June 2001-Final Page 12 of 16 DE! aa aaneae INC. Instrumentation and Controls, Central Control Room and Motor Control Center The Power Plant will be equipped with all instrumentation and controls necessary for trouble-free, semi-automated operation of the Plant. The CCR (central control room) will include operator stations with color monitors, keyboards, track balls and event and alarm printers. The CCR will house also the output and monitoring devices of the steam turbine power generating system as well as pertinent information relating to the District Heating system. A separate motor control center (one for the entire plant) will be provided in a separate room of the main building. Other Plant System and Equipment as Required for Complete Plant All equipment and sub-systems required for a complete plant have been included in the plant estimated cost. Items not included are: 18 Lease or purchase of land for plant. 2: Electrical substation and powerline. District Heating System The plant will include provisions for connecting to a central district heating system. It will include a Central Heat Exchanger Station for heating water circulating between the plant and the heat receivers in the City’s DH system. The circulating water will be heated with extracted steam condensing in the heat exchanger. For specific information on the heat supply for the DH system see Section I, Design Input Data and Assumptions. The piping system from the Central Heat Exchanger Station to the City of Bethel and other communities is not included in the Power Plant cost. Bethel Feasibility Study June 2001-Final Page 13 of 16 RES S=. ENE SERVICES INC. Vi PERFORMANCE CALCULATIONS In the framework of this Feasibility Study, performance calculations were done; various results of the calculations are included in the various tables and other calculations. Bethel Feasibility Study June 2001-Final Page 14 of 16 PRECISION PES = SERVICES INC. VI. CAPTICAL COST ESTIMATE The following cost estimate for the project is based on equipment quotations obtained from major equipment vendors and estimates. The installation cost of the equipment was based upon vendor estimates and a percentage of equipment cost. The Capital Cost Estimate includes, as base, the total tum-key cost of the project as specified above. It includes also the cost of the project without the additional hydrated lime scrubber and the selective, non-catalytic reactor (SNCR) for NOx control. These two items will not be required if the emission standards are set at levels described in Section Air Pollution Control System. Bethel Feasibility Study June 2001-Final Page 15 of 16 PRECISION ENERGY SERVICES, INC. BETHEL COGENERATION PROJECT 5 MW + DISTRICT HEATING Some cost items Include installation Bethel, AK 5 MW power plant with District Heating Capital Cost Elements Basic Specifications Qty Unit cost Install Total tt eee + Fuel Preparation Consumption Req'd storage (ST) for 9 months Coal recelving & unloading dock STiday 150 | _ 35,500 | | 1|___736,000| 1,195,500 | _ 1,930,500 Conveyors & stacker to storage area ST/day 150 35,500 1 450,000 90,000 540,000 Breaker and grinding mill ST 15 N/A 1 220,000 44,000 264,000 Loading for fumace feed and bunkers ST/hr 15 N/A 1 285,000 57,000 342,000 a —— + {Coal feeders & Raw Coal piping from Bunker ST/hr_ 15 N/A 1 220,000 44,000 264,000 Limestone & Hydrated Lime Unloading and Handling {Limestone Hopper and conveyors to storage ST/day_ 444 1 355,000 71,000 426,000 Limestone storage Building 1 300,000 60,000 360,000 2 Limestone reclaimer and conveyor system 1 455,000 91,000 546,000 Combustion System - 2 parallel systems Metering bin Included | Fuel feeder(s) Included Limestone feeder Included | —_—— FBC, BMS, Aux. StUpBumer, bed recirc., boller, included refractory, structural steel Included | CA Blower Included _|SCFM 33,850 |Ap Inch WC 48 Boiler with SH, attemperator, sootblowers Ib/hr 100,000 2 2,475,000 990,000 6,930,000 Economizer MM Btu/hr 22 |AH Btu/lb 221 Baghouse Included acm 51,501 Tubular Air heater MM Btu/hhr_ | 11 1 285,000 99,750 384,750 ID fan __|Included — |ACFM 51,501 |Ap inch WC 15 PoC (flue gas flow) lb/hr 165,248 |SCFH 2,114,247 Subtotal 2,760,000 1,089,750 7,314,750 Environmental control system i Stack DIA ft 43 100 2,000 210,000 480,000 SNCR system GUL PLT OEE ce Bethel Summary CC 5MW 6/21/2001 Page 1 of 3 PRECISION ENERGY SERVICES, INC. BETHEL COGENERATION PROJECT 5 MW + DISTRICT HEATING Flues and ducts included in Installation cost Ash handling _ _ Ash system and silo for storage, installation included Steam piping Feedwater piping Boller Instrumentation in addition to included with boilers Plant Instrumentation and Control \Deaerator System T, Boiler |Feedwater Pumps & motors Power generation Steam turbine & generator Crane Condenser Cooling Tower Cooling Water Pumps Cooling system Piping & Valves _|Subtotal Water Treatment system Make up water system District heating system (inside plant fence only) main heat exchanger + piping Standby Bollers system for heating Oil storage Tank and loading system Standby Generators 2 @ 1000 kw Electrical Sub-station Breakers & Motor Control Centers Electrical - wiring, etc. Foundations and asphalt balance of Bethel Summary CC SMW 6/21/2001 Page 2 of 3 PRECISION ENERGY SERVICES, INC. BETHEL COGENERATION PROJECT 5 MW + DISTRICT HEATING Structural steel 1 87,500 Structural steel balance of plant Boiler/ Turbine Building 1 87,500 Installed 1,400,000 Maintenance Bullding and shop equipment Platforms and access balance of plant _ Site preparation Insulation/painting included 38,500 65,000 Incl. with boiler 80,000 Subtotal 4,032,500 250,000 350,000 250,000 75,000 675,000 Engineering and Project management @12% 2,752,594 Freight @ 3.5% of equipment cost 770,726 Environmental Permitting Cost 60,000 Rolling Stock 400,000 26,004,070 Contingency + 15% 3,900,611 Complete Plant 29,905,000 Unit Cost per MW 5,981,000 Complete Plant Cost without additional Scrubber and SNCR system 28,710,000 Unit Cost per MW 5,742,000 Bethel Summary CC 5MW 6/21/2001 Page 3 of 3 = Bethel, AK 5 MW power plant with District Heating PRECISION ENERGY SERVICES, INC. BETHEL COGENERATION PROJECT 15 MW + DISTRI Some cost items Capital Cost Elements Basic Specifications Include installation HEATING Fuel Preparation ___|Consumption Req'd storage (ST) 255 days Coal receiving & unloading dock ___-|STiday | 320 75,200 | 1 918,750 2,293,550 3,212,300 ____|Conveyors & stacker to storage area - STiday | 320] _~— 75,200] 1 500,000 100,000 600,000 Breaker and grinding mill __|ST/hr 15 N/A | 1 340,000 68,000 408,000 _|Loading for furnace feed and bunkers i _ |ST/hr 15 N/A 1 390,000 78,000 468,000 Coal feeders & Raw Coal piping from Bunker ST/hr 15 | N/A 1 275,000 55,000 330,000 | Subtotal 2,423,750 2,594,550 5,018,300 Limestone & Hydrated Lime Unloading and Handling Limestone Hopper and conveyors to storage ST/day 15 | 1 443,750 88,750 532,500 Limestone storage Building 123 . 450,000 90,000 | 540,000 Limestone reciaimer and conveyor system * . 622,500 124,500 747,000 | } 1,516,250 (Combustion System - 2 parallel systems Metering bin Included Fuel feeder(s) |inctudea Limestone feeder Included _____|FBc, BMS, Aux. StUpBumer, bed recirc., boiler, _|!noluded refractory, structural steel Included CA Blower Included Iscem 70,386 |Ap Inch WC 48 | Boiler with SH, attemperator, sootblowers [tome 200,300 | 2 4,950,000 | 1,980,000 13,860,000 Economizer MM Btu/hr 49 |AH Btu/lb Baghouse Included ACFM 107,102 Tubular Air heater MM Btu/hr | 24 1 427,500 149,625 577,125 ID fan Included |ACFM 107,102 |Ap inch we | 15 PoC (flue gas flow) Ib/nr 343,676 |scrn 4,396,837 | ‘Subtotal 5,377,500 2,129,625 14,437,125 Environmental control system Stack __|DIAt | 5.3 100 2,500 100 | 260,000 SNCR system 580,000 Bethel Summary CC 15MW 6/21/2001 Page 1 of 3 PRECISION ENERGY SERVICES, INC. BETHEL COGENERATION PROJECT 15 MW + DISTRICT HEATIN - Subtotal 840,000 Flues and ducts Included in installation cost ee Ash handling _ a = ___|Ash system and sito for storage, Installation included | 1,520,750 Steam piping _ | | | 290,000 Feedwater piping ee ee | eee een | Suna | SUL 140,000 —_ moms —— - + Boiler Instrumentation in addition to included with boilers 120,000 Plant Instrumentation and Control | = 240,000 — 4 Deaerator System - | 250,000 Boller_|Feedwater Pumps & motors | 4 L 55,000 al 275,000 | + Power generation _ ‘ Steam turbine & generator MWe nom. 15 | 2 | 2,625,000 918,750 7,087,500 Crane -_ 1 120,000 42,000 162,000 _ ‘Condenser 2 140,000 56,000 392,000 Cooling Tower | 1 240,000 84,000 324,000 Cooling Water Pumps _ 3 45,000 15,750 182,250 ‘Cooling system Piping & Valves Subtotal } Subtotal 8,147,750 - 4 Water Treatment system | | 120,000 Make up water system | | L 45,000 District heating system (inside plant fence only) main heat exchanger + piping | 2 38,000 24,700 125,400 Standby Boilers system for heating 1 960,000 336,000 1,296,000 Oll storage Tank and loading system | 1 15,000 Standby Generators 2 @ 1000 kW 2 70,000 17,500 175,000 Electrical Sub-station 1 90,000 36,000 126,000 Breakers & Motor Control Centers lo ee i 1 80,000 32,000 112,000 Electrical - wiring, etc. _ 4 | 1 150,000 150,000 300,000 Foundations and asphalt balance of plant 1 250,000 Bethel Summary CC 15MW 6/21/2001 Page 2 of 3 PRECISION ENERGY SERVIGES, INC. BETHEL COGENERATION PROJECT 15 MW + DISTRICT HEATIN Structural steel | 1 J 87,500 i 1 87,500 Boiler/ Turbine Building Installed 1,400,000 Maintenance Building and shop equipment included | 38,500 Office 65,000 Platforms | ; incl. with boller Platforms and access balance of plant , 120,000 Subtotal 4,072,500 Site preparation iL 450,000 Insulation/painting 550,000 250,000 Performance tests 95,000 Sub-total 895,000 Engineering and Project management @12% 4,770,166 Freight @ 3.5% of equipment cost 7 1,335,646 Environmental Permitting Cost 60,000 Rolling Stock 600,000 44,927,137 Contingency + 15% 6,739,071 Complete Plant 51,666,000 Unit Cost per MW | 3,444,400 Complete Plant Cost without additional Scrubber and SNCR syst 50,271,000 Unit Cost per MW 3,351,400 Bethel Summary CC 15MW 6/21/2001 Page 3 of 3 IDES === Sia SERVICES INC. VI. O&M ESTIMATE The operation and maintenance cost estimate is included in the Feasibility Evaluation spreadsheets. See explanations and remarks provided on the spreadsheets. The O&M Cost Estimate includes the following cost items: Personnel including payroll taxes Zs Cost of maintenance; it was assumed that the maintenance cost of equipment is 5% of the purchase cost of equipment (the entire equipment is replaced within 20 years); the maintenance cost of the buildings, foundations, roads and stationary structures was assumed 2.5% and the respective cost electrical equipment (breakers, motor starters, transformers, ...), controls and instrumentation is 10%. 3: Cost of basis fuel — coal at $63.00 per short ton. This item is the largest one in the cost category. This item may be reduced if local coal or even low rank fuels such as peat, lignite, are utilized. 4. Ash disposal cost was assumed to be shipping cost same as for shipping coal and consumables plus $10 tipping fee for disposal at a site close to the coal mine. In fact this charge may be not applicable because of possible utilization of the ash for cement substitution. 5. Additional fuel (Fuel Oil #2) for operation of rolling stock, start up, outages, and occasional heating. 6. The cost of acquisition of consumables such as limestone, hydrated lime, ammonia, chemicals for water treatment, is determined according to listings at local Pacific NW suppliers; shipping cost is assumed to be same as that of coal. The item Cost of Money, being the second largest (after fuel cost) should be evaluated carefully, specifically, the loan term, required equity percentage and the interest rate. Bethel Feasibility Study June 2001-Final Page 16 of 16 PRECISION ENERGY SERVICES INC. BETHEL COGENERATION PROJECT 5 MW + DISTRICT HEATING 1 |INPUT DATA ALL MONEY VALUES IN DOLLARS 2001 1.13 |Loan percent | 70.0% 1.1 _|Plant Capital cost $ 29,905,000 1.14 |Equity percent 30.0% 1.2 _ |Plant electric output, net Mw 5.0 |Parasitic power MW 0.80 1.15 |Loan amount 20,934,000 a8 Price $ / MW-hr 85.00 | $0.08/kW-hr 1.16 |Equity amount 8,971,000 1.4 Plant Thermal output for DH, net delivered to City of Bethel MM Btu/day 1,444 1.17 |Loan period 7 1.5 _|Operating years years 20 1.18 |Principal not paid for years 2 1.6 |Calendar days days 365 1.19 |Loan interest rate 8.0% 1.7 |Coal demand ST/ day 138.9 1.20 |Interest paid in the first 2 years Siyear 3,349,440 1.8 |Coal cost delivered to Bethel, Plant pier $/ST 63.00 1.21 |P+l| payment 29,564,717 1.9 _ | Ash production including gypsum from SO, control ST / day 25.7 1.22 |Principal paid at year end, average per year 4,186,800 1.10 |Ash disposal (shipping to Canada + tipping fee) at$/ST 40.00 1.23 | Interest gein7 , calculated at year end, 1,233,000 1.11 |Cost of Fuel Oil ($1.25/gallon) $/MM Btu 9.26 Year 1 Year 2 Year3 Year 4 Year 5 Year6 Year 7 Year 8 Year9 Year 10 Year 11 Year 12 Year 19 Year 20 2 Revenue Availability 85% 90% 95% 95% 95% 95% 95% 95% 95% 95% 95% 95% 95% 5% 2.1 Power revenue 3,164,550 3,350,700 3,536,850 3,536,850 3,536,850 3,536,850 3,536,850 3,536,850 3,536,850 3,536,850 3,536,850 3,536,850 3,536,850 3,536,850 22 |x energy revenue (Price per MM Btu = Fuel Cost per MM Btu) 4,148,387 4,392,410 4,636,433 4,636,433 4,636,433 4,636,433 4,636,433 4,636,433 4,636,433 4,636,433 4,636,433 4,636,433 4,636,433 4,636,433 Total Revenue 7,312,937 7,743,110 8,173,283 8,173,283 8,173,283 8,173,283 8,173,283 8,173,283 8,173,283 8,173,283 8,173,283 8,173,283 8,173,283 8,173,283 3 Cost 3.1___|Personnel 3.11 |Manager 1 48,000 48,000 48,000 48,000 48,000 48,000 48,000 48,000 48,000 48,000 48,000 48,000 48,000 48,000 3.12 |Operation and Maintenance (2 x 4 persons) @ $36,000 /y 8 288,000 288,000 288,000 288,000 288,000 288,000 288,000 288,000 288,000 288,000 288,000 288,000 288,000 288,000 3.13 |Payroll taxes 30% 100,800 100,800 100,800 100,800 100,800 100,800 100,800 100,800 100,800 100,800 100,800 100,800 100,800 100,800 Total personnel cost 9 436,800 436,800 436,800 436,800 436,800 436,800 436,800 436,800 436,800 436,800 436,800 436,800 436,800 436,800 3.2 |Utilities and Consumables 3.21 | Electric power (generate own; consumption only during outages) 44,676 29,784 14,892 14,892 14,892 14,892 14,892 14,892 14,892 14,892 14,892 14,892 14,892 14,892 3.22 _|Fuel (coal) 2,715,412 2,875,142 3,034,872 3,034,872 3,034,872 3,034,872 3,034,872 3,034,872 3,034,872 3,034,872 3,034,872 3,034,872 3,034,872 3,034,872 3.22 _| Additional fuel (start-up, outage) 28,470 18,980 9,490 9,490 9,490 9,490 9,490 9,490 9,480 9,490 9,490 9,490 9,480 9,490 3.23 |Limestone, hydrated lime, ammonia and other consumables 653,835 685,237 716,639 716,639 716,639 716,639 716,639 716,639 716,639 716,639 716,639 716,639 716,639 716,639 3.3 |Maintenance cost (Eqt 5%, Bidg 2.5%, El. 10%) 1,008,450 1,008,450 1,008,450 1,008,450 1,008,450 1,008,450 1,008,450 1,008,450 1,008,450 1,008,450 1,008,450 1,008,450 1,008,450 1,008,450 3.4 __ |Ash disposal (shipping to Canada + tipping fee) 318,440 337,171 355,903 355,903 355,903 355,903 355,903 355,903 355,903 355,903 355,903 355,903 355,903 355,903 3.5 Insurance fee (Fire, Accident) 50,000 50,000 50,000 50,000 50,000 50,000 50,000 50,000 50,000 50,000 50,000 50,000 50,000 3.6 Miscellaneous 10% 520,608 544,156 562,705 562,705 562,705 562,705 562,705 562,705 562,705 562,705 562,705 562,705 562,705 562,705 3.7 Sub-total cost (before cost of money) 5,726,691 5,985,721 6,189,751 6,189,751 6,189,751 6,189,751 6,189,751 6,189,751 6,189,751 6,189,751 6,189,751 6,189,751 6,189,751 6,189,751 Cost of money (interest on debt financing, Syear loan) 8,630,717 1,674,720 1,674,720 1,674,720 1,389,253 1,080,949 747,980 388,374 3.8 | Total cost 7,401,411 7,660,441 7,864,471 7,579,004 7,270,700 6,937,731 6,578,125 6,189,751 6,189,751 6,189,751 6,189,751 6,189,751 6,189,751 6,189,751 Principal repayment 20,934,000 3,568,335 3,853,802 4,162,106 4,495,075 4,854,681 3.90 |Cost with Principal repayment 7,401,411 7,660,441 11,432,806 11,432,806 11,432,806 11,432,806 11,432,806 6,189,751 6,189,751 6,189,751 6,189,751 6,189,751 6,189,751 6,189,751 4.00 _| Sales profit including Principal repayment (88,474) 82,669 (3,259,524)| _ (3,259,524)| _(3,259,524)|__-(3,259,524)| (3,259,524) 1,983,532 1,983,532 1,983,532 1,983,532 1,983,532 1,983,532 1,983,532 5.10 |IRR__ at total cost of investment (30% equity + 70% debt) 0.2% (8,971,000) (88,474) 82,669 (3,259,524) (3,259,524) (3,259,524) (3,259,524) (3,259,524) 1,983,532 1,983,532 1,983,532 1,983,532 1,983,532 1,983,532 1,983,532 5.20 |IRR__attotal cost of project (100% equity) 0.1% (29,905,000) (88,474) 82,669 308,812 594,279 902,583 1,235,551 1,595,157 1,983,532 1,983,532 1,983,532 1,983,532 1,983,532 1,983,532 1,983,532 | Explanations, remarks Cost of limestone, hydrated lime, ammonia and other consumables was calculated assuming shipping cost to Bethel, AK to be equal to that of coal (~$33 / ST) This cost includes also cost of boiler feed water preparation (demineralization) and chemical addition. ‘The cost of hydrated lime and ammonia and of related capital equipment will be eliminated if the emission standards are set as per discussion of the Air Pollution Control System 6/21/2001 BethFEAS 06 2001 Feas 5 MW PRECISION ENERGY SERVICES, INC. BETHEL COGENERATION PROJECT 15 MW + DISTRCT HEATING INPUT DATA ALL MONEY VALUES IN DOLLARS 2001 .13 |Loan percent 11 |Plant Capital cost $ 51,666,000 1.14 |Equity percent 30.0% 1.2 _ |Plant electric output, net Mw 15.0 |Parasitic power MW 1.20 1.15 |Loan amount 36,166,000 13 |Price $ / MW-br 90.00 | $0.08 / KW-hr' 1.16 |Equity amount | 15,500,000 4 1.4 _|Plant Thermal output for DH, net delivered to City of Bethel MM Btu/day 1,444 | 1.17 |Loan period 1.5 | Operating years years 20 1.18 |Principal not paid for years 4.6 |Calendar days days 365 | 1.19 |Loan interest rate 8.0% 1.7 |Coal demand ST/day 306.1 1.20 | Interest paid in the first 2 years $iyear 14,910,601 1.8 _ |Coal cost delivered to Bethel, Plant pier $/ST 63.00) 1.21 |P+| payment 51,076,601 14.9 _|Ash production including gypsum from SO, control ST/day 54.4 1.22 |Principal paid at year end, average per year 7,233,200 1.10 __|Ash disposal (shipping to Canada + tipping fee) at $/ST 40.00 Interest a1 in7 . calculated at year end, 2,130,000 1.11 |Cost of Fuel Oil ($1.25/gallon) $/MM Btu 9.26 Year 1 Year 2 Year 3 Year 4 Year 5 Year 6 Year 7 Year 8 Year 9 Year 10 Year 11 Year 12 Year 19 Year 20 Zi Revenue Availability 85% 90% 95% 95% 95% 95% 95% 95% 95% 95% 95% 95% 95% 95% 2.1 |Power revenue 10,052,100 | 10,643,400 | 11,234,700 | 11,234,700} 11,234,700 | 11,234,700} 11,234,700 | 11,234,700 | 11,234,700 | 11,234,700! 11,234,700 |__ 11,234,700 |_11,234,700 | _ 11,234,700 2.2 _|DH energy revenue (Price per MM Btu = Fuel Cost per MM Btu) 4,148,387 4,392,410 4,636,433 4,636,433 4,636,433 4,636,433 4,636,433 4,636,433 4,636,433 4,636,433 4,636,433 4,636,433 4,636,433 4,636,433 Total Revenue 14,200,487 | 15,035,810} 15,871,133 | 15,871,133} 15,871,133 | 15,871,133 | 15,871,133 | 15,871,133 | 15,871,133 | 15,871,133 | 15,871,133 | 15,871,133 | 15,871,133 |__ 15,871,133 3 |Cost 3.1 |Personnel 3.11__|Manager 1 48,000 48,000 48,000 48,000 48,000 48,000 48,000 48,000 48,000 48,000 48,000 48,000 48,000 48,000 3.12 | Operation and Maintenance (2 x 4 persons) @ $36,000 /y 10 360,000 360,000 360,000 360,000 360,000 360,000 360,000 360,000 360,000 360,000 360,000 360,000 360,000 360,000 3.13 _| Payroll taxes 30% 122,400 122,400 122,400 122,400 122,400 122,400 122,400 122,400 122,400 122,400 122,400 122,400 122,400 122,400 Total personnel cost 1 530,400 530,400 530,400 530,400 530,400 530,400 530,400 530,400 530,400 530,400 530,400 530,400 530,400 530,400 |_32 |Utilities and Consumables 3.21 _|Electric power (generate own; consumption only during outages) 70,956 47,304 23,652 23,652 23,652 23,652 23,652 23,652 23,652 23,652 23,652 23,652 23,652 23,652 3.22 |Fuel (coal) 5,983,668 6,335,649 6,687,629 6,687,629 6,687,629 6,687,629 6,687,629 6,687,629 6,687,629 6,687,629 6,687,629 6,687,629 6,687,629 6,687,629 3.23 _|Additional fuel (start-up, outage) 44,737 29,825 14,912 14,912 14,912 14,912 14,912 14,912 14,912 14,912 14,912 14,912 14,912 14,912 3.24 _|Limestone, hydrated lime, ammonia and other consumables 1,251,037 1,316,392 1,381,747 1,381,747 1,381,747 1,381,747 1,381,747 1,381,747 1,381,747 1,381,747 1,381,747 1,381,747 1,381,747 1,381,747 3.3__|Maintenance cost (Eqt 5%, Bidg 2.5%, El. 10%) 1,810,221 4,810,221 1,810,221 1,810,221 1,810,221 1,810,221 1,810,221 1,810,221 1,810,221 1,810,221 1,810,221 1,810,221 1,810,221 1,810,221 3.4 __|Ash disposal (shipping to Canada + tipping fee) 674,929 714,630 754,332 754,332 754,332 754,332 754,332 754,332 754,332 754,332 754,332 754,332 754,332 754,332 3.5 _|Insurance fee (Fire, Accident) 50,000 50,000 50,000 50,000 50,000 50,000 50,000 50,000 50,000 50,000 50,000 50,000 50,000 3.6 _|Miscellaneous 10% 1,036,595 1,083,442 1,125,289 1,125,289 1,125,289 1,125,289 1,125,289 1,125,289 1,125,289 1,125,289 1,125,289 1,125,289 1,125,289 1,125,289 3.7 _ |Sub-total cost (before cost of money) 11,402,543 | 11,917,863 | 12,378,184} 12,378,184 | 12,378,184 | 12,378,184 | 12,378,184 | 12,378,184 | 12,378,184 | 12,378,184 | 12,378,184 | __ 12,378,184 |__ 12,378,184 | __ 12,378,184 Cost of money (interest on debt financing, Syear loan) 2,893,280 2,893,280 2,893,280 2,400,102 1,867,469 1,292,226 670,964 38 _|Total cost 14,295,823 | 14,811,143 | 15,271,464 | 14,778,285 | 14,245,653 | 13,670,410} 13,049,147 | 12,378,184 | 12,378,184 | 12,378,184 | 12,378,184 | 12,378,184 | 12,378,184 | 12,378,184 Principal repayment 36,166,000 6,164,728 6,657,906 7,190,539 7,765,782 8,387,045 3.90 _|Cost with Principal repayment 14,295,823 | 14,811,143 | 21,436,192} 21,436,192 | 21,436,192 | 21,436,192 | 21,436,192 | 12,378,184 | 12,378,184 | 12,378,184 | 12,378,184 | 12,378,184 | 12,378,184 | __ 12,378,184 Sales profit including Principal repayment (95,336) 224,667 | _(5,565,059)| _(5,565,059)|__(5,565,059)| __(5,565,059)| _(6,565,059)|_ 3,492,949 3,492,949 3,492,949 3,492,949 3,492,949 3,492,949 3,492,949 IRR__at total cost of investment (30% equity + 70% debt) 0.5%| (15,500,000) (95,336) 224,667 | _(6,565,059)| (6,565,059)! (5,565,059)|_ (5,565,059)| (6,565,059)|__ 3,492,949 3,492,949 3,492,949 3,492,949 3,492,949 3,492,949 3,492,949 IRR _ at total cost of project (100% equity) 0.3%| (61,666,000) (95,336) 224,667 599,669 1,092,847 1,625,480 2,200,723 2,821,986 3,492,949 3,492,949 3,492,949 3,492,949 3,492,949 3,492,949 3,492,949 Explanations, remarks Cost of limestone, hydrated lime, ammonia and other consumables was calculated assuming shipping cost to Bethel, AK to be equal to that of coal (~$33 / ST) This cost includes also cost of boiler feed water preparation (demineralization) and chemical addition. The cost of hydrated lime and ammonia and of related capital equi will be eliminated if the emission standards are set as discussion of the Air Pollution Control System 6/21/2001 BethFEAS 06 2001 Feas 15 MW ECONOMIZER BAGHOUSE SCRUBBER AMBIENT AIR COUMBUSTION AIR FAN STACK INLET SILENCER COAL RECEIVING AND STORAGE 8 MO. STORAGE Sy ces ATMOSPHERIC FLUID BED aoe + BOILER + SUPERHEATER 3 mw (10 Mw) 2” Hg (a) STEAM INPUT CENTRAL HEAT 51,000 TO EXCHANGE. STATION aaa CONDENSATE 80,000 LB/HR PREPARATION DEAERATOR TANK T 80,000 - 120,000 gph —CRUSHER @ 20 PSIA GRINDER CONDENSATE CONDENSATE DA STEAM STEAM 600 psig 750° F ee ATMOSPHERIC FLUID BED ie eur + BOILER + SUPERHEATER 3 uw (10 MW) AMBIENT AIR POWER PLANT OUTPUT: OPTION 1 — S MEGAWATTS OPTION 2 — 15 MEGAWATTS FW 400° F STEAM FOR DISTRICT HEATING: INLET BOTH OPTIONS - 51,000 TO 80,000 Ib/hr SILENCER COUMBUSTION AIR FAN BAGHOUSE ECONOMIZER THIS DRAWING IS THE PROPERTY OF PES, THE DESIGN AND PRECISION De Terane aE EAE at ENERGY WITHOUT WRITTEN PERMISSION FROM PES. . SERVICES INC. STACK TI Web Site:http://www.pes—world.com E-mail:energy@pes—world.com T TITLE: BETHEL COGENERATION PROCESS FLOW DIAGRAM + DRAWN BY: JOC APPROVED BY: DATE: 08/29/00 ; T ; samt ee SCALE: NTS. poor. fu HAL {EAR 122-2000-1.dwg 7 | PRELAADURY ca/oroo| wc JOB NO. DRAWING NO. SHEET: Lz NO. REVISION pare | BY | CHK 122 2000 1 OF 1 [Re 80 MW COAL PLANT Introduction PPE ia,” SERVIC VICES INC. 1. INTRODUCTION This report has been prepared to be used as a part of a feasibility study of a power plant intended to be developed for the supply of electric power to the Donlin Creek mine site to be located at Crooked Creek, Alaska. In addition, the possibility of providing power to Bethel and the communities in the immediate vicinity of the generating station and/or along the transmission line route to the mine site will be evaluated. The goal of this report is to provide the project developers sufficient information to identify the least expensive, long-term power production options without the traditional requirement to minimize the up front capital investment. Environmental permitting standards and expected performance related to the operation of the power plant have been noted in Section III to make the developer aware of the possible requirements. The costing information provided herein is based on the application of the Circulating Fluidized Bed (CFB) technology for generating steam in an integrated boiler. The decision to use the CFB technology has been made by the project developers based on earlier studies. Two CFB boilers will be fired with coal imported most likely from Canada. This report is based on medium volatile coal supplied from the Quinsam Coal Corporation coal mine near Campbell River on the Vancouver Island, British Columbia, Canada. This coal represents an average thermal coal mined in Western Canada or Alaska. For the purpose of this Study, Alaskan coal has not been included due to lack of developed coal deposits in the vicinity of the plant and the low heating value and cost of the commercial coal available in Alaska. CFB combustion is a modern technology that is characterized by high combustion efficiency (low loss on ignition), low-cost coal preparation and low-cost emission controls. The technology exceeds the performance of such leading edge technologies as the Clean Coal plant at Healy, AK. The technology has become an industry standard for coal-based power generation. Bids have been obtained from the most advanced and experienced vendors: Babcock & Wilcox, Kvaerner Pulping and Ahlstom ABB. The evaluations include provision for heat energy that could be used for district heating of the City of Bethel. The feasibility study did not evaluate the cost or savings available for the district heating system. The power plant specifications are provided on the following page. PRECISION ENERGY SERVICES INC. DONLIN CREEK POWER PLANT PROJECT SPECIFICATIONS No. Specification Units One system Entire Plant 1 Power plant output MWe 40 80 2 Steam parameters psia 1,400 oF 950 3 Condensing turbine at in. Hg (a) 2 - Generating efficiency h, 80% 5 Extraction steam for DA and DHH psig 20 6 Steam flow, condensing cycle lb/hr 249,090 498,000 7 Steam flow, extraction cycle lb/hr 72,787 146,000 8 Total steam flow to turbine lb/hr 321,877 644,000 9 Boiler blow-down Ib/hr 4,902 9,800 10 Steam generation in boiler Ib/hr 326,779 653,800 11 Power generation, Condensing Cycle kW 33,718 67,440 12 Power generation in Extraction Cycle kW 6,282 12,560 13 Total generation kW 40,000 80,000 14 Coal demand at heating value Btu/Ib 10,620 Coal demand for 80 MW plant (2 boilers) Ib/hr 88,667 Coal demand @ 95% availability ST/year 368,900 Coal demand without district heating ST/year 345,433 15 Limestone demand Limestone demand for entire plant (2 boilers) ST/day 48.0 Limestone demand at 95% availability ST/year 16,655 16 Ash Flow Ash flow from coal lb/hr 5,800 Ash flow including CaSO,/, Ib/hr 8,384 Total ash flow from entire plant ST/day 100 ST/year 35,000 Le, District Heating Heat supply to heat exchanger station Btu/hr 60,000,000 Heating water flow in DH system lb/hr 545,000 Heating water return at 120°F; heat exchange AH = 110 Btw/Ib Description of Power Plant PRECISION RES 2 SERVICES INC. 2. DES ON OF THE POWER PLANT A complete coal fired power plant has been evaluated for the production of 80 MW of electrical power. The plant will include two separate boiler and turbine islands to allow independent operation of the plant on one system at 40 MW. The Power Plant will include the following systems: 1 Coal receiving and unloading dock 2 Coal storage area including stacking and retrieving equipment, crushers and furnace feeding conveyors. 30 Two circulating fluidized bed combustors with integrated boiler, superheater, economizer and air heater. Two turbine and generator process lines including switch gear and substation. Steam condensers with cooling towers and feedwater circulating pumps. Feed water chemical treatment and deaerator. Air pollution control system including baghouse, SNCR system, ducting and stack Fans and blowers for combustion air, flue gas induced draft and auxiliary. om Nana Instrumentation and controls, central control room and motor control center. 10. Auxiliary equipment and installations such as loaders, diesel fuel storage tanks, stand by boilers for start up and auxiliary steam demand and other. 11. Maintenance shop with tools. 12. The plant will be housed in appropriate buildings. The buildings will also include facilities for the office personnel — locker rooms, lunchroom, etc. Fuel Receiving, Storage and Combustor Feedin m Coal will be shipped from the ocean port at Campbell Creek, Prince Ruppert or Westshore Terminal of the Port of Vancouver, all British Columbia, Canada on 45,000 to 50,000 ton vessels, which will bring the coal 90 miles off-shore near Bethel. Here the coal will be loaded on 400 ft long, 10,000 ton self unloading barges and supplied to the Plant’s receiving and unloading dock. The plant will receive the entire yearly coal supply during a 4 to 6 months summer window and stored in a coal storage area. The Fuel Receiving, Storage and Combustor Feeding System will be built as follows: 1 Coal receiving and unloading dock will be located at the riverfront and will include pilings in the river for two barges 400 feet long each. River depth at these pilings must be 17 feet or greater. The dock will be attached to the pilings to hold one large coal-receiving hopper. nr: a SERVIC. VICES INC. 10. te 12: Excavation fill to support dock. It may be necessary to provide sufficient fill at river’s edge with a concrete quay to support heavy equipment. Coal receiving office/building to house an office, lunchroom, and warehouse of disposable items coming in by barge. Coal unloading equipment. A coal receiving hopper within reach of slewing conveyor from barge. The hopper will be large enough for receiving maximum unloading tonnage per hour from barge. Structural Support. It may be necessary to support receiving hopper on pilings if the ground is unable to support this large structure. Coal conveyors to storage area and stacker. Receiving belt conveyor, 60” to 72” wide from dockside hopper to coal storage. Such a conveyor would be elevated and equipped with a tripper. Bridge conveyor stacker. This would be an elevated horizontal conveyor at right angle to the receiving conveyor, spanning over 400 feet, distributing coal on two piles 30 feet high and 900 feet long. Coal Storage Pad. This area will store two piles of coal 30 feet high, 400 feet wide by 900 feet long. An area of 400 feet x 400 feet between piles for loader operation. The soil we be tested to determine the method of design, construction and stabilization of the ground pad. Three sides of each coal pile will be retained by concrete walls at least 10 feet high to control spillage. A fire prevention and protection system will be installed at this storage area. Rubber tired loaders with a bucket capacity of 15 cubic yards will be used to move coal from either coal pile to the reclaim hopper at a rate consistent with that required to operate the plant. Reclaim hopper and supports. Located between the two coal piles. The loader will move the coal to the reclaim hopper that is located at ground level. Conveyor to crusher house. An incline belt conveyor from the reclaim hopper to a splitter chute will direct coal to either of two coal crushers. Conveyor will be completely covered. Loader Maintenance Shop to provide safe and warm environment to service the two diesel bucket loaders. Provide bridge crane and grease pits for both loaders, as well as storage of hydraulic fluids, engine oils and antifreeze. Diesel fuel to be stored above ground near maintenance shop. Storage tanks will be furnished for eight months or longer supply of fuel. Storage tanks can be filled by barge/ship to avoid handling and possible spills. All other mobile equipment would be diesel powered to avoid handling gasoline. Block heaters will be applied in all diesel powered equipment with power hook-ups throughout the area. aE: — SERVICES INC. 14. 15; 16. 17, 18. Breaker and grinding mill. A crusher house for two, ring type, single roll crushers will be provided. Reclaim conveyor will feed either crusher. Two coal crushers 100 tph/each. Each crusher has the individual capacity to fill the coal bunkers. Permanent magnets will be before the crushers to remove tramp metal. Crushed coal conveyors, two required, to feed coal to the bunkers inside the boiler building. Each conveyor independently feeds coal to bunkers of each boiler. Conveyor redundancy allows coal conveyance to all bunkers regardless of which crusher is operating. The loading system for furnace feed will include four double chamber bunkers to provide adequate and uninterrupted supply of fuel to the CFB burners. The number of bunkers is based upon the CFB being equipped with two fuel metering feed screws on either side of each CFB burner. Distribution conveyors with trippers. The four bunkers for the CFB burners will be fed on top with a belt conveyor and tripper. The two conveyors from the two crushers feed individually the two distribution conveyors that service four bunkers. Diverter gate from the two crusher conveyors can feed either distribution conveyors independently or together. Flexibility of the system allows minimum loss of generating power. Gravity feed chutes to each of the four fuel feed metering screws. One two-chamber bunker is dedicated to each metering screw. This avoids plugging of one bunker when shutting down a fuel feed screw. Coal Fired CFB Boilers Three of the most advanced and experienced CFB vendors had been requested to provide budget price bids; they are Babcock & Wilcox, Kvaerner Pulping and Ahlstom ABB. Two trains of the integrated CFB furnace - boiler system will be included in the Power Plant; each system will typically consist of: Circulating fluidized bed furnace with cyclone, water walls and steam drum with connecting tubes and piping Backpass Tube Panels/Headers Superheater, attemperator and interconnecting steam piping Economizer with feedwater piping ASME Code Valves & piping as well as boiler trim valves; safety valves with vent piping and silencers Feedwater stop and check valves Tubular air heater Auxiliary start-up burners with lighters and flame detectors Burner Management System Primary and secondary combustion air blowers with motor drives Fuel and limestone feeders PE PRECISION ERERGY SERVICES INC. - Bed drain system with ash screw coolers - Integrated boiler, including piping, refractory, insulation and lagging/casing - Boiler instrumentation - Structural steel including platforms, grating, handrails The integrated CFB furnace, boiler and superheater system will produce superheated steam at 1400 psi and 900°F to be used in the generating system. Steam Turbine and Generator System Two trains of the Steam Turbine and Generator system will be included in the Power Plant; each system will typically consist of: - Turbine unit with condensing steam exhaust and one back pressure steam extraction outlet with non-return valves for district heating and de-aerator. - Required piping, insulation blankets, sheet metal lagging - Generator, 13.8 kV, 60 Hz, 3600 rpm, 0.85 PF with brush-less excitation and coolers sized for water temperature 85°F. Generator shaft is monitored for vibrations. - Oil System on separate baseplate for lubrication and control oil with interconnecting piping and oil coolers sized for water temperature 85°F. Two main oil pumps and one emergency DC pump. - Complete stand-alone digital control system handling all required turbine and generator controls (closed and open loop) and monitoring instrumentation (power output, pressures, temperatures, vibrations, etc.) of the steam turbine and generator unit. The control system includes a coordinating controller plus separate control units for the turbine governor function, steam turbine safety trip functions and generator voltage regulator functions. - Operator station with color monitor, keyboard, track ball and event and alarm printer. - Unit is built for indoor installation with noise attenuation to 85 dBA. Quotes for complete steam turbine generating system have been obtained from Alstom Power, Dresser-Rand and Siemens Westinghouse. Steam Surface Condenser With two feedwater circulating, liquid ring vacuum pumps. Each pump at 100% capacity. The condenser is built of 304L stainless steel tubing and tubesheets and coal tar epoxy coated water boxes. The surface condenser quote was provided by Alstom Power. Cooling Tower One for both trains; fiberglass structure, stainless steel connecting hardware, heavy duty PVC film pack fill, two 28’ diameter fans with drive (200 hp), fire retardant FRP fan cylinders for velocity recovery and other. The cooling tower quote was provided by Psychrometric Systems, Inc. PDE aoe SERVIC VICES INC. Feed Water Chemical Treatment and Deaerator A complete feedwater system would be supplied. Boiler feedwater and deaerator for each boiler would be included. ir Pollution Control System The air pollution control system will include in each CFB-boiler-turbine-generator line the following sub-systems: - Multiclone — supplied together with the CFB furnace. - Baghouse — supplied together with the CFB furnace - Selective Non-Catalytic Reduction system for NOx control — engineered by PES, - Limestone injection system for SO, reduction in the fluidized bed — supplied together with the CFB furnace. The system will include sufficient limestone storage capacity. . Induced draft fan — supplied together with the CFB furnace - Ducting to the stack— supplied together with the CFB furnace The plant will have one multi-flue stack for discharging clean flue gases to the atmosphere. The stack may have to be equipped, depending on the environmental permit, with continuous emission monitoring (CEM) devices: - SO, monitor - Opacity monitor - NOx monitor - Oxygen monitor - Particulate concentration monitor The CEM devices, if required, will be supplied by AMETECH and/or AIM. Instrumentation and Controls, Central Control Room and Motor Control Center The Power Plant will be equipped with all instrumentation and controls necessary for trouble-free operation of the Plant. The CCR (central control room) will include operator stations with color monitors, keyboards, track balls and event and alarm printers. The CCR will house also the output and monitoring devices of the steam turbine power generating system. A separate motor control center (one for the entire plant) will be provided in a separate room of the main building. PDE aaa SERVIC. VICES INC. Other Plant System and Equipment as Required for Complete Plant All equipment and sub-systems required for a complete plant have been included in the plant estimated cost. Items not included are: 1. Cost of permits or fees. 2 Lease or purchase of land for plant. 3. Electrical substation and powerline. District Heating System The plant will include provision for connecting to a central district heating system. It will include a heat exchanger for heating water circulating between the plant and the heat receivers in the neighboring communities. The circulating water will be heated with extracted steam. At the maximum demand for heat, the plant will supply to the district heating system 60 MM Btu/hr. The piping system from local communities to the heat exchanger station is not included in the Power Plant cost. Performance Calculations PES a SERVIC. VICES INC. 3. PERFORMANCE ATIONS The Donlin Creek Power Plant Performance Calculations provide calculations of steam production, coal and limestone demand, as well as ash production of the plant. The Calculations are for a single 40 MW system and combined for a total of 80 MW. The Plant’s environmental performance is included following the calculations. The design shows a high-efficiency plant in the range of 87%. PRECISION ENERGY SERVICES, INC. DONLIN CREEK POWER PLANT PERFORMANCE CALCULATIONS Steam I/O data One generation line Two generation lines Power plant output 40 80 Steam parameters i 1,400 950 3 |Condensing turbine at Vv in. Hg (a) 2 4 |Generating efficiency ne 80% 80% 5 |Theoretical steam rate, condensing TSRe__ |Ib/kW-hr 5.91 6 |Practical steam rate, condensing (TSRc/n,) Ib/kW-hr 7.39 7 |Backpressure steam for DA and DHH psia 20 8 |Theoretical steam rate back pressure Mbt Ib/kW-hr 9.27 9 |Practical steam rate, back pressure (TSRc/n,) Ib/kW-hr 11.59 10 |Net required steam flow, condensing cycle Mc Ib/hr 249,090 | 498,000 11 |Net required steam flow, backpressure cycle |Mb Ib/hr 72,787 146,000 12 | Total steam flow to turbine Mt Ib/hr | 321,877 644,000 13 |Boiler blow-down Mbd lb/hr | 4,902 | 1.50% 10,000 14 |Steam generation in boiler M |ibmr 326,779 654,000 15 |Power generation in Condensing Cycle |Nc |kw | 33,718 | 67,000 16 |Power generation in Backpressure Cycle INb kW | 6,282 13,000 17 |Total generation kw | 40,000 80,000 | T SH Steam enthalpy |Hsh Btu/Ib 1,463.2 Back pressure steam enthalpy at 20 psig Hbp Btu/Ib 1,167.1 | | B_|Deaerator balance | | 20 |Water enthalpy at 20 psig Hw Btu/lb 228 I psig 20 259 °F 21 |Condensate flow Ib/hr 249,090 I | | ‘|Btu/ib 68 101 °F) | - 22 |Make-up water for 1.5%Mc blowdown | Ib/nr 4,902 | | - | | Btulb 8 | 40 °F [ 23 |Steam input to DA | libmr | 43,597 87,000 | _ 24 |Steam input to DHH | |Ib/nr | 29,190 | 58,000 | _ 25 Total flow to economizer | libre 326,855 [ Ipsig 20 259 °F) 26 Total back pressure flow | Ib/rr | 72,787 | | 146,000 | | | | | C_|DH heater (DHH) balance | | | | 30 |District heating maximum duty, estimate Qdh Btu/hr 30,000,000 | 60,000,000 31 |ALAT = 110°F, retum water at 120°F | |Btutb 88.0 | | 32 |Total required DHH water flow Mdh | Ib/hr ‘| 272,727 | | 545,000 | Ee |Add steam at 20 psia for DHH water heating lib | 29,190 | 58,000 [5% heat losses included | | | | | D_|Feedwater from DA | [Btunb | 228.0 |psig | 1,400 | 259 °F | 40 |Economizer duty, enthalpy out | | Thermal Caics0900 10/03/00 Page 1 of 2 PRECISION ENERGY SERVICES, INC. DONLIN CREEK POWER PLANT PERFORMANCE CALCULATIONS Thermal Calcs0900 Energy increase in ECO including 0.5% heat loss |Btu/hr 105,969,169 211,938,000 309 Boiler Saturated steam at 1400 psia Enthalpy increase in boiler (BO) 52 |SH Steam enthalpy Btu/Ib | 1463.2 | 950 53 |Enthalpy increase in superheater (SH) Hsh Btu/lb 288 54 |Boiler thermal duty including 0.5% heat loss Qb Btu/hr 209,740,402 419,481,000 55 |Superheater duty including 0.5% heat loss Qsh Btu/hr 94,572,062 189,144,000 56 |Boiler & SH duty Qb Btu/hr 304,312,465 608,625,000 | | | F Coal demand i 60 |Boiler, SH and ECO duty Q |Btu/hr 410,281,634 | 820,563,000 61 |Assumed plant efficiency In | I 82.2% | Includes district heating as a loss 62 |Heat input demand |Btu/hr 499,174,657 998,349,000 63 |Coal heating value, net Btu/lb 10,620 64 |Required input, first estimate Ib/hr 47,003 65 |At 25% XA, combustion air input lb/hr 494,980 990,000 66 |Gaseous PoC flow lb/hr | 536,183 1,072,000 G |Air Heater (winter conditions) | 70 |Air heater duty, air enthalpy increase Har Btu/lb 64.59 Ambient aes (30) |Heat to °F 250 71 |Air heater duty in winter Q Btu/hr 31,972,322 63,945,000 72 |Duty in summer (60°F ambient) | Btuhr | 17,166,264 | 34,333,000 73 |Heat loss in flue gas at 350°F |Qfg Btuw/hr | 35,579,292 | 71,159,000 | | | | H | Thermal Performance | | 80 |Estimated heat losses {Qi Btu/hr | 24,958,733 5% 49,917,000 | 81 | Total plant thermal duty |Qt |Btu/hr 470,819,659 | 941,639,000 82 |Boiler plant efficiency (without DHH) in 87.1% 83 |Heat rate without district heating |Btu/kW-hr 11,020 | | 84 |Boiler plant efficiency (with DHH) in | 93.5% 85 |Heat tate with district heating | |Btu/kW-hr 11,770 | | 10/03/00 Page 2 of 2 PRECISION ENERGY SERVICES, INC. DONLIN CREEK POWER PLANT PERFORMANCE CALCULATIONS Coal demand Quinsam coal, net Required coal input with district heating Coal demand for 80 MW pliant (2 boilers) Coal demand @ 95% availability Coal demand without district heating Limestone demand SO, generation Compliance standard Required reduction Reduction with limestone, CaCO, demand @ Ca/S Limestone demand for entire plant (2 boilers) Limestone demand at 95% availability K |Ash Flow 410 |Ash flow from coal 111 |Ash flow including CaSOy/, (from SO, capture) 112 | Total ash flow from entire plant 113 |Total ash flow from entire plant Thermal Calcs0900 10/03/00 Page 3 of 2 PRECISION ENERGY SERVICES INC. Power Plant Environmental Performance 10% 0.020 0.150 0.300 0.095 No. Pollutant Units Standard Expected Performance 1 Opacity % 3-minute average 20% Zs Particulates Ib/MM Btu, hourly average 0.020 33 co Ib/MM Btu, hourly average 0.200 4. NOx Ib/MM Btu, 30-day rolling average 0.350 5. SO, Ib/MM Btu, 3-hour average; 0.100 Ib/MM Btu annual average 0.086 or 90% reduction 0.086 Capital Cost Estimates PE ca SERVICES INC. 4. CAPTICAL COST ESTIMATE The following cost estimate for the project has been based upon equipment quotations obtained from major equipment vendors and estimates. The installation cost of the equipment was based upon vendor estimates and a percentage of equipment cost. Dontin Creek Project Capital Cost Estimate ration |Coal recelving & unloading dock STiday 3,500 | Unloading equipment | Conveyors & stacker to storage area STiday 3,500 Breaker and grinding mill SThr 192 | Loading for fumace feed and bunkers ST 192 | | Coal feeders & Raw Coal piping from Bunker SThr 192 6,431,000 Limestone Unloading and Handling i Limestone Hopper and conveyors to storage Limestone storage Building Limestone reclaimer and conveyor system |Combustion System - 2 parallel systems Each system Metering bin ST 192 |CF 7,680 0 0 Fuel feeder(s) ib/hr 49,727 0 0 Limestone bin for 7 day storage st 4,402 |CF 110,058 Limestone feeder tbe 2,184 | IMM Btu/hr , 528 |CFBC, BMS, Aux. StUpBumer, bed recirc., boiler, refractory, structural steel ICA Blower SCFM 115,120 [Ap psi 3 |(?) 1,335 [kW 2/CFB Boiler with SH, attemperator, steam output Ibe 345,605 2 13,275,000 12,500,000 39,050,000 Economizer IMM Btu/hr 100,789 |AH Btulb 292 |Tin 228.0/Tout 500 |Multiclone and ash reinjection Tubular Air heater IMM Btuhhr u Tair Tin -30/Air Tout 250) |Sootblowers ‘ PoC (flue gas flow) Wb/he 567,253 |SCFH 7,259,937 Subtotal o 47,231,000 Environmental control system 'Baghouse at 350°F 1 9/21/0010:41 AM Donlin Creek Project Capital Cost Estimate Baghouse to ID fan duct ID Fan - stack duct Ash handling Ash system and silo for storage. SH, Attemp, BO Internal steam piping ‘Steam piping to turbine Materials Small Bore Piping and Misc. Boiler Instrumentation Ptant instrumentation and Control ‘Cooling Water Pumps Cooling system Piping & Valves Water well for boiler makeup potable water [River water system for cooling towers District heating system (inside plant fence only) ‘Standby Boilers system (2) for heating Olt storage Tank and loading system Stationary Dock Crane st Generators 2 @ 1000 kW 2 9/21/0010:41 AM Donlin Creek Project Capital Cost Estimate 139,478,663 20,921,799 160,400,462 3 9/21/0010:41 AM O&M Estimates IDE PRECISION ENERGY SERVICES INC. Vv. O&M ESTIMATE Operation and maintenance cost estimate. The following estimate was based in part from actual numbers PES obtained from a 100 MW CFB coal fired plant. Adjustments were made to labor costs for the plant location. The cost of coal, limestone and ash are based upon actual material and freight quotes. The cost of ash disposal was set at the cost of freight as there was interest in the material from two companies. Supporting information is included for several areas of the O&M estimate. OPERATION MAINTENANCE COSTS Donlin Creek Project Year Operations OH Staff $600,000 | Fuel Expenses | Support/Start-up Fuel | $5,000 $60,000 Coal (350,000 tons/year) $1 ,268,750| $15,225,000 Labor for above (1 per shift) $16,000 $192,000 Steam Expenses | Limestone Costs (17,000 tons/yr) $22,000) $264,000 Bed Material Make-up Costs | $0 $0 Ammonia Costs | $0 $0 Raw Water Costs $4,000) $48,000}. Miscellaneous Chemical Costs $15,000 $180,000 Labor for above (4 per shift) $82,000) $984,000 Electrical Expenses $45,000 $540,000 Miscellaneous Steam Power Expenses | $25,000 $300,000 Regulatory Compliance Costs Internal Compliance Costs $7,500 $90,000 External Consultants Costs $10,000 $120,000 Maintenance of Plant Maintenance of Structures Maintenance Supervision & Engineering Steam Generator, Pressure Parts & Refractory Fuel Handling System Ash Handling System $10,000 $15,000 $180,000 $75,000) $900,000 $8,000] $96,000 $20,000] $240,000 $120,000 | | | | Air & Flue Gas Equipment rT $6,000 $72,000 Emissions Controls Systems (Baghouse and | Limestone) | $15,000 le $180,000 Other Equipment (Demineralizer, Main Steam, | | Boiler Feedwater, Make-up) $6,000 $72,000 | Maintenance of Electrical Plant | $20,000 $240,000} | Maintenance of Miscellaneous Steam Plant | $15,000) $180,000 T T Maintenance of Rolling Stock | $10,000} $120,000 | | Ash Disposal - Freight Only | $35,000) $420,000 | | | 00-249 10/3/00 OPERATION MAINTENANCE COSTS Donlin Creek Project OH Expenses, Insurance, Supplies, Training, Etc! $20,000} $240,000 Coal, Limestone and Ash cost O&M Cost Less Coal, Limestone and Ash Operator O&M Fee @ 8% of Non-Fuel, Limestone and Ash Cost Total O&M cost with fee Total O&M Cost Per KW 00-249 10/3/00 Plant Manager Operations Manager Production Manager Purchasing Manager Assistant Account Manager Assistant Plant Engineer Regulatory Compliant Total Operations Lead Operator Secondary Operator Assistant Operator Electrical/Mechanical Coal Yard Operator Total x 5 Shifts = int ce See Attached Total Total Staffing 00-250 9-19/00 DONLIN CREEK STAFFING ee 9 people — ee 5 25 people 13 people 45 people WER P. ANCE P L 1. One Maintenance Support (maintenance manager/shop supervisor) 2. One Instrument Technician 3. Two Mechanics — day shift 4. Two Electricians — day shift 5. Two Machinists — day shift 6. Two Welders — day shift 7. Two Helpers/Apprentices 8. One Equipment Operator Total 13 There are not provisions for servicing/maintenance power transmission lines from Bethel to Crooked Creek. 00-248 9/19/00 SO190 SiSy ye 10. 12. jes 14. 15; 16. 17. 18. 19: 20. 21° 22. 23. 24. 25. 26. 21s 28. 29. 30. 31: 32. 33. 34. 35: 36. Sf. 00-247 9/19/00 MAINTENANCE SUPPORT ITEMS Machine shop area/building 100’ x 150’ heated, sodium vapor lights, 5 ton bridge crane, welder hookups 440 vac, lunch room, locker room, rest rooms, foreman’s office, tool room, print storage, drawing table area, 20’ high bay under bridge crane, fire suppression Welding shop area/building 100’ x 150’ heated, sodium vapor lights, 10 ton bridge crane, welder hookups 440 vac, other items share with machine shop, fire suppression 16” engine lathe, 10’ bed 10” bench lathe, 5’ bed 10” post radial dress press Small 5/8 drill press Vertical milling machine Horizontal milling machine with angle heat Horizontal cut-off band saw Vertical bandsaw Iron worker 300 amp wire feed welder, 2 required 300 amp stick welder Three gas welding gauges, torches, miscellaneous tips, cutting torches, tanks and hoses One year supply of welding wire two to three size dia. One year supply of welding rods, various sizes + grades Steam “Jenney” cleaner Annealing gas furnace Structural steel and storage rack Plate steel and storage Round, tubing, square, keystock, alloys Nuts and bolts, grades 5 and 8 50 ton vertical press 200 ton horizontal press One large set of outside calipers 6” to 12” diameter One set of inside micrometers Safety glasses Bump caps (hard hats) Coveralls, welding leathers and gloves Steel work benches Vises of various sizes to fit on steel benches Miscellaneous storage cabinets Milling machine attachments Various lathe attachments Miscellaneous hand power tools Miscellaneous hand tools TOTAL Instrument repair shop 20’ x 30’ room $975,000 $625,000 $75,000 $15,000 $30,000 $15,000 $35,000 $80,000 $15,000 $25,000 $30,000 $40,000 $15,000 $12,000 $5,000 $5,000 $8,000 $5,000 $10,000 $5,000 $5,000 $5,000 $4,000 $15,000 $6,000 $3,000 $500 $500 $2,000 $2,000 $1,000 $1,500 $10,000 $6,000 $5,000 $5,000 $2,096,500 $21,000 38. Spare parts & storage $30,000 39. Miscellaneous measuring instruments $15,000 40. Miscellaneous furniture, benches, bench lights, vises and stools $8,000 TOTAL $2,170,500 00-247 9/19/00 Coal Cost & Transportation PPE fn. sop SERVICES INC. 6. COAL COST & TRANSPORTATION re) "P.O. Bex 5000 Business: 250-286-3204 Quinsnm COAL CORPORATION FAX MESSAGE - from (250) 286-9727 Peete eReaTa TL TE:__Ang 22 2000 oat Kellos FAX #:_(Z08) 762 - MH FROM olen t: #OF PAGES:__Z ee: as Dee : ee ae As “Al ove hen Conversebyn vaclier Re-3 Ae Pod attnered a besharrol speeifrcshon chet Lov or thyrn sol We cor oPP- rhe cach ot US 432.00 per shect ton Yn ls, our Medd |. Pout Bor Locsl, uf Neer Compbell River ee Tf a | athe ah mits has thebe h conhuet me . —— —————————— ———-- Ooo eee (ypical result) (minimum) QUINSAM THERMAL COAL QUALITY SUMMARY Gross (dry) Gross (air dry) Gross (as received) Net (as received) Residual Moisture Ash Content (air dried) Feared Carbon (air dried) Volatile Matter (air dried) Oxidizing condition Initial Deformation Temp. Softening Temperature Hemisphere Temperature Fluid Temperature (dry ash free basis) (dry ash free basis) (Gry ash free basis) Metric Prod. Tynical 6800 kcalkg 6600 kcal/kg 6200 kcalikg 5900 kcal/kg 9.0% 3.0% average 13.5% 47.0% 36.5% 70.1% 48% - 0.9% 08% 9.8% 13.5% 0.78% «a 100% We 38.0% 27.3% 8.5% 15.9% 0.3% 02% 0.1% 16% 0.6% 41% 3.4% deg. 1338 - 1393 1409 - 1457 1432 - 1487 1468 - 1488 1412 - 1468 1454-1477 1454 - 1481 1458 - 1491 < 0.025 % <0.0004% <1.75% imp. Prod. Iynical 12,240 Btwib 11,880 Bab 11,160 Btuib 10,620 Bub 50.0 mm X 0 mm 2.0 mm XO mm awor es we The project involves receiving coal from Quinsam Mine in tandem B-train trailers.. unloading into hoppers, storage into a 20,000 tonne (nominal) concrete storage dome. gravity reclaim and loading into up to 10.000 dwt barges. Seabulk was involved in the design of the entire project including civil works and the barge berth. http://www. seabulk.com/seabul/middle.html 9/11/00 Aha nme nee 2 ames Sree 2 we eneeneee a epY eH Vem Tandem trailer truck dumping coal into the receiving hopper. Seabulk Systems Home http://www.seabulk.com/seabul/middle.html 9/11/00 phony 205 9 Avenue SE. Calgary, Alberta T2G ORs Phona: (403) 260-8800 Facsimile (403)264-7339 / (403)265-879¢ / (403)260-9885 Date: September 14, 2000 To: Mike Oswald From: lan R Wakely Precision Energy Services Fax: 1 208 762 1113 Number of Pages: 1 FAX MESSAGE: Mike, In reference to our telephone conversation regarding your feasibility study for coal-flres P/S In Alaska, please find our Indicative specification for thermal coal ex-Westshore Terminal, Roberts Bank, Port of Vancouver. We suggest that In your economic model you apply a coal price of US$32.00 (Thirty Two Dollars) per metric tonne FOB, basis 5750 kcal/kg NAR / 10,300 BTU NAR. We look forward to hearing from you on your findings In due course. Kind regards, hen fhe Any problem in transmission should be directed to the sender at telephone (403) 260-9800 Technical Information FORDING COAL LIMITED FORDING CMO - THERMAL PRODUCT-M TYPICAL PROPERTIES SOURCE INFORMATION: PREPARATORY PLANT LOCATION Medium Volatile AND TRANSPORTATION: Fy Mi.....sscssse-vsccrsrseecsererseeeressersenseeseeeers:- COM! Mountain Plant Heavy Media - Cycione Location Sparwoos, British Columbia Prep. Plant Capacity 4.0 mtpa Transportation CP Rall Port Westshore Bulk Terminals Vancouver, BC, Canada TYPICAE COAL QUALITY: Yo MOIStUTS, BS TECBIVOD «nscnssecsesseveereeeseveseseenee 13.5 FUSION TEMPERATURES °C % Inherent Moisture ........... eee (REDUCING ATMOSPHERE) % Ash (ARB)... a 12.120.0 Initial Deformation... sctaseenssaesseoae 1404 °C % Sulphur (ARB)............ 0.05 SCOPING asccssceecennass_cesssooeast +1480 °C Yo VM (ARB) -neneosscorsesorsvenecs .. 23.0 = 0.0 Hemispherical........ s-sseee*1480 °C % Fixed Carbon (ARB) .........-ssecore 49.0 - 52.0 Ty, +1480 °C PST cerns .o 162 min, K. Cal/Kg (NAR)......... eeeeen 7A ASH MINERAL ANALYSIS (DB) BTUILB (NAR).......00.e. .-. 10,330 | SI a casera seeatcenseeacet gee ocean SEL DS SURO eccoccencessscumteceseanevee tetera a 0-50 mm — ULTIMATE ANALYSIS (DB) We CORON srsrcassscsersuteonvemidscccasasonsesasciesessceentemasaess OEE: % Hydrogen....... 4.26 Yo Nitrog@n.......seseee 0.95 us) DRAB x stress tccscorors 3.70 TTT a af % Sulphur... sane 0.45 avssseeenneenO 40 De) sey Gen Scceseessrcccsnecesserocsseareecnse ete arene i giBT, a svconsenserneoesecarecencceneee 91 SULPHUR FORMS (DB) % Organic. ateetecenecceasecseseeerececcsesscssecnsessssceseneccesesonese 0.42 BBBE/ACIC RALIO .......essce-n-nseresererverernnssesecssecereseceseeeee Os 14 Slagging index........ +---0.063 Fouling Index ......see-cseseee cossneseceveneesconeee sorocanseeseee- 10) % Sulphate SeChlorine in Coal occa <ccacecsssecswseusecseossesssorsaseacn0-019 Haragrove Gnncability Index .......-.es.ceccce-receeerereees eeeOS © fording 205 - Ninth Avenue S.E. Calgary, Alberta T2G OR4 Coal Association of Canada - Prices the COAL Association of Site About Map * Coal and the Economy ahr areca a) il U.S. DOLLARS PER METRIC TONNE Info bGer 1 811] ait ite (eC eRe LL Me Vikan CLS le Yue ae er tars be DEEL) Page 1 of 2 AVERAGE EXPORT COAL PRICE F.0.B. VANCOUVER Metallurgical *Average price. Back to Statistics Introduction PRODUCTION BY MINE http://www.coal.ca/prices.htm 09/29/00 Coal Association of Canada - Prices Page 2 of 2 | 1998 | Mine Operator Principal Owner || Type || PF (Million Coal Type Tonnes) Lignite A 5.7 Lignite A | ie oun ary Dam/Shand | Luscar Ltd. mmmaaanal |__| Strip [Open ]| ] igh vol Coal Valley Luscar Ltd. Pit 1.8 bieamingas Ic A : se | ee ] edium volatile ‘oal Mountain Fording Coal Limited Pit Tel, bitininous | | medium an Fording River Fording Coal Limited om 79 low volatile bituminous Genesee _|| Fording Coal Fonding Coal Lined Strip 3.5 | Sub-bituminous B 5 ; ta en|| 4, || Mediumandlow | Greenhills Fording Coal Limited | Pit 4.0 volatiles Gilnainaie * ee | Medium volatile] Gregg River Luscar Limited [Fr | L7 biuininous Highvale Luscar Ltd. | "Copomtion Strip 12.7 Sub-bituminous B : | || Low and medium Line Creek Luscar Ltd. 2.9 volatile bitanninoas ardinal R k [ Open | —— a | Luscar uuscar Ltd. Pit 2.8 bstuthinchas High volatile Obed Luscar Ltd. [pe jeeeronee Paintearth Luscar Ltd. Strip 3.0 Sub-bituminous _ | Poplar River Luscar Ltd. 3.6 ignite [Sheerness —] map| 33 _—_]|_Sab-brummnous | Whitewood Orne oe pa eetaes Strip 2.6 Sub-bituminous B —— Limited Corporation | Back to Statistics Introduction Site Map | About the CAC | Info Centre | Coal in Canada | The Classroom | Feedback | Canadian Conference on Coal | Coal News | Contacts | Home Copyright © 1998 The Coal Association of Canada. All Rights Reserved http://www.coal.ca/prices.htm na/ainn Suite 200, 3851 Shell Road. Richmond, BC Vex 2W2 SEABULK SYSTEMS INC. Canada Tei: (604) 273-1378 PORTS + SELF-UNLOADERS Fax: (604) 273-1358 e-mail: sbs@seabulk.com Ref. NB-204145 fax: 208-762-1113 September 13, 2000 Precision Energy Services Hayden Lake, Idaho U.S.A. 83835 Atto: Mr. Sam Fulton Dear Mr. Fulton, Ref.: Coal Shipments, Bethel, Alaska I refer to your enquiries on September 12, 2000, my discussions with Sid Sridhar and comment as follows: 1. The proposal notes in item 9, “Freight Rates,” that the freight rate is for delivery of coalV/ash from the Quinsam Coal barge loading facility to and from Bethel, Alaska. _ PES are responsible for the delivery of coal to the Quinsam Coal barge loading facility. Biso [Tow Usp 2. Tilbury Cement and other companics have the potential for using coal ash. Pleasc provide to SBS the detailed specifications of the coal ash to enable SBS to source potential customers. We trust that this answers your outstanding points. Please do not hesitate to contact us should you require further information. Youts sincerely, SEABULK SYSTEMS INC. George Gauld, M. Eng, P. Eng. cc: Sid Sridhar i= = D:\MS\NB\204145 precision_energy | 3sept00.doc Website: www. seabulk.com Suite 200, 3837 Shell Road. Richmond, BC VGX 2W2 SEABULK SYSTEMS INC. Canada aa PORTS + SELF-UNLOADLRS set il e-mail: sbs@scabulk.com Ref. NB-204094 fax: 208-762-1113 September 11, 2000 9 pages Precision Energy Services Hayden Lake, Idaho U.S.A. 83835 Attn: Mr. Sam Fulton Dear Mr. Fulton, Ref.: Coal Shipments, Bethel, Alaska Pursuant to our telephone conversation, we are pleased to submit a proposal for delivery of coal and limestone from Vancouver Island, British Columbia to Bethel, Alaska and hauling back ash to cement plants in British Columbia based on your requirements outlined in your fax of September 8, 2000. Our proposal is based on using a CSL self- unloader together with our 10,000dwt vessel (STV). The undersigned will be away in China next week. In my absence, please contact either George Gauld or Patrick Kennedy if you require any clarifications. Yours sincerely, SEABULK SYSTEMS INC. Foimlie~ Sid Sridhar, P. Eng. President Encl. BS DAMSINB\204094 precision. 1 1sept00.doc Se ae Website: www.seabulk.com SHIPPING FREIGHT RATE INDICATION Seabulk Systems Inc, in association with Canada Steamship Lines (hereinafter collectively referred to as the “shipping contractors”) are pleased to make the following freight rate indication for the account of Precision Energy Services (PES) USA (hereinafter referred to as ‘PES’) for delivery of coal from Middle Point, B.C. to Bethe) Alaska and return haul of Ash to British Columbia. i ‘on: Peri The freight rate indication is for a period of 5 years commencing in the third quarter of 2001. Transhipper (STV) The shipping contractors will supply one (1) owned, managed or chartered self-unloading barge of approximately 10,000 dwt with following outline characteristics: - Lloyds class or equivalent - Flag: Canadian - Operating draft: 6 metres (max.) - One single tunnel hopper (open), elevating pocket-belt conveyor and 35 metre telescopic boom able to trim vessels up to Panamax size. - Significant operating wave height: 1.5 metres - Operable in swells up to 2 metres and 45 kav/h wind - Design transhipment rate: 3000 tph (based on 1.6 vm’ material on lump size 50mm (max.)) - Onboard diesel generator 700 kW - Self-tensioning winches for warping alongside vessel - Fendering between transhipper and vesse! - Cargo system controls Bulk Carriers All cargo will be carried in Self-unloading ships Panamax size carrying 50,000 tonnes capable of discharging at 2,000 tonnes/hour into a ‘STV’ at an anchor site near Bethel, Alaska. Annual Tonnage PES will guarantee a minimum annual tonnage of 500,000 tonnes coal and 52,000 tonnes of ash (STV backhaul). In each year PES will declare additional tonnage (if required) range of 200,000 tonnes, 3 months before start of the year. Shipments to be fairly evenly spread throughout the 5-month window in Alaska. hy liv The shipping contractors will deliver the transhipper to PES at Middle Point, British D:AMS\NB\204094 precision_energy.| I sept00.doc (i 10. 11. Columbia, during the last quarter of 2001. Cargo Description The cargo to be transhipped shall be coal (100mm [max.] size) and free of foreign objects that might damage the self-unloading system. The cargo for back haul will be ash. If the transhipper or CSL vessel is damaged as a result of PES loading any cargo not meeting the description of the cargo, PES shall indemnity and hold the shipping contractors harmless with any associated loss of transhipper performance. The shipping contractors shall repair any damage to the transhipper at PES’s time and expense. nshipmen: S The shipping contractors guarantee that the transhipper wil] be able to deliver, weather permitting, at an average rate of 20,000 tonnes per day SSHINC provided PES supplies coalV/ash to the transhipper at an average rate of 2500 tonncs/hour. PES will be responsible for providing a barge berth with minimum 5-metre water draft and a stockpile arrangement to receive coal at Bethel, Alaska. reight Rates: The shipping freight rate for delivery of coal/ash from the Quinsam Coal barge loading Cos T facility to and from Bethel, Alaska will be USD$11.50 per tonne. jae ana nes Freight charges shall be payable monthly in advance and shall be madc by bank transfer to the shipping contractors’ designated bank free of expense to the contractors. vert: aw This shipping freight rate contract would be construed in accordance with the laws of Canada and contain a mutually acceptable arbitration clause in British Columbia. Confidentiality All details of the proposal shall be kept private and confidential by PES. D:\MS\NB\204094 precision _energy. | lsept00 doc Ste OUTLINE SPECIFICATION 10,000 OWT SEA BULK-TRANSrER VESSEL Pace lor 4 ——————— rE 10,000 dwt Sea Bulk-Transfer Vessel = OUTLINE SPECIFICATION SYSTEM DESCRIPTION The Sea Bulk-Transfer Vessel (STV) is a unique development to handle bulk cargo and operate in open sea conditions. The vessel has an above-deck hopper with a nominal capacity of 7300 m’ and an unloading system capable of discharging cargo at 2200 cu. m/hour. The vessel also has the capability to self-load, thereby permitting use of the barge at facilities that have limited barge-loading capability. \ BARGE PARTICULARS (Refer to General Arrangement drawing) General: Class Notation: A.B.S. & Al, un-manned barge for ocean service. The barge is to be configured in accordance with the preliminary General Arrangement. The barge will have a single main deck, straight stem, semi-cylindrical bow and open (without hatches). There will be a small focsle forward, and the unloading boom, elevator casing, machinery spaces and control room will be aft. The barge will feature hoppered holds, side water ballast tanks, an unloading tunnel and a void double-bottom below the unloading tunnel. There will be a forepeak, and various ballast, void. Fuel will be carried in storage and service tanks aft. Barge may have a void double bottom. Barge and all components and machinery installed shall conform to Transport Canada’s “Ship Electrical Standards” — TP 127 or equal. Barge and all components and machinery installed shall conform to the IEEE 45 Standard for Electrical Installation on Shipboard. Hull: Damage stability and SOLAS watertight subdivision of tunnel not required. Good quality marine epoxy and corrosive paint system on all steel work. Main Particulars: (to be confirmed by shipbuilder) - Length (LOA): 112m - Moulded Breadth: 28 m - Depth: 7.40 m - Loaded Draft: 5.0 (max.) - Deadweight: 10,000 t - Cargo Hold Capacity: 7300 m? (nominal) DAMS\377\misc\OutlineSpec-STV.24nov99.doc OUTLINE SPECIFICATION 10,000 pw SEA BULK-TRANSPER VESSEL PAGE 2 OF 4 - Discharge Capacity: 3000 tph Self-Unloading System: e In general, the self-unloading system will comprise bulk flow gates to be arranged over a single tunnel conveyor, a single elevator and a boom mounted discharge conveyor. The single tunnel conveyor will run continuously — the cargo being carried between the continuous tunnel conveyor and the pocket belt as the means of elevation. The boom structure, associated hoist and slew systems and associated conveyor will be as per this preliminary specification. e The primary cargoes are stone/sand and gypsum. e The continuous unloading rate is to be 3,000 MT/hr for stone/sand (1.5 vm’) and maximum lump size 100 mm. e The barge will have hoppered holds inclined at 40 degrees. e Slewing shuttle-boom to be covered and fitted with fog nozzle water-spray system at both ends. Water spray system able to operate from barge or shore water supply. e Elevating system and unloading boom to be located aft. e Anelevated tripper stacking conveyor (self-load). e The unloading and ballast systems to be operated from the control room, air- conditioned, with good visibility of the boom-head while discharging. Tunnel gates and vibrators to be able to be operated both remotely from the control room and locally by personnel stationed in the tunnel if desired. e Dredge/slurry pumps to be fitted in wells forward and aft in the cargo tunnel, discharging into holding tanks for cargo residues. ¢ The main components of the self-unloading system are the following and are to be designed to operate under the conditions listed in the section “Principal Characteristics”: - One (1) continuous tunnel conveyor - 40 degree hopper - Electric Conveyor Drives - Hydraulic take-ups - Hydraulic or electric slewing - Hydraulic luffing - Hydraulic power units to serve take-up, gates and vibrators, luffing and slewing - One (1) boom: length of 21 metre + 14 metre shuttle, slewing 270 degrees to port and starboard, luffing range of +7, -15 degrees. D:AMS\377\misc\OutlineSpec-STV 24nov99.doc a) OUTLINE SPECIFICATION = 10,000 nwi SEA BULK-TRANSFER VESSEL Pacr 3 oF 4 - Tunnel gates: bulk flow - Remote hydraulically operated gates with solenoid valve remote controls - Hydraulic vibrators: fitted under lower hold slopes in tunnels, with one vibrator every other gate, with solenoid valve remote controls ° All conveyors to be designed to operate in up to two (2) degrees trim and two (2) degrees heel. ¢ All conveyors to be fitted with emergency stop cords on both sides and safety guards mounted to each pulley. Belt scrapers to be fitted on each conveyor belt head pulley. ¢ System components in the tunnel will be subjected to frequent high-pressure hose wash down. For this reason it is imperative that all equipment be designed, selected and protected for excessively wet and corrosive conditions. e All motors, will be AC Induction type rated 440 volt, 3 phase, 60 Hz with the following features: - Continuous duty at ambient temperature of 45 degrees Celsius - Service factor of 1.0 - Class F insulation - Class B temperature rise - Fitted with 115 volt single phase space heaters - 1800 rpm nominal - Totally Enclosed Fan Cooled - Water Proof Enclosure for above deck service Performance: All equipment is to be designed to operate for service with the following criteria: Aur: -20C and Zero Relative Humidity to +35C and 100% R.H. Water: -2C to +30C Wind: 45 km/hr Operation (145 km/hr Stowed) of Self-unloading Boom List: 2 degrees Port or Starboard Operation Tnm: 2 degrees operation of Self-Unloading System Power: 440 Volt, 3 Phase, 60 Hertz A-C Deck Machinery: Windlass: two (electric) Mooring winch: four (electric) Anchor: two (c/w chain cables) Life buoys and life jackets per class rules DAMS\377\misc\OutlineSpec-STV.24n0v99.doc oD OUTLINE SPECIFICATION {_ 10,000 Dwr SEA BULK-TXANSFER VESSEL PAGE 40F 4 ‘ a Accommodation: One day room per 5 crews One electric room One hydraulic room One generator room eeee Painting: e Shot blast to S.A 2.5 and 200 microns of hi-build epoxy to International Paints Specification 5 e Cathodic Protection: Yes Electric Generator: ¢ 1000kW Caterpillar or equivalent (unloading system) ¢ 200kW Caterpillar or equivalent (marine system) © emergency generator caterpillar or equivalent for lighting Lighting: e Fluorescent lamp in accommodation e Halogen flood light on deck D:\MS1377\msc\OutlineSpee-STV.24n0v99.doc A Ot Tl peeitet lt att at + bE et hilly eek Ee) Y/ s N Pemene ymcing 6 te Frame Syncing 2c) PUApR er peep te be af De fp bitte Lisiseam | ISSUED FOR F Pas ™ 6s iw ts ils ei lee 140s de 1880's a) CONSTRUCTION PATE? PENDING |} 1 View U. \SS37799 - 10 000 DWT STV\ready2go\377S001.dug Mon Mar 13 11:37:47 2000 Seabulk Systems Inc. - 0.L.P. 1) AIAN a + Mak Lda} tat lad fdas a oi 0 we 70 2s tame Spar. 199 600—}— Fe ‘ I TR SR ae rt: SSH SE SESS) SDSS SS ES RSH CSEM Saat Sw a Sep eal lat we ce. peyote Dee NN NK | eet! Sa prety a S SP SAS FSS See FESE i ; eee Hold 3 ae 4 Ln (} beta re—y¥ yy | yy 4 | efer: nce’7); = = H Ve _——a ™-.. _ — ~~ 4s 50 ss 6 a ao Elevation View Att Mr Raphael Berezowski - here is the message we sent to Mr Kellas yesterday. —-Original Message— From: ELSY, DAVID Sent: Wednesday, September 06, 2000 4:47 PM To: —‘kellashp@pes-world.com’ Cc: —‘tfe@foss.com’ Subject: COAL FROM VANCOUVER TO BETHEL To; Harry Kellas - Precision Energy Services Ce: Tom Cobum - Foss Maritime From: David Elsy - Navios Handybulk Date: Sept 6, 2000 Ref: Ocean shipments of coal from Vancouver Island to off loading anchorage for trans-shipment to Bethel, Alaska. In consultation with Alaska pilots we have determined that the closest safe location to Bethel to discharge an ocean going vessel is in the southem part of Nakina Bay near Cape Newenham. This is about 90 nautical miles from Bethel. Based on our extensive experience of ship to barge discharge operations and considering the cargo volume to be shipped over a limited duration season, we have focussed on using the following type of vessel. A Navios bulk carrier of about 46,000 metric tons deadweight on a draft of 11.60 meters. +#/0 Ff ug id fe Length overall 185.00 m — pat k Breadth 31.00 m Esa 5 holds and hatches, cranes of at least 25 metric tons safe working load. Crane outreach from shipside of minimum 8.50 m. Electro hydraulic grabs of 10 cubic meters capacity. Vessel to be capable of self- discharging into barges placed along either side of vessel at an average minimum rate of 10,000 short tons/24 hr period. Crew on board the vessel will drive the cranes working around the clock. Vessel to be equipped with 2 payloaders for hold clean up also operated by vessel's crew. Vessel will be non USA flag, and conforming to all international and USA, Canadian regulations. We would dedicate the ship to consecutive voyages loading Vancouver Island and arriving at the discharge anchorage about every 19 - 20 days, during the season Mid June to October, vessel would be able to perform 8 voyages with a cargo intake of 45,000 short tons/voyage. The selection of this size vessel and the issue of dedicating it for the season has several benefits. 1) Familiarity - both of vessel with the trade and barges/barge operators with the vessel. 2) Efficiency of discharge - crew operate all discharge equipment 3) Minimizing position/reposition cost vs using multiple vessels. 4) Additional insurance premium payable for trading to waters north of the Alaska Peninsula. Underwriters should view favorably. Freight rate. US$ 11.00/Short Ton We have based our rate indication on the following parameters 1) Vessel is to be loaded at a minimum rate of 1,000 metric tons/hour, loading by shore conveyor with trimming spout to optimize all space in vessel holds. Cargo is loaded “free onboard” ie cargo interests pay for any loading terminal charges. Vessel to pay all usual port costs, pilots, tugs, line handlers, customs immigration, agency fees. Loading to be 24 hrs/day Sundays and holidays included. 2) Vessel is to self discharge into barges placed alongside vessel at anchorage. Vessel can discharge at a minimum rate of 10,000 short tons/24 hr period and sufficient barges to be supplied to enable vessel to achieve this rate. Crew operate all cargo handling equipment, cost of which included in freight rate. 3) Port and marine fuel prices incorporated in rate are based on today’s prices. 4) Additional insurance premium on vessel Hull and Machinery for trading north of Aleutians limited to maximum 10% of H and M value per voyage. 5) Weather delays, once vessel arrives at anchorage, if weather prevents barges from coming alongside or swell or wind prevents vessel from safely discharging then this time is to count as time on demurrage at $ 660.00/hour. 6) Commissions on freight, there are none - rate is net of any commissions. This is a preliminary freight rate indication based on the information presently available to us, if size of vessel or cadence of discharge or any other terms and conditions have to be amended at a later time we reserve the right to review/modify our figures. If you have any questions please give me a call directly at 203-961-7227 or email handybulk@navios.com. Regards Precision Energy Services Inc September 18, 2000 To: Sam Fulton Re: Limestone, Coal and Fly Ash Bethel, Alaska Thank you for your inquiry regarding the proposed power plant in Bethel, Alaska. Our typical limestone specification is as follows: % CaO 53.0 greater than 94 % CaCo3 MgO 0.5 sio2 1.0 A1203 0.2 Fe203 0.2 Moisture content at time of shipment would be in the 3-5% range A % inch minus product is the most commonly produced size and would be ground down and dried at the plant site prior to injection. Pricing for a % inch minus product FOB barge at Texada would be in the range of $3.50 US/ton until December 31, 2000. As mentioned, we have a shipping facility which can load Panamex vessels that have a draft of 42 feet. We have previously transshipped coal from Quinsam from this facility. In addition, we operate 2 cement plants in the Pacific Northwest, one in Seattle and one in Vancouver, B.C. We are a major producer of concrete and use flyash in our mixes as well as market flyash for power authorities. We would be pleased to look at the logistics of supplying limestone, coal and marketing of flyash from this proposed facility, If you have any further questions, please call me at 604-502-7660. B. K. Saunders Vice President of Marketing wa TOTAL P.@1 OcaVuin Systems unc Page 1 of 6 10,000 DWT Sea Bulk-Transfer Vessel (STV) OUTLINE SPECIFICATION Patent Pending so sseereericere ys SYSTEM DESCRIPTION The Sea Bulk-Transfer Vessel (STV) is a unique development to handle bulk cargo and operate in open sea conditions. The vessel has an above-deck hopper with a nominal capacity of 7300 m3 and an unloading system capable of discharging cargo at 2200 cu. m/hour. The vessel also has the capability to self-load, thereby permitting use of the barge at facilities that have limited barge-loading capability. With the large boom slewing range it is possible to use the boom aft to transfer bulk cargos from a shiploader to a ship in deeper water. BARGE PARTICULARS http://www.seabulk.com/seabul/sti-stv-1.htm] 9/11/00 ee ee Sy Senne eee rage 2010 — a : Ea els eit oul em acai For a much clearer drawing you can use Autodesk's Volo View Express or Whip 4.0 and click on the above drawing. General: Class Notation: A.B.S. & Al, un-manned barge for ocean service. The barge is to be configured in accordance with the preliminary General Arrangement. The barge will have a single main deck, straight stem, semi-cylindrical bow and open (without hatches). There will be a small focsle forward, and the unloading boom, elevator casing, machinery spaces and control room will be aft. The barge will feature hoppered holds, side water ballast tanks, an unloading tunnel and a void aoublesbottor below the unloading tunnel. There will be a forepeak, and various ballast, void. Fuel will be carried in storage and service tanks aft. Barge may have a void double bottom. Barge and all components and machinery installed shall conform to Transport Canada's "Ship http://www.seabulk.com/seabul/sti-stv-1.html 9/11/00 OCAVULR OYSICLUD LUE Page 3 of 6 Barge and all components and machinery installed shall conform to Transport Canada's "Ship Electrical Standards" - TP 127 or equal. Barge and all components and machinery installed shall conform to the IEEE 45 Standard for Electrical Installation on Shipboard. Hull: Damage stability and SOLAS watertight subdivision of tunnel not required. Good quality marine epoxy and corrosive paint system on all steel work. Main Particulars: (to be confirmed by shipbuilder) - Length (LOA): 112 m - Moulded Breadth: 28 m - Depth: 7.40 m - Loaded Draft: 5.0 (max.) - Deadweight: 10,000 t - Cargo Hold Capacity: 7300 m3 (nominal) - Discharge Capacity: 3000 tph Self-Unloading System: In general, the self-unloading system will comprise bulk flow gates to be arranged over a single tunnel conveyor, a single elevator and a boom mounted discharge conveyor. The single tunnel conveyor will run continuously - the cargo being carried between the continuous tunnel conveyor and the pocket belt as the means of elevation. The boom structure, associated hoist and slew systems and associated conveyor will be as per this preliminary specification. The primary cargoes are stone/sand and gypsum. The continuous unloading rate is to be 3,000 MT/hr for stone/sand (1.5 t/m3) and maximum lump size 100 mm. The barge will have hoppered holds inclined at 40 degrees. Slewing shuttle-boom to be covered and fitted with fog nozzle water-spray system at both ends. Water spray system able to operate from barge or shore water supply. Elevating system and unloading boom to be located aft. An elevated tripper stacking conveyor (self-load). The unloading and ballast systems to be operated from the control room, air-conditioned, with good visibility of the boom-head while discharging. Tunnel gates and vibrators to be able to be operated both remotely from the control room and locally by personnel stationed in the tunnel if desired. Dredge/slurry pumps to be fitted in wells forward and aft in the cargo tunnel, discharging into holding tanks for cargo residues. The main components of the self-unloading system are the following and are to be designed to operate under the conditions listed in the section "Principal Characteristics": - One (1) continuous tunnel conveyor - 40 degree hopper - Electric Conveyor Drives - Hydraulic take-ups http://www.seabulk.com/seabul/sti-stv-1.htm] 9/11/00 Seabulk Systems Inc Page 4 of 6 - Hydraulic take-ups - Hydraulic or electric slewing - Hydraulic luffing - Hydraulic power units to serve take-up, gates and vibrators, luffing and slewing - One (1) boom: length of 21 metre + 14 metre shuttle, slewing 270 degrees to port and starboard, luffing range of +7, -15 degrees. - Tunnel gates: bulk flow - Remote hydraulically operated gates with solenoid valve remote controls - Hydraulic vibrators: fitted under lower hold slopes in tunnels, with one vibrator every other gate, with solenoid valve remote controls All conveyors to be designed to operate in up to two (2) degrees trim and two (2) degrees heel. All conveyors to be fitted with emergency stop cords on both sides and safety guards mounted to each pulley. Belt scrapers to be fitted on each conveyor belt head pulley. System components in the tunnel will be subjected to frequent high-pressure hose wash down. For this reason it is imperative that all equipment be designed, selected and protected for excessively wet and corrosive conditions. All motors, will be AC Induction type rated 440 volt, 3 phase, 60 Hz with the following features: - Continuous duty at ambient temperature of 45 degrees Celsius - Service factor of 1.0 - Class F insulation - Class B temperature rise - Fitted with 115 volt single phase space heaters - 1800 rpm nominal - Totally Enclosed Fan Cooled - Water Proof Enclosure for above deck service Performance: All equipment is to be designed to operate for service with the following criteria: Air: -20C and Zero Relative Humidity to +35C and 100% R.H. Water: -2C to +30C Wind: 45 km/hr Operation (145 km/hr Stowed) of Self-unloading Boom List: 2 degrees Port or Starboard Operation Trim: 2 degrees operation of Self-Unloading System Power: 440 Volt, 3 Phase, 60 Hertz A-C Deck Machinery: Windlass: two (electric) Mooring winch: four (electric) Anchor: two (c/w chain cables) Life buoys and life jackets per class rules Accommodation: One day room per 5 crews One electric room One hydraulic room http://www.seabulk.com/seabul/sti-stv-1.html 9/11/00 Seabulk Systems Inc Page 5 of 6 One hydraulic room One generator room Painting: Shot blast to S.A 2.5 and 200 microns of hi-build epoxy to International Paints Specification Cathodic Protection: Yes Electric Generator: 1000kW Caterpillar or equivalent (unloading system) 200kW Caterpillar or equivalent (marine system) : emergency generator caterpillar or equivalent for lighting Lighting: Fluorescent lamp in accommodation Halogen flood light on deck Seabulk Transfers Inc. Home http://www.seabulk.com/seabul/sti-stv-1-html 9/11/00 VeavuIA OY dSICLUD Le Page | of 2 Seabulk System Inc., formerly Lassing Dibben (Pacific), has been involved exclusively in Bulk Materials Handling Systems since 1989. The firm changed its name in 1994 to Seabulk Systems Inc. to reflect our increasing involvement with the marine industry. A major achievement of Seabulk is the development of a unique gravity reclaim system for use in self-unloading ships. Seabulk has obtained US Patents for this invention. Three new panamax self- unloading ships for Canada Steamship Lines and Egon Oldendorff are being built at Jiangnan Shipyard, China using this new Seabulk reclaim system. A second self-unloading design has been developed by Seabulk Systems based on the use of an above deck reclaimer. A third new development by Seabulk is a semi-submersible transhipper, The Sea Spider, for open sea transfer of bulk material from barge to ship. Seabulk System Inc. has worked on several Marine Bulk Terminals. The firm is a recipient of awards for Engineering Excellence. The main focus of Seabulk is the development of proprietary new Material Handling Systems for the marine industry. PRINCIPAL FIELDS OF ACTIVITY Marine Terminals Marine Transportation Bulk Materials Handling Environmental Upgrading Self-unloading Vessels DESCRIPTION OF SERVICES Design and Build Market Studies Detailed Engineering Purchasing and Expediting Feasibility Studies Project Management Inspection and Commissioning Site Selection Construction Management and Supervision TYPICAL PROJECTS Planning and Development e Development of iron ore/coal Terminal, India e Feasibility study for marine transportation of bulk cement, India (funded by CIDA) e Feasibility study for marine terminal for loading metal concentrates, Alaska Materials Handling Seaport facility for loading lead/zinc concentrates, Red Dog mine project, Alaska Coal export facility, Puntas Arenas, Chile Ore import terminal, Coos Bay, Oregon Coal export terminal, Campbell River, B.C. http://www.seabulk.com/seabul/background.html 9/11/00 deaDuik Sysiems inc Page 2 of 2 Self-unloading Vessels Design of 60 000 dwt vessel for iron ore, Canada Steamship Lines Design of 6 000 dwt barge for concentrates, Foss Maritime, Seattle Design and build of three 70 800 dwt self-unloaders, China Conversion of a 36 000 dwt bulk carrier to self-loader/self-unloader International Projects e Fertilizer trans-shipment facility, Thailand e Marine terminal study, iron ore briquettes, Venezuela e Preliminary design, coal terminal, Indonesia e Bulk sugar terminal, Barbados GET microsoft Internet ES a Seabulk Systems Home http://www.seabulk.com/seabul/background.html : 9/11/00 Canada Steamship Lines 3 The Problem... Some locations require the transfer of bulk materials from shallow-draft barges or other inshore vessels, to bulk carriers serving distant markets. But the traditional method of employing floating cranes equipped with grabs in this role , often falls short of expectations. Beacause of their inherent "grab-lift-slew-dump-slew-grab" operation, they offer relatively slow and expensive cargo handling. They are generally unable to load Cape-size vessels and are often subject to delays caused by adverse weather and sea conditions. The Solution... By combining the proven technology of the offshore industry with that of modern cargo-handling systems in a truly innovative fashion. The Sea Spider semi-submersible bulk cargo transfer provides a highly stable and 1 of 3 9/11/00 12:13 PM 2 of 3 reliable operating environment capable of loading ships up to Cape-size. The system offers continuous and cost-effective unloading and transfer of a wide variety of dry bulk cargoes -- including coal, iron ore, grain, and aggregates -- from barges to deepsea vessels at a sustained rate of 1,500 metric tonnes per hour for coal. Formed in 1998 to market, build and operate the unique Sea Spider transfer system, Semisub Transhipper Inc. is a joint-venture between CSL International, Egon Oldendorff of Liibeck, Germany and Seabulk Systems of Vancouver. STI is currently constructing the first Sea Spider in the Far East to enter service in 1999. For more information about the Sea Spider: CSL International 55 Tozer Road Beverly, MA 01915 U.S.A. (978) 922-1300 (978) 922-1772 (fax) CSL Asia International Plaza #26-08 10 Anson Road Singapore 079903 Tel: +65 324 0311 Fax: +65 324 0322 e-mail: cslsing@si .com. 9/11/00 12:13 PM a Canada Steamship Lines How a Self-Unloader Works The CSL self-unloader is among the most innovative vessels in the shipping indu today. State-of-the-art technology allows the ship to perform unloading operati that are impossible with ordinary dry-bulk carriers. Customers the world « recognize the advantages of having these self-unloaders haul their cargos. TI The CSL fleet : : How advantages include: self-unloader S works Bulk cargo discharge rates of up to 6,000 tonnes per hour. Self-unloaders Continuous operation, 24 hours a day, 7 days a week. in action No cleanup required, reducing port congestion and demurrage costs. Significant savings in capital investment for cargo-receiving facilities ashor Additional savings in shore labour, stevedoring, and dock maintenance cos Tailor-made solutions for the most demanding transportation requirements Anatomy of a Self-Unloader Although many different components--and a crew of skilled personnel- necessary for the smooth operation of a self-unloader, there are four main feati that allow the ship to discharge cargo independent of on-shore assistance. As shown in the illustration above, the unloading process begins with the dry-t material being systematically released onto the cargo hold conveyor belt. The cz then travels to the shuttle transfer and elevating conveyor belt where it is carriec to the discharge boom. The boom, which features yet another conveyor, is sw out to either side of the ship and the cargo is neatly off-loaded. 1 of 3 9/11/00 12:23 PM 1. Cargo hold conveyor belt Cargo flows by gravity through a series of hydraulica controlled gates onto conveyor belts beneath the cars The gates are closed during transit and opened at a ct rate during discharge (left). 2. Shuttle transfers From the cargo hold conveyors, the mater to shuttle transfers (left) which supply the elevating conveyor belts. Back t in illustration 3. Elevating conveyo The cargo is then squee between two belts as it to the main deck (left), transferred onto a conv: the discharge boom. Cargo is squeezed between the two beits 4. Discharge boom The discharge boom conveyor carries the ca the self-unloader to the receiving facility on ~ Cargo can be placed anywhere within a wi whether the ship features a straight or a boom. ? of 3 9/11/00 12:23 PM Vendor Quotes ADE PRECISION SERVICES INC. 7. VENDOR QUOTES PRECISION FAX COVER SHEET ENERGY SERVICES INC. DATE: August 31, 2000 Number of pages including cover sheet: 1 TO: Joe Yarusiski PHONE: 407-736-5660 COMPANY: Siemens Westinghouse Power Corp. FAX: 407-736-6389 FROM: Sam Fulton . PHONE: 208-772-4457 COMPANY: Precision Energy Services FAX: 208-762-1113 SUBJECT: Steam Turbine Power Generation MESSAGE: Please submit budget quote for a 45 mw steam turbine power generator to the following general specifications: I Steam supply — 390,000 Ib/hr maximum, 346,000 Ib/hr. normal/design 2; Steam pressure to turbine 900 psi 35 Steam temperature 900°F 4. Steam condensing pressure 2” HGA 5: Single extraction for DA heater and high pressure water heater. Pressure and flow not available at this time. 6. Bottom steam exhaust to condenser Ts Include weights and outside dimensions BPAXED 8. Direct connection drive pet ltl le 9. Independent support base 10. Independent lube system with cooling Provide other characteristics not covered by this fax. Please call if you have further questions. I would like a reply by the week of September 5", ASAP. CC: Rafal Berezowski HOME OFFICE - P.O. Box 1004, Hayden Lake, ID 83835 USA * Phone (208) 772-4457 + Fax (208) 762-1113 EAST COAST OFFICE-P.O. Box 120, Cedar Mountain, NC 28718 USA « Phone (828) 884-7758 * Fax (828) 884-7779 www.pes-world.com PRECISION FAX CO RES Peni VER SHEET SERVICES INC. DATE: August 30, 2000 Number of pages including cover sheet: 1 TO: Mark Conroy PHONE: 909-477-5701 COMPANY: GE Power Systems FAX: 909-477-5744 FROM: . Sam Fulton PHONE: 208-772-4457 COMPANY: Precision Energy Services * FAX: 208-762-1113 SUBJECT: Steam Turbine Power Generation EA Xx BD MESSAGE: <9 Please submit budget quote for a 45 mw steam turbine power generator to the following general specifications: 1. Steam supply — 390,000 Ib/hr maximum, 346,000 Ib/hr. normal/design 2s Steam pressure to turbine 900 psi 35 Steam temperature 800°F 4. Steam condensing pressure 2” HGA ob Single extraction for DA heater and high pressure water heater. Pressure and flow not available at this time. 6. Bottom steam exhaust to condenser Ts Include weights and outside dimensions 8. Direct connection drive Oo; Independent support base 10. Independent lube system with cooling Provide other characteristics not covered by this fax. Please call if you have further questions. I would like a reply by the week of September 5*, ASAP. HOME OFFICE - P.O. Box 1004, Hayden Lake, ID 83835 USA + Phone (208) 772-4457 + Fax (208) 762-1113 EAST COAST OFFICE-P.O. Box 120, Cedar Mountain, NC 28718 USA « Phone (828) 884-7758 » Fax (828) 884-7779 www.pes-world.com PRECISION FAX COVER JRE Pee SHEET SERVICES INC. DATE: August 30, 2000 Number of pages including cover sheet: 1 TO: Don Wold PHONE: 503-693-1221 COMPANY: Courtney-Nye FAX: 503-640-8424 FROM: . Sam Fulton PHONE: 208-772-4457 COMPANY: Precision Energy Services » FAX: 208-762-1113 “SUBJECT: Steam Turbine Power Generation D FAXES MESSAGE: oe Please submit budget quote for a 45 mw steam turbine power generator to the following general specifications: 1. Steam supply — 390,000 Ib/hr maximum, 346,000 Ib/hr. normal/design Ds Steam pressure to turbine 900 psi 35 Steam temperature 800°F 4. Steam condensing pressure 2” HGA ay Single extraction for DA heater and high pressure water heater. Pressure and flow not available at this time. 6. Bottom steam exhaust to condenser 7. Include weights and outside dimensions 8. Direct connection drive 9. Independent support base 10. Independent lube system with cooling Provide other characteristics not covered by this fax. Please call if you have further questions. I would like a reply by the week of September 5", ASAP. HOME OFFICE - P.O. Box 1004, Hayden Lake, ID 83835 USA + Phone (208) 772-4457 + Fax (208) 762-1113 EAST COAST OFFICE-P.O. Box 120, Cedar Mountain, NC 28718 USA « Phone (828) 884-7758 * Fax (828) 884-7779 www.pes-world.com PRECISION ENERGY SERVICES INC. August 30, 2000 Don Beebe Kvaemer Enviropower, Inc. 8008 Corporate Center Drive Charlotte, NC 28226 Fax: 704-541-1128 AXED Sir; gee rere Our client is developing a power plant project in Alaska. Precision Energy Services has been retained as a consultant to assist the client with preliminary design and feasibility studies. We will appreciate it very much if you can provide budget pricing for the project or systems thereof: The nominal power generating capacity is 80 MW electric. Technology: The client intends on having 2 (two) trains, each consisting of one circulating fluidized bed boiler with superheater and steam turbine. The design capacity of each train should be 45 MWe. At normal operations, the boilers would run at 40 MWe each. During maintenance of 1 system, the other shall be capable of running at 50 MWe generating output. Assumed steam parameters: 900°F, 900 psia. You may propose different parameters, if you believe that the system will be more efficient. The plant may have one each deaerator and condenser common for both trains. Air-cooled condenser will be considered, however, it is not a requirement. The parasitic power shall be minimized, if possible to not more than 5 MW. Fuel: Coal — see attached fuel data. Expected Permit Requirements: The requirements are based on another generation project recently completed in the area. . Opacity 20%, 3-minute average . Particulates 0.020 Ib/MM Btu, hourly average . co 0.200 Ib/MM Btu, hourly average s NOx 0.350 Ib/MM Btu, 30-day rolling average . SO2 0.100 Ib/MM Btu, 3-hour average; 0.086 Ib/MM Btu annual average or 90% reduction With your response please provide the following: le Budget price of equipment of your supply. 2 Estimation of the installation cost of systems to be supplied by your company. 3. Maximum coal size that can be handled by the CFB combustor. 4. What change in coal properties will your proposed system be able to tolerate; will it be able, for instance, to handle low rank coal at net heating value of 7000 Btu/lb? 5. Please list all complete systems/equipment included in your scope of supply. HOME OFFICE - P.O. Box 1004, Hayden Lake, ID 83835 USA * Phone (208) 772-4457 + Fax (208) 762-1113 EAST COAST OFFICE-P.O. Box 120, Cedar Mountain, NC 28718 USA * Phone (828) 884-7758 * Fax (828) 884-7779 PRECISION ENERGY SERVICES INC. 6. Please specifically exclude equipment that can be reasonably expected to be a part of a specific system. For instance: blow-down tank for boiler, combustion air blower for the CFB combustor. Response to this question please provide in the first order of importance. Te Please determine the coal demand based on the attached coal specification. 8. Please describe the technical support that your company and/or your vendors can and would be ready to provide during project planning, detailed engineering, construction, start up and operations. 9. Please provide a description of your performance guarantee and materials and workmanship warranties. We will appreciate your response by September 11, 2000. Should you require additional information, please feel free to call, fax or e-mail your request. Thank you for your cooperation. Rafal Berezowski Project manager QUINSAM THERMAL COAL QUALITY SUMMARY Caloric Value Gross (dry) Gross (air dry) Gross (as received) Net (as received) Proximate Analysis Total Moisture Residual Moisture Ash Content (air dried) Fired Carbon (air dried) Volatile Matter (air dried) Ulfimate Analysis Carbon (dry basis) Hydrogen Nitrogen Sulphur Oxygen (by difference) Ash Content Total Suiphur (Air Dries) Hardorove Grindability Index Emduct Size Ash Analysis Sid, ALO, Fe,0, Cad (ypical resutt) MgO Na,O KO TO, P.O; SO, Undetermined Ash Eusihiltiy = Reducing condition intial Deformation Temp. Softening Temperature (minimum) Hemisphere Temperature Fluid Temperature Oxdizing condition intial Deformation Temp. Softening Temperature Hemisphere Temperature Fluid Temperature Chlorine Content (dty ash free basis) Phosphons Content (dry ash free basis) Carhen Dioxide (Ory ash free basis) 15.3% 0.1% 18% 0.6% 4.1% 3.4% deg 1338 - 1393 1409 - 1457 1432 - 1467 1468 - 1488 1412 - 1468 1454 - 1477 1454 - 1481 1458 - 1491 < 0.025 % <0.0004% <1.75% tmp. Prod. Iunical 12,240 Bhuib 11,880 Bub 11,160 Bhwib 10,620 Bhuib 50.0 mm X 0 mm 2.0 mm XO mm PRECISION ERERGY SERVICES INC. August 30, 2000 Brad Thompson Company 12025 - 115th Avenue N.E., Suite 250 Kirkland, WA 98034-6935 Fax 425 825-1909 e-mail: bradtco@nwlink.com Sir; Our client is developing a power plant project in Alaska. Precision Energy Services has been retained as a consultant to assist the client with preliminary design and feasibility studies. We will appreciate it very much if you can provide budget pricing for the project or systems thereof: The nominal power generating capacity is 80 MW electric. Technology: The client intends on having 2 (two) trains, each consisting of one circulating fluidized bed boiler with superheater and steam turbine. The design capacity of each train should be 45 MWe. At normal operations, the boilers would run at 40 MWe each. During maintenance of 1 system, the other shall be capable of running at 50 MWe generating output. Assumed steam parameters: 900°F, 900 psia. You may propose different parameters, if you believe that the system will be more efficient. The plant may have one each deaerator and condenser common for both trains. Air-cooled condenser will be considered, however, it is not a requirement. The parasitic power shall be minimized, if possible to not more than 5 MW. Fuel: Coal — see attached fuel data. Expected Permit Requirements: The requirements are based on another generation project recently completed in the area. . Opacity 20%, 3-minute average . Particulates 0.020 Ib/MM Btu, hourly average . co 0.200 Ib/MM Btu, hourly average . NOx 0.350 Ib/MM Btu, 30-day rolling average . SO, 0.100 Ib/MM Btu, 3-hour average; 0.086 Ib/MM Btu annual average or 90% reduction With your response please provide the following: 1; Budget price of equipment of your supply. 2 Estimation of the installation cost of systems to be supplied by your company. 3. Maximum coal size that can be handled by the CFB combustor. 4. What change in coal properties will your proposed system be able to tolerate; will it be able, for instance, to handle low rank coal at net heating value of 7000 Btu/Ib? 5. Please list all complete systems/equipment included in your scope of supply. HOME OFFICE - P.O. Box 1004, Hayden Lake, ID 83835 USA * Phone (208) 772-4457 + Fax (208) 762-1113 EAST COAST OFFICE-P.O. Box 120, Cedar Mountain, NC 28718 USA * Phone (828) 884-7758 * Fax (828) 884-7779 PRECISION SERVICES INC. 6. Please specifically exclude equipment that can be reasonably expected to be a part of a specific system. For instance: blow-down tank for boiler, combustion air blower for the CFB combustor. Response to this question please provide in the first order of importance. ia Please determine the coal demand based on the attached coal specification. 8. Please describe the technical support that your company and/or your vendors can and would be ready to provide during project planning, detailed engineering, construction, start up and operations. 9. Please provide a description of your performance guarantee and materials and workmanship warranties. We will appreciate your response by September 11, 2000. Should you require additional information, please feel free to call, fax or e-mail your request. Thank you for your cooperation. Rafal Berezowski Project manager PRECISION FAX COVER SHEET ENERGY SERVICES INC. DATE: September 5, 2000 Number of pages including cover sheet: 1 TO: Don Wold PHONE: 503-693-1221 COMPANY: Courtney-Nye FAX: 503-640-8424 FROM: Sam Fulton PHONE: 208-772-4457 COMPANY: Precision Energy Services - FAX: 208-762-1113 va SUBJECT: Steam Turbine Power Generation FAXED A-S-— MESSAGE: We wish you to quote on the following added features to your quote of August 31*. a Supply condenser for 264,200 lb/hr. 2” Hga at Extraction steam conditions 20 psi at 63,700 Ibs/hr. 3. Turbine inlet steam temperature 900°F 4. Steam pressure 900 psia, optional 1300 psia 5) D.A. for 333,000 lb/hr. @ 20 psia 6. Steam to D.S. 35610 lb/hr. @ 20 psia ie Controls and instrumentation included as separate cost 8. Estimated installation cost as separate 9! Minimum lifting capacity for a bridge crane and can you supply? Call Rafal or me, if need be, about the added conditions. (cc: Rafal Berezowski HOME OFFICE - P.O. Box 1004, Hayden Lake, ID 83835 USA * Phone (208) 772-4457 + Fax (208) 762-1113 EAST COAST OFFICE-P.O. Box 120, Cedar Mountain, NC 28718 USA « Phone (828) 884-7758 + Fax (828) 884-7779 www.pes-world.com PRECISION FAX COVER E PES 5 7 SERVICES INC. DATE: September 8, 2000 Number of pages including cover sheet: 1 TO: Michael Lombard PHONE: 562-944-6137 COMPANY: Westmont Industries FAX: 562-946-5299 FROM: Sam Fulton SE PHONE: 208-772-4457 COMPANY: Precision Energy Services : FAX: 208-762-1113 SUBJECT: Coal Handling Equipment “Ay MESSAGE: AA Please provide budget figures for equipment or systems to handle coal from barges to power plant coal bunkers. The following is a list of items we believe necessary to handle and convey coal quantities. L Barge unloading cranes/conveyor equipment that can move coal from barges to a receiving hopper/conveyor at the rate of 200 short tons per hours. This is based on a 20 hour day, 30 days per month for 4 months, window of opportunity. Unloading facilities will therefore be idle for 8 months. Take into account electrical heat for winterizing the equipment. 2. Conveyor/stacker of the coal to 2 storage piles 30 feet high, 400 feet wide and approximately 900 feet long. Distance from barge unloading, 2000 feet. All conveying equipment should be covered. Winterize for 8 months. 3. Reclaiming hopper/conveyors. Possible use of diesel bucket loaders that can move approximately 65 short tons per hour on a 12 month basis. Reclaimer should handle approximately 100 tons per hour. 4. Crusher/sizing for %” from the reclaimer. Crusher to handle 100 tons per hour. Original coal size unknown at this time. SD. Coal bunkers, supply conveyors, distribution conveyors, chute gates, etc. minimum of 2 coal bunkers per boiler. Plant will have 2 boilers. I would appreciate any suggestions or methods that may apply to this region. We can basically fill the areas that Westmont may have little or no knowledge. Please send information on your company, products and capabilities in the area of material handling. Do not hesitate to call for information. HOME OFFICE - P.O. Box 1004, Hayden Lake, ID 83835 USA + Phone (208) 772-4457 + Fax (208) 762-1113 EAST COAST OFFICE-P.O. Box 120, Cedar Mountain, NC 28718 USA * Phone (828) 884-7758 * Fax (828) 884-7779 www.pes-world.com PRECISION FAX COVER SHEET IDE ENERGY SERVICES INC. DATE: August 30, 2000 Number of pages including cover sheet: 1 TO: Mark Conroy PHONE: 909-477-5701 COMPANY: GE Power Systems FAX: 909-477-5744 FROM: _ Sam Fulton PHONE: 208-772-4457 COMPANY: Precision Energy Services - FAX: 208-762-1113 SUBJECT: Steam Turbine Power Generation MESSAGE: <= Please submit budget quote for a 45 mw steam turbine power generator to the following general specifications: 1. Steam supply — 390,000 lb/hr maximum, 346,000 Ib/hr. normal/design 2: Steam pressure to turbine 900 psi 3 Steam temperature 800°F 4. Steam condensing pressure 2” HGA 3. Single extraction for DA heater and high pressure water heater. Pressure and flow not available at this time. 6. Bottom steam exhaust to condenser 7. Include weights and outside dimensions 8. Direct connection drive 9: Independent support base 10. Independent lube system with cooling Provide other characteristics not covered by this fax. Please call if you have further questions. I would like a reply by the week of September 5", ASAP. HOME OFFICE - P.O. Box 1004, Hayden Lake, ID 83835 USA + Phone (208) 772-4457 * Fax (208) 762-1113 EAST COAST OFFICE-P.O. Box 120, Cedar Mountain, NC 28718 USA « Phone (828) 884-7758 * Fax (828) 884-7779 www.pes-world.com Babcock & Wilcox a McDermott company 710 Airpark Road Napa, CA 94558-7518 (707) 259-1122 Fax: (707) 265-1000 September 1, 2000 Precision Energy Services P.O. Box 1004 Hayden Lake, ID 83835 Attention: Mr. Rafal Beregowski Project Manager Reference: Preliminary Information Two CFB's for Alaska Dear Rafal, This is in response to your fax inquiry of August 30, 2000, wherein you requested preliminary information for two (2) CFB's for Alaska. Babcock & Wilcox is most interested in the opportunity to work with you on this project. B&W's CFB boiler design incorporates a number of unique features which result in significant benefits for the power plant and operator. Reduce Maintenance Costs and High Availability e The elimination of thick refractory linings reduce repair costs e Lower and more uniform gas velocities reduce tube erosion e U-beam separators have required negligible maintenance Enhanced Operating Flexibility and Efficiency Reduced start-up time due to elimination of thick refractory e Extended operating tumdown without auxiliary fuel firing e Higher solids collection efficiency improves fuel and limestone utilization Lower Installed Cost e Compact design and smaller footprint minimizes overall installed cost e In Repowering applications, compact size often permits new CFB to be installed in same space occupied by the existing boiler Precision Energy Services September 1, 2000 Attn: Mr. Rafal Beregowski Page -2- For your specific project, we have based our scope of equipment on two (2) boilers, each rated at 385,000 Ibs/hour capacity 900 psig and 950 F. The scope (per boiler) is as follows: * Steam Drum and Furnance * Superheater, Attemperator & Piping ; Economizer e ASME Code Valves & Piping ¢ Safety Valves and Silencers ¢ Boiler Trim Valves e Tubular Air Heater ¢ Auxiliary Start-up Burners with Lighters and Flame Detectors ¢ Burner Management System © Primary and Secondary FD Fans w/Motor Drives « ID Fan w/Motor Drive ‘¢ Coal Feeders and Raw Coal Piping from Bunker Outlet Limestone Silo * Limestone Feed System from Silo to Furnace ¢ Bed Drain System w/Ash Screw Coolers ? Multiclone Dust Collector and Ash Reinjection System « Baghouse with Accessories and Controls ° Flues and Ducts from FD Fan to Baghouse ¢ Dampers w/Drives and Expansion Joints § Sootblowers w/Piping and Controls * Boiler Instrumentation (field devices) + Boiler Refractory, Insulation and Lagging/Casing Boiler Integral Steel e Boiler Structural Steel including Platforms, Grating, Handrails, etc. » Special Tools : Operating and Maintenance Instructions - Freight to Job site - Erection Consultant . Start-Up Engineer Budget Price, two (2) boilers Baghouses and accessories (materials only) FiO'BsAlaske (505) 5) ess) 66951 1 1 te) 1920;550,000. Budget PriceErection . . . . - - «© © ee + © «© « $12,500,000. Precision Energy Services September 1, 2000 Attn: Mr. Rafal Beregowski Page -3- We have estimated the erection price based on a typical site located within the 48 contiguous states and have not applied any consideration for a construction site in Alaska. We have not performed any large boiler erection in Alaska for several years and do not have an accurate basis for adjusting this estimate. Note that this budget price was prepared on a one (1) day basis and does not contain the same accuracy as a detailed estimate. A detailed estimate entails a preliminary design and formal quotations from major subcontractors and suppliers. This budget price should not be construed as an offer to sell. An offer to sell can only be presented with our complete proposal with terms and conditions. The maximum coal size that can be handled by our CFB depends on many factors in the coal analysis, but in general, a 95% though a mesh in the size range of 1/2 " to 3/4" can be acceptable. Changes in coal properties can be handled in our CFB unit, however, we would like detailed coal analysis since other considerations such as moisture, volatile matter, ash etc. should be reviewed. We anticipate that the boiler efficiency for this coal would be approximately 90% CFB boiler efficiencies are very similar to conventional drum boiler performance. B&W can provide a wide range of technical services and would be able to support the project during planning, engineering, construction, start-up and operation. B&W has the resources capability and desire to perform the entire project on a EPC basis as described in our "Power Systems" brochure. B&W is more than an equipment only supplier, more than a furnish and erect supplier and can be a integral part of you total project. We could welcome an opportunity to discuss our total EPC capabilities. Performance guarantees and material workmanship warranties would be similar to conventional boiler guarantees/warranties. T hope that this letter answers the questions contained in your fax. Precision Energy Services September 1, 2000 Attn: Mr. Rafal Beregowski Page -4- Should you have any additional questions please do not hesitate to call me at 1 (800) 382-2577 or email me at ki Very truly yours, The Babcock & Wilcox Company CAL mock Calven K. Mock General Sales Manager Babcock & Wilcox a McDermott company Caiven K. Mock 710 Airpark Road General Sales Manager Napa, CA 94558-7518 Phone: (707) 259-1122 800 382-2577 Fax: (707) 265-1000 cxmock@pgg.madermott.com September 19, 2000 . Precision Energy Services PO Box 1004 Hayden Lake, Idaho, 83835 Attention: Mr. Rafal Beregowski Project Manager Reference: Two CFB’s for Alaska Dear Rafal, This is in response to your questions of September 14, 2000 sent by Fax. a. Estimated auxiliary power requirements for two trains of 50 MW capacity is 5 MW. bh. Expected limestone consumption for one boiler at 40 MW generating output, per normal load is 3500 Ibs/hour. 90% CaO content in limestone was assumed. . 92% Sulfur removal can be achieved without a scrubber. d. No SNCR is required. The uncontrolled NOx from our CFB without an SNCR or SCR will be 0.15 Ibs/MMbtu. Technology Increasing the steam pressure and temperature will increase system efficiency, however, it will also increase the capital cost. Conditions for evaluated cost optimization should be considered. The boiler should be equipped with a fluid bed bottom ash cooler with solids stripping capability to ensure adequate furnace solids with this “low solids input” fuel (moderate ash and low sulfur, the latter resulting in low limestone feed.) Fuel Fuel proximate analysis provides ash content (air dried, i.e. @3.0 of residue moisture) of 13.5%. Fuel ultimate analysis provides ash content (dry basis, i.e. @ O%moisture also of 13.5%. One of these numbers has to be correct. Expected Permit Requirements With the given fuel analysis, SOZemissions of 0.100 Ib/MMBtu (specified 3 hour average) corresponds to the 92.4 reduction and 0.086 Ib/MMBtu (specified annual average) corresponds to the 93.4% reduction and not to the 90% reduction as stated in the letter. There is a substantial difference in SO2 reduction requirements that should be clarified. Please let me know if I may be of further assistance. Very truly yours, Babcock & Wilcox CAL Mock Calven K. Mock General Sales Manager ee FAX BABCOCK & WILCOX COMPANY 710 AIRPARK ROAD NAPA, CA 94558-7518 Fax Number: 707 265-1000 Phone: 707 259-1122 DATE: q- 19- 2000 ee Lox 142 3 ’ crom = CAL eck, NUMBER OF PAGESTO FOLLOW __& MESSAGE: Babcock & Wilcox Internal Recirculation-— Circulating Fluidized-Bed Boilers A Simplified Approach to Improved Flexibility ~" and Reliability ‘Ee * The Technology of Choice Since 1867, Babcock & Wilcox (B&W) has been the leading worldwide producer of steam generation technology and equipment. B&W remains in the forefront of technological advancements related to efficient and environmentally sound combustion methods for waste fuels, corrosive fuels and hard-to-burn fuels. In addition to being a preeminent boiler supplier, BaW is a turnkey supplier, owner and operator of power plants. Drawing upon its extensive technical expertise and operating experience, B&W developed the internal recirculation cir- culating fluidized-bed (IR-CFB) boiler which has become the technology of choice for power plant owners seeking economy, reliability and flexibility. BeW's unique separator technology leads to a compact, economical, low- maintenance CFB boiler design. 0 BaW's IR-CFB technology offers: = High combustion efficiency = A compact, economical . design saan f = Higher reliability and availability Lower maintenance costs Reduced erosion Fuel flexibility Low emissions Recycle System ws Forced Draft Fan Overbed Burner Pnmary Air Windbox J Two-Stage Particle Separation for Superior Combustion Efficiency BaW’s unique IR-CFB boiler design employs a patented two-stage particle separation system to provide high-solids loading and a uniform furnace temperature profile (U.S. Patent Number 5,363,812, issued Nov. 15, 1994). The benefits of this technological break- through include superior combustion efficiency, low emissions and improved overall plant performance. Our two-stage system includes a primary U-beam impact U-Beam Primary Particie parator| Leal: a gama Par aie Recirculation Lo Fuel & Limestone =——- womens - pe stand SS eeerereeeert ta Bed Drain Ge ieee Membrane Panel Fiue G 0: us \ =~ | id: Flow =\: ; ~ Vo aol U-Beam Plan view of the U-beam impact separator. separator and a secondary multi-cyclone dust collector which work together to provide a combined particle collection efficiency in excess of 99.8 percent. The U-beams, a staggered array of stainless-steel chan- nels at the furnace exit plane, The two-stage particle collection system of the IR-CFB provides Sa improved performance, as well as a simplified, cost- effective boiler design. To Baghouse |Multi-Cycione Dust Collector ew Improves Performance, Reduces Costs capture nearly all of the solids suspended in the flue gas leaving the furnace and inter- nally recirculate these solids to the lower furnace. The multi-cyclone dust collector, with small-diameter «10-inch, 250-millimeter) cyclones, cap- tures the finer material that passes through the U-beam particle separator and returns this material to the lower furnace in a controlled manner. Being able to regulate the secondary recycle system provides the operator with unprecedented control over furnace temperature, resulting in improved boiler performance and load response. Compact, Economical Design BaW’s two-stage particle separation system results in a compact, simplified boiler arrangement. The entire U-beam particle separator is tucked into an 8-foot-deep (2.4-meter) cavity at the furnace exit. Compared to cyclone CFB designs, the IR-CFB requires significantly less building volume. And by relying on inter- nal recirculation, the IR-CFB design eliminates J-valves, loop seals and high-pressure blowers which are required with other CFB designs. With the IR-CFB, compact and simple means economical. Higher Availability, Lower Maintenance For the last 50 years, one goal of boiler manufacturers has been to eliminate thick, uncooled refractory and hot expansion joints from their designs, in order to reduce the expense and lost time associated with refractory maintenance. B&aW’s engineers were the first in the CFB industry to achieve this goal through the development of the IR-CFB boiler. The furnace, U-beam separator and super- Individual | Gas Outlet Hoods Access for Hign Hardness Inspection Collection Components The secondary multi-cyclone dust collector in BEW’s unique two-stage particle Separation system provides increased collection efficiency of fine particles. By locating the dust collector downstream of the convection pass in a region of cooler flue gas, and by using high hardness wear-resistant material, maintenance is minimal. The design also permits easy access to all internal components. heater enclosures are constructed entirely of top-support, gas-tight, all-welded membraned tube walls which do not require hot expansion joints. The small amount of refractory that is used in the IR-CFB is applied to selected areas of the water- cooled enclosure surface in a thin layer which is only % inch (146 millimeters) thick in the lower furnace and never more than 3 inches (76 millimeters) thick elsewhere. As a result, BaW's IR-CFB requires less than one-fourth of the total refractory found in a hot cyclone CFB design and less than one-half of the refractory used in a water- cooled or steam-cooled cyclone CFB unit. This construction has significantly reduced the need for refractory maintenance in BaW’s operating CFB units. Low Flue Gas Velocities to Reduce Erosion Erosion is a major cause of maintenance problems in CFB boilers due to the high solids loading in the flue gas. The 7. | La : Designed to Minimize Maintenance The U-beam primary impact separator is located within a water-cooled enclosure that is protected by a thin, cooled layer of refractory. severity of this erosion is exponentially related to the velocity of the flue gas through the system. A cyclone particle separator depends upon an extremely high flue gas velocity (approaching 90 feet/second, 27 meters/second, at the cyclone inlet) to provide the energy needed to efficiently disengage the particles from the flue gas. By comparison, the U-beam particle separator is designed to operate efficiently with a flue gas velocity of only 26 feet/second (8 meters/ second) at full-load operating conditions. The efficiency actu- ally increases as the flue gas velocity through the separator decreases. By operating at such a low gas velocity, the potential for erosion_in the IR-CFB is significantly reduced. To date, because of proper material selection and low fiue gas velocities, the U-beam separators in B&W's coal-fired CFB units have not required any maintenance due to erosion throughout years of operation at design load conditions. Oo wa Allinternal primary solids recirculation (U-beams) No thick refractory due to elimination of hot cyclones and hot return legs Unique primary air nozzles (bubble caps) Gravity fuel feed and fly-ash recycle system Features and Benefits = Greater than 99.8% particle collection efficiency = Provides a means to control particle size distribution in furnace, which results in improved carbon burnout, limestone utilization, emissions and heat transfer = Reduces operating costs = Compact design requires 20-30% less building volume than cyclone-based CFB boilers - Critical for repowering projects = Lowers auxiliary power consumption compared to cyclone-based CFB boilers = Significantly reduces erosion in upper furnace and superheater compared to cyclone designs ® To date, no U-beam erosion maintenance required in BaW’s coal-fired CFBs since going into operation in 1989 = No high-maintenance vortex finders or hot expansion joints; therefore no maintenance expenses for these items = Thin, cooled refractory used by BaW places no restriction on boiler start-up or shut-down rate = Significantly reduces need for refractory maintenance «. Virtually eliminates forced outages due to refractory failures = Requires only one-fourth of the total refractory compared to hot cyclone CFB designs = Vertical, flat membraned tube panels within furnace perform evaporative or superheat duty = Eliminates need for an external heat exchanger # Proven reliability and low maintenance = Reduces back sifting of solids during low-load operation = Reduces need for periodic cleaning of nozzles and primary air windbox = Minimizes erosion inside nozzle caused by the re-entrainment of back-sifted solids a Eliminates maintenance costs and forced outages typically associated with sootblowers = Reduces maintenance, forced outages and auxiliary power requirements by eliminating the mechanical fuel injection and pneumatic fly-ash recycle systems » Allows wider load swings = Reduces operating costs during low-load operation ~ Fuel Flexibility, Lower Emissions Fuel Flexibility One of the main advantages of CFB technology is that it allows the owner to specify a wide variety of fuels to optimize the profitability of the facility. Baw has the engineering expertise and operating experience needed to supply an IR-CFB boiler that is capable of burning specified fuels, such as: Bituminous coal Bituminous gob or high-ash waste coal Sub-bituminous coal Lignite and brown coal Anthracite culm Coal cleaning tailings Petroleum coke Other fuels such as wood, biomass, shredded tires and sludge also are candidates, Engineers at B&’W’s research center evaluate the operation of the 2.5-megawatt IR-CFB test facility. This fully instrumented facility is more than 75 feet (23 meters) tall and 28 inches (711 millimeters) square—providing results that can be directly scaled to commercial-size IR-CFBs with great confidence. depending on their percentage of heat input, moisture content and emissions requirements. The IR-CFB boiler also can be designed to burn several speci- fied fuels in the same unit. This provides the additional Located in Ebensburg, Pennsylvania, USA, this 52-megawatt power plant burns high-ash waste coal with B&*W% circulating fluidized -bed technology to produce electricity and process steam. B&W is an owner of this plant and responsible for the operation and maintenance of the facility. flexibility needed to respond to changes in the fuel markets. 3 Emissions Control As is the case with all fluidized-bed technologies, the IR-CFB boiler can control SO, emissions by adding limestone to the bed material. Relatively low NO, emissions also are inherent in the IR-CFB due to low furnace temperatures and staged combustion. In addition, the IR-CFB’s patented secondary particle recycle system provides increased control, not found in other CFB technologies, to maintain an optimum uniform furnace temperature which is essential for low SO2 and NO, emissions. ) ” FluidizedBed Technologies to Meet Every Need There is no substitute for actu- al operating experience. B&W has that experience and a proven track record of high availability for all types of fluidized-bed technologies —including our bubbling fluidized-bed and pressurized fiuidized-bed combustion technologies. Bubbling Fluidized-Bed Technology For fuels with high moisture contents and low heating values, such as sludges and high-moisture biomass, Baw recommends the use of bubbling fluidized-bed (BFB) technology. This simple boiler design is generally the lowest cost alternative for these fuels. B&W offers an “open bottom” Limestone Day Bin ie Fue! Belt ——- Conveyor J Fuel Metering Bin Bed Cooling Screws: Mechanica! Ash Conveyor as BFB design which is ideal for burning fuels containing large pieces of non-combustible material, such as rocks and scrap metal, that typically would clog the bed drain system. For small boiler applications (less than 80 dTPD of sludge), BaW can supply a completely shop-assembled BFB boiler. BFB technology also is well- suited for retrofit applications on stoker fired boilers. Fast Internal Circulating- Bed Technology The fast internal circulating bed (FICB) boiler is a unique combination of both CFB and BFB technologies. It is designed to burn waste fuels with a high percentage of Be=W’s open-bottom BFB boiler is ideal for burning high-moisture fuels like wood, bark and sludge. non-combustible matter, such as municipal refuse, shredded tires and car shred- der fluff. The FICB also can efficiently burn coal and biomass fuels. Compared to standard BFB units, the FICB’s compact design can reduce overall plant costs. Innovative Energy Solutions B&W is committed to the continuing advancement of its fluidized-bed technologies. This commitment is demonstrated through the state-of-the-art fluidized-bed test facility at BaW’s Research and Development Center in Alliance, Ohio, USA. The test facility is used to evaluate innovative concepts for new components and processes, while providing results which are representa- tive of commercial-size units. Through innovative energy solutions and total-scope services, B&W is dedicated to powering the world in an environmentally safe, efficient and economical manner. Others may copy our name, but no one can duplicate the engineering excellence and advanced technologies developed by the original Babcock & Wilcox. /nsist on us by name. For more information, or a complete listing of our sales and service offices worldwide, call 1-800-BABCOCK (222-2625) in North America. Outside North America, call (330) 753-4511 or fax (330) 860-1886 (Barberton, Ohio, USA). Or access our Web site at http://www.babcock.com. Canada: Cambridge, Ontario Edmonton, Alberta Montreal, Quebec Saint John, New Brunswick Vancouver (Richmond), British Columbia Czech Republic: Prague Egypt: Cairo England: London India: Pune Indonesia: Jakarta Mexico: Mexico City People’s Republic of China: Beijing Poland: Warsaw Russia: Moscow Taiwan: Taipei Turkey: Ankara United States of America: Akron (Wadsworth), Ohio Atlanta, Georgia ; Kanoria Chemicals, located in Charlotte, North Carolina Cherry Hill, New Jersey Renukoot, India, uses IR-CFB Chicago (Downers Grove), Illinois technology to burn sub-bituminous Cincinnati, Ohio : ae Denver (Sheridan), Colorado high-ash coal. Plant capacity Houston, Texas is 231,400 pounds/hour Kansas City, Missouri (105 TPH). Babcock & Wilcox: San Francisco (Vacaville), California serving the world’s fluidized-bed technology needs. Powering the World Through Teamwork and Innovation™ The information contained herein is provided for general information Purposes only and is not intended or to be construed as a warranty, an offer, or any representation of contractual or other legal responsibility. © The Babcock & Wilcox Company. All rights reserved. Powering the World Through Teamwork and Innovation is a service mark of The Babcock & Wilcox Company. E101-3148 5MD7A Kverner Pulping September 13, 1999 Via Telefax Fax Number: 208-762-1113 No. of Pages = 5 +14 Mr. Rafal Berezowski Precision Energy Services, Inc. P.O. Box 1004 Hayden Lake, ID 83835 Subject: Coal Fired Power Plant Project Budgetary Proposal for Two (2) New Fluidized Bed Boiler Systems Kvaerner Proposal No. 87081 Dear Mr. Berezowski: In response to your lettcr dated August 30, 2000. Kvaerner Pulping Inc. (KPI) is pleased to submit our budgetary proposal the supply of two (2) new Circulating Fluidized Bed (CFB) Boiler systcms to generate steam for power generation. Description: This proposal is for the design, manufacture, and delivery uf two new CFB boiler systems firing bituminous coal. Mechanical erection of all KPl-supplied equipment and hardwarc is assumcd to be by others. Kvaemer’s CFB boiler can efficicntly burn a wide variety of fuels including coal. petroleum coke. coal wastes such as gob and culm, lignite, peat, sludge. bark, wood waste, rubber, TDF, and agricultural waste. ‘his boiler is designed for bituminous coal firing, as defined in the Design Basis below. A reference list of all our CFB installations is enclosed as Attachment 1. Design Basis: The boilcr design was based on Precision Energy Service Inc.'s (Clicnt’s) specified steam conditions. boiler data, and fuel analyses, except that the steam outlet pressure was increased to 1310 psig and the final superheat temperature was increased to 950F as per discussion with you. A feedwater temperature of 360F was assumed by KPI. A limestonc analysis for sulfur capture was assumed by KPT. The design fuel is bituminous coal. For this budgetary quotation, optional equipment, such as a limestone crushing system, was excluded from the KPT scope of supply. The technical description of the proposed cquipment will be provided with the firm price quotation. All boiler design data indicated below is predicted performance. Guarantecd performance will be provided with the firm price quotation. Process data shown is for each of two (2) CFB boilcr systems. Kracmer Pulping Inc 269 Reach Rose Tatcwvrw 717 2253362 = P.O. Sox 3398 Fax 717 327-3155 KVZERNER Williassaor. PA 17701-0308 Kvaerner Pulping Mr. Rafal Berezowski - Precision Energy Services Inc. Two CFB Boiler Systems KPI #87081 Fuel Paramcters Fuel Analyses (as received): Carbon, % wt. Hydrogen, % wt. Sulfur, % wt. Nitrogen, % wt. Chlorides, % wt. Oxygen, % wt. Ash, % wt Moisture, % wt. HHV, Btw/lb as fired Sorbent Parameters Bituminous Coal 63.79 4.46 0.73 0.82, 0.0 8.92 12.29 9.00 11,138 The following chemical analysis was assumed by KPI. Limestone Analysis: CaCO,. % wt. MgCO,, % wt. Inerts. % wt. Moisture, ‘% wt. Reactiveness Boiler Parameters Plant Elevation, ft above Sea Ievel Ambient Air Temperature, °F Lxcess Air, % Stack Temperature, ‘F Ash Discharge Temperature, "F Main Steam: Main Stewm Flow, |b/hr Steam Pressurc, psia Stcam Temperature, °l" Feed Water Temperature, °F 90.0 1.0 9.0 0.0 lligh 100 68 20 300 400 450,000 1,325 950 360 Page 2 Sept 13% 2000 KVAERNER™ Kverner Pulping Mr. Rafal Berezowski - Precision Linergy Scrvices Inc. Page 3 Two CFB Boilcr Systems Sept 13" 2000 KPI #87081 Boiler Parameters (cont'd) Gross Thermal Output. MWth (i.e., Heat Input x Boiler Efficiency) 149.5 Gross Power Generation, MWc* 45 * Note: 30% MWe/MWth Lifficiency Assumed Mass Flows Rates: Bituminous Coal 53,091 Limestone, |b/hr 5,630 Total Air, lb/hr 536,978 Total Ash, lb/hr 10,721 Total Flue Gas, lb/hr (wet basis) 584,096 Ca/S Molar Ratio 42/1 Boiler Efficicncy, % HHV 86.3 Plant Heat Rate, Btu/k Wh Gross* 13,142 Fluidized Bed Boiler Dimensioning: Combustor Width, ft 30 Combustor Depth, ft 15.67 Combustor Height, ft 80 Estimated auxiliary power requirement for each CFB system is 2,300 kW (i.e. 4,600 kW for both systems). A preliminary genera] arrangement sketch lr each boilcr system is enclosed as Attachment 2. Typical ovcrall plot plant dimensions are: Boiler Building: 155 ft Width x 125 ft Length x 135 ft Height. Baghouse and 1.1D. Fan: Additional 90 ft Length (approx.) Emissions sO, 0.100 Ib/MM Btu (92.4% Sulfur Capture) Particulates 0.015 Ib/MM Buu NO, 0.350 Ib/MM Btu co 0.100 Ib/MM Bru Kverner Pulping Mr. Rafal Berezowski - Precision Energy Services Inc. Page 4 Two CFB Boiler Systems Sept 13° 2000 KPI #87081 Other Information Requested by Client: The Client requested additional information on various aspects of the boiler design and performance. Responses to these are provided as follows: ¢ Our normal coal sizing recommendation is nominally 4” x 0. ¢ ‘the CFB system is inherently capable of handling variations in coal propertics, including changes in rank and in ash content. Mowcver, such changes may be accompanied by the need to reduce boiler capacity. For example, it will be necessary to check whether the fan capacities, the fucl and sorbent feeding system capacities, the bottom ash cooling system capacily, and the ash handling system capacities arc adequate; and, the resultant gas velocities throughout the system will need to be checked for increased erosion potential. ‘he Client specifically asked about a change to a low-rank coal at 7000 BTUAb: assuming 23% fuel moisture and 23% ash content, the following changes in flow rates might be obtaincd with the unit at full load: Fuel flow increase = 90% Air flow increase = 10% Flue gas flow increase = 16% Total ash increase = 410% (assuming 23% ash fuel) Also, if the fuel sulfur content increases significantly it may not be possible to achieve the requested SOx emission of 0.1 Ib/MM Btu. Clearly, if such fucl changes are significant it is recommended that the boiler and auxiliary equipment be designed to handle the range of fuels that may be expected. Scope List The detailed scope of supply list is provided in Attachment 3. Terminal Points: The detailed list of terminal points is provided in Attachment 4. Warranty and Guaruntecs: The two CFB boiler systems arc guaranteed for workmanship for a period of 12 months after delivery. KPI would also typically guarantee certain performance items with a firm price proposal. KVEERNER™ Kverner Pulping Mr. Rafal Berczowski - Precision Energy Services Inc. Page 5 Two CFB Boiler Systems Sept 13% 2000 KPI #87081 Schedule: The typical budget schedule from contract award to start of testing is 25 to 28 months. Budget Pricing: Budgetary pricing for two (2) CFB boiler systems, as described in the scope of supply, is: Budget Pricing - Equipment Supply: $34 million USD This pricing does not include mechanical crection, and is based on manufacturing in the United States; for foreign manufacturing about 10% price reduction may be possible. The above prices are estimates only and should not be constnued as an intent to sel]. An intent to sell will be made as part of a firm price proposal. Thank you for inviting Kvaerncr to assist Precision Energy Services in the preparation of your proposal and your interest in Kvaerner’s technology. Please let us know if you have any questions. Very truly yours, KVAERNER PUL PING INC. Michacl Alliston Fluidized Bed Boiler Technology cc: Don Beebe File - # 87081 KPI CFB Reference Preliminary General Arrangement Side Elevation 1. _ 3. Preliminary Scope T.ist 4. Preliminary Terminal Points List Attachments: KVAERNER™ Kvaerner Pulping REFERENCE LIST 1 (4) ‘ Circulating Fluidized Bed Boilers CUSTOMER Oy Alholmens Kraft Ab ie ; Bark, peat, sludge, Pietarsaani sitet REF. coal ERE Fintand a 2000 |SogamaSA.. i (<t‘ é‘sdrC™;# 27 43 jee peeeer: rea ROF—is| 2x |Meirama 1999 |EC Tychy S.A. 375 | E100 S401] iiniitos ili | nCoas man Tychy | ee OanG Saas EIRENE EE Hebe | seins | erect et | Ee MIC Ec ONOT aH 1999 | Indah Kiat Pulp & Paper 122 125 540 317 Bituminous coal, 3x Perawang, Sumatra peat ae Indonesia oe 1996 | Archer Daniels Midiand(ADM) | 151. | 90 | 482 | 350 | Bituminouscoal Decatur, Illinois USA “3998 |Archer Daniels Midiand (ADM) | 151.~+*| 90. | 482 | 350 | Bituminouscoal _ Cedar Rapids, lowa USA "j996 | United Paper Mills Ltd. Rauma Paper Bark, peat. sludge. coal CYMIC® boiler “Bituminous coal Decatur, Illinois USA “1995 | Walsh Construction, Exxon Corp. | 38 90 | 513_ Pet coke coker gas | 2x | Billings, Montana | USA oer I cctcahetaedes sca cae nsco ed snc abte enscmmsasaesraeastssniesresensarerEeey “4994 [VO Intemational Oy Tat P60 510 | ~~ 32~*| Peat, wood waste Vapo Oy, Lieksa Finland CYMIC® boile "7993 |Norrkoping EnergiAb~*(|~~42.~«Y~«140+~«| ~<S40 | +125 | Bituminous coal. Handeloverket wood waste EEEEIEE |S OCI. EH TeCPEO ESP EFEPEESPOTEETHE | SEC REEE| | Ee EAE EEEEE Te | EUR 1993 | Parsons Main 60 103 $13 Bituminous coal Sunnyside, Utah waste BH A ctaunsanessarssstneaeatgaes 1993 | Michigan State University Lansing, Michigan Jee USA a RDF = Refuse Derived Fuel REF = Recycled Fuel Kvaerner Pulping REFERENCE LIST Circulating Fluidized Bed Boilers Cedar Rapids, lowa hemicals Co. 1991 | Archer Daniels Midland (ADM) Decatur, Illinois els Midland (ADM) Decatur, Illinois DELI-| CUSTOMER STEAM]! STEAM | THERMAL VERY TEMP. | CAPACITY bar "°c Bechtel, Scrubgrass 90 Bituminous coal 2x_| Kennerdell, Pennsylvania waste yeaaees |USA prmecensoens 1992 |Perstorp AB TG | a7 |B | Goal, peat, wood | Perstorp waste eee | Sweden 3992 |Clarion Power. —=~=~S~S*~*=<“‘*~*YSCS*SC<«é*S SYS | ~~S~S*S*&YSCSBituminouss coal | Piney Creek, Clarion, Pennsylvania waste wc Oa eee | 4991 |Archer Daniels Midiand(ADM) | 60. | 90 | 482 | 140 | Bituminouscoal _ 2 (4) oven gas. Supplied by Nippon Steel Co. 1990 | Grebro Energi AB 71 | 1a9 *| 540 165 | Coal. peat, wood | Orebro waste ERE We ee ta Ete coe an EE Ene Ee 1989 | Woodland Biomass Power Inc. 32 65 482 77 Agri waste, wood California waste, rice hulls USA “1989 |Nassjo Krattvarmestation | 12 180 [49030 Beat Coal, wood Nassjo waste Sweden "]989 | Mendota Biomass Power inc. | 32. ~+| 65 | 482 | 77 | Agnwaste, wood California waste USA “4989 [Chalmers Tekn HOgskola.==SOsd|SSS~=~™ 945 [Hot [8 Coal, biomass Gétebrog water oi ween eee AT SE RMARsO USES OLAS 1989 | Bechtel, Montana One Project 45 90 513 Bituminous coal Colstrip, Montana waste (Gob) USA RDF = Refuse Derived Fue! REF = Recycled Fuel Kvaerner Pulping REFERENCE LIST 3 (4) Circulating Fluidized Bed Boilers LI- | CUSTOMER Archer Daniels Midland (ADM) Bituminous coal Decatur, Illinois |USA a semen pol sia ceomnbeseee ts, serie eta 1988 Rust Inte §2 90 513 t Anthracite mining Frackville, Fucneyieeria waste (Culm) __-|US ae 1987 |Archer Daniels Midland (ADM) | 60. +| 90 | 482 | 140 | Bituminous coal _ 3x | Cedar Rapids es lowa, USA 1987 |Thyssen Industie SSS a eg 525 [ae Gag Brown coal | Kassel een SEMA anes ee ee 1986 | Archer Daniels Midland (ADM) 54 90 482 Bituminous coal 4x | Decatur, Illinois gee Se ete ee ec LILI [Eererereme Greeeeetteal Geeeeemeeesees oe oe 1986 | Eskilstuna Varmeverk 16 Hot 50 Wood waste Eskilstuna water eeseemeeseneen | Sweden JEIEAUREIRE ones neeeneee isan eneeeeeae eee mf eosnemnveereeorrrse eorset fisececoesssscmas aa eossesennsseseeeseeeees 2) cael ccsosasstocssovecscactonteeatorereeer 1986 | Generator Energiproduktion 16 Hot 2.5 Match waste, wood Tidaholm water waste | Sweden et | 1986 |Kariskoga Kommun& SOS 48 [a8 [300 [40 «YY Coal, peat, wood 2x | Nobel Chematur waste ____..| Sweden Be 1985 |Sande PaperMilAS SSCS aT a sat 26 Coa REF, wood Norway waste, industrial oe DS LS SEL l el Eee 1985 | Uddevailla Energiverk 16 Hot | 40 Coal, peat, wood Uddevalla water waste ee Sweden 1985 |@odens Torwarme ~ ~+.~S~S«CY—S 16. | Hot | 20 | Peat. wood waste | Boden water Sweden Saree 3984 |MoindalsEnergiverk == = = = | 96 Rot a0" Coal, peat, wood Moindal water waste Sweden eeneeees eocegenes yeoeesecence! "7984 |Nykopings Varmeverk pong Hot | 40~~«|~SCCoal, peat, wood 2x =| Nykoping water waste | Sweden L J RDF = Refuse Denved Fuel REF = Recycied Fuel Kvaerner Pulping REFERENCE LIST 4 (4) Circulating Fluidized Bed Boilers DELI-} CUSTOMER TEAM | STEAM an cat hana 1984 | Sundsvalls Energiverk Sundsvall Sweden pemmencorsoencancoes soe ‘Avesta Energiverk Avesta Sweden Studsvik Energi Studsvik Sweden |Gotaverken Samfallighetsforening Goteborg Sweden ROF = Refuse Derived Fue! REF = Recycled Fuel KVARNER’ Mr. Rafal Berezowski - Precision Energy Services Inc. Page | Two CFB Boiler Systems Sept 13° 2000 KPI #87081 ATTACHMENT 3 SCOPE OF SUPPLY (x = scope of supply) Foundations Off-Site Utilities Plant Control & MCC Rooms and Laboratory Boiler House and Steam Turbine Building | Siding and Roofing Building Finishes STRUCTURAL STEEL Grid Steel for Top Supported Boiler | Boiler Support Structure xX } Duct Support Structures Equipment Support Legs, Equipment Hanger Rods, Springs, Washers PROCESS SYSTEMS FLUIDIZED BED BOILER Steam Orum Steam Drum Internals Furnace Membrane Wallis and Headers ! Loopseal Tubes and Headers xX Xx xX X | | Superheater Tubes and Headers | | Reheater Tubes and Headers pi [ Reneater Connecting Steam Piping | Supply and Riser Piping cs Eee Downcomers x Spray De-Superheater xX Spray Water Piping X Sweetwater Condenser N/A : | Feedwater Piping Upstream of Stop Valve xX | Feedwater Piping Downstream of Stop Valve Siete ra sean ett | een eI | Steam Piping Within 10 ft of Superheater and Reheater xX t Outlets se : 2 a aa Mr. Rafal Berezowski - Precision Energy Services Inc. Page 2 Two CFB Boiler Systems Scpt 13" 2000 KPI #87081 ATTACHMENT 3 Blowdown, Drain, and Vent Piping Within ASME Boundaries (2™ drain valve located at operating level) Economizer with Headers “ a AUXILIARY PIPING Cooling Water Piping to and from Devices Plant Air Piping x To KPI B/L i accaneenemee mmm OTST et eae Me TOKPI BIL X__| Te KPI BIL ears eee cece TPCT BOILER VALVES AND FITTINGS Vent Vatves Drain Vaives Feed Water Stop and Check Valves Main Steam and Reheat Steam Stop Valves Boiler Trim Drum Safety Valves xX Main Steam Safety Valves x | Silencers for Safety Vaives DE Sa adeeb ge ER Tg TT Sootblower Piping X Feed Water and De-Superheater Spray Control Vaives AT A x FABRICATED STEEL COMPONENTS ee ee : x x xX x Xx il x Loop Seals) N/A Using watercooled | Air Heater (Gas-to-Air) x Air Heater (Steam Coil) xX [Primary Air Plenum (Windbox) | NA _| ____| Using watercooled | Air and Flue Gas Ducts X Hoppers and Access Doors xX Buckstays xX K Air Heater Hopper Load Burners with Burner Management Sootbiowers with Piping and Vaives and Local Controls x 4 b oeeiean Precaraneaii Semon 00000) eRe Te SCR/SNCR/Scrubber System N/A None required Bed Maintenance System N/A peer CUNT LO TINO OU NTU ere a Le EUR Mr. Rafal Berezowski - Precision Energy Scrvices Inc. Page 3 Two CFB Boiler Systems Sept 13* 2000 KPI #87081 ATTACHMENT 3 COMBUSTION AIR SYSTEM Primary Air Fan with Motor and Inlet Silencer x Secondary Air Fan with Motor and Inlet Silencer Air Duct Dampers with Operators Air Ducts Expansion Joints Loop Sea! Blower(s) with Motor(s) and Inlet Silencer(s) FLUE GAS SYSTEM Induced Draft Fan wil with Motor Baghouse with Supports, Access, and Local Controls Hoppers and Access Doors Flue Gas Ducts Expansion Joints Main Stack x ><| >< | >< RAW WATER SYSTEM TREATED WATER SYSTEM | CONDENSATE SYSTEM | FEEDWATER SYSTEM | STEAM TURBINE GENERATOR COOLING WATER SYSTEM EQUIPMENT COOLING WATER SYSTEM BOILER BLOWDOWN uae COMPRESSED AIR SYSTEM X X PEL Lec + min x WASTE WATER SYSTEM | CHEMICAL FEED SYSTEM | AUXILIARY FUEL SYSTEM _— | SAMPLE COOLING SYSTEM jE LL f MATERIAL HANDLING SYSTEMS | BED MATERIAL REMOVAL SYSTEM Bed Ash Cooling Screws | Bed Ash Coolers c Bed Ash Solids Discharge System Xx AT | Bed Ash Pneumatic Conveying System with Piping and ] Controls Xx } Bed Ash Storage Silo(s) | Bed Ash Conditioning System x xX Xx x xX x a | FLY ASH REMOVAL SYSTEM } Fly Ash Pneumatic Conveying System with Piping and | Controls Fly Ash Storage Silo(s) Fly Ash Conditioning System — Mr. Rafal Berezowski - Precision Energy Services Inc. Page 4 Two CFB Boiler Systems Sept 13% 2000 KPI #87081 ATTACHMENT 3 Limestone Preparation | Pneumatic Loading System Limestone Storage Silo(s) Limestone Screw Feeders Limestone Rotary Airlocks Limestone Pneumatic Feed System with Piping and Controls FUEL FEED SYSTEM Feed Preparation and Storage Feed Conveyor(s) to Feed Silo(s) Fuel Feed Silo(s) Fuel Feeders SAND FEED SYSTEM | Pneumatic Truck Unloading System | Sand Storage Silo | Sand Feed System X | REFRACTORY, INSULATION, PAINTING | Refractory Materials xX Refractory Anchors f x Refractory Installation x insulation and Lagging | | Insulation Pins | Insulation and Lagging Installation | Touch-Up Painting | MECHANICAL | INSTRUMENTATION AND CONTROLS | Distributed Control System Supply, Configuration, Field } Start-Up, De-Bugging, and On-Site Training } Engr. & Design of Boiler Logic Diagrams } Engr. & Design of Functional Control Diagrams | Waste Treatment Control | Baghouse Contro! | Ash Handling System Control } Steam Turbine Control |_ Turbine Generator Supervisory System Mr. Rafal Berezowski - Precision Energy Services Inc. Page 5 Two CFB Boiler Systems Sept 13 2000 KPI #87081 ATTACHMENT 3 ee rR SEES) PRET AO EPSE pS OMNES a Primary instruments Secondary Instruments Balance of Plant Instruments Control Valves For KP] Scope Boiler Oxygen Analyzer Economizer Outlet Continuous Emissions Monitoring System Motor Starters Electrical Heat Tracing LIGHTING SYSTEM SPECIALTY ELECTRICAL SYSTEMS Fire Detection System System (Equip. & Structures) Intercom and CCTV Systems Telephone System OUTDOOR SUBSTATION x p-TRANSMNSSION LING 25 eS” ld EE [ENGR.& PROJECT MANAGEMENT TT | PROJECT MANAGEMENT | (For KPI's Scope of Supply) | Home Office Project Management | Engineering Management | Field Office Staff and Management | Safety Program | Quality Control Program ENGINEERING Civil x Architectural Design. Xe - Mr. Rafal Berezowski - Precision Energy Services Inc. Page 6 Two CFB Boiler Systems Sept 13" 2000 KPT #87081 ATTACHMENT 3 Ea nia EQ fate eee Survey Artist Rendering TRAVEL KP! Travel Customer Travel CONSTRUCTION (For Equipment in KP!'s Scope of Supply) Erection Services x : | 1 >< | PERMITS Building Permits Environmental and Operating Construction Licenses | CONSTRUCTION FINANCING [4+ : | BONDS | INSURANCE | Standard Corporate Policies Builder's Risk } Force Majeure TAXES | PLANT COMPLETION H Permanent Piant Opera Operating, Maintenance, and Supervisory Staff | Craft Labor for Start-Up Support Incl. 1&C a paee | KPI Per-Diem KPI Per-Diem KPI Per-Diem | Start-Up Spares Utilities and Services for Start-Up & Testing | Sand, Fuel, and Sorbent for Start-Up and Testing Ash Disposal Performance Test Protocol, Execution, and Report 4 Emissions Testing (Outside Firm) Mr. Rafal Berezowski - Precision Energy Scrvices Inc. Page 1 Two CFB Boiler Systems Sept 13" 2000 KPI #87081 Attachment 4 TERMINAL POINTS The proposal scope of work is based on the terminal points and interfaces specified in this section. Fluidized Bed Boiler Fuels and Additives Coal e At the discharge flanges of the coal bunker hoppers Limestone e At the discharge flanges of the limestone bunker hoppers e At the inlet of the transport blower inlet filter Natural Gas e Atthe inlets to the start-up bumer valve racks e Atthe outlets of the natural gas vent lines Bed Material e At the inlets to the sand nozzles on the loopseals Combustion Air e At the inlet of the primary and secondary air fan inlet silencers e At the inlet of the loopseal blower inlet filter e At the duct support points Flue Gas e Atthe stack inlet flange Mr. Rafal Bcrezowski - Precision Energy Services Inc. Page 2 Two CFB Boiler Systems Scpt 13" 2000 KPI #87081 Attachment 4 Solid Residues Bed Ash Material e At the outlet flanges on the bottom ash surge tank. Flyash e Atthe outlet flanges of the air heater hoppers. e At the outlet flanges of the baghouse hoppers. Feedwater At the inlet to the feedwater check valve e At the inlet flanges of the attemperator nozzles Steam e Atthe steam inlet to the main steam stop/check within 10’ of boiler At the low pressure steam piping at equipment connections At the outlet flanges of safety valves. At the outlet flange of the Electromatic Relief Valve. At the outlet of the boiler vent valves At the outlets of the steam sampling valves close coupled to the process connection. Condensate e At the condensate outlet flanges of the steam coil air preheaters. e Atthe outlets of sootblower thermal drain units e Atthe oulets of water sampling valves close coupled to the drum. e Atthe outlet of the boiler blowdown line at the operating level e At the outlet of the second boiler drain valves at the operating level Mr. Rafal Berezowski - Precision Energy Scrvices Inc. Page 3 Two CFB Boilcr Systems Scpt 13" 2000 KPI #87081 Attachment 4 Utilities and Services Cooling Water e At the cooling water inlet connections of equipment requiring cooling water e At the cooling water outlet connections of equipment requiring cooling water Instrument Air e At the inlet connections of equipment and instrumentation requiring instrument quality compressed air Plant Air e At the inlet connections of equipment requiring plant (service) quality compressed air Nitrogen e At the inlet of the nitrogen connection on the steam drum Electrical e At motor terminal boxes, for motors supplied by KPI e Atterminals of sootblower MCC main disconnect switches e At terminals of individual sootblower starter contractors e Atthe terminals of solenoid controlled valves Controls e Atinstrument wire terminals e At equipment and instrument pressure connections e At thermowell connections e At bed temperature thermocouple wire terminals e At thermowell connections e At draft connections f e Atair flow meter connections e Atair and flue gas test connections At pressure connections ° From: craig.r.winchester@us.abb.com Received: by abb-us01-ussmtp.abb.com Fri, 8 Sep 2000 14:40:44 -0400 To: Bradtco@nwlink.com cc: frederick.j.dion@us.abb.com Message-ID: <85256954.00669834.00@abb-us01-ussmtp.abb.com> Date: Fri, 8 Sep 2000 14:47:21 -0400 Subject: Budget Price for Alaska FiCirc Dear Brad, We are please to provide a budgetary price for the supply of 2 x 40MW FiCirc CFB's for the sum of $36,343,000 D&R. We estimate the erection to be $8,000,000 for the equipment supplied. | have included a scope list and a boiler performance sheet. We have assumed that a baghouse is required to meet the particulate requirements and is included in the price. (See attached file: PESDOW.doc) (See attached file: PESPerformance.xis) In regards to your question regarding coal sizing, we provide the following : Coal should be sized less than 19mm with an average size about 6mm. There is no problem running at 100% MCR with the low rank coal as described. If you have any other questions, please feel free to contact me. Regards, PAGE 1 FI-CIRC (OR) FBB SCOPE VERIFICATION LIST (DIVISION OF WORK) NR = Not Required SUPPLIED SUPPLIED BYCE BY OTHERS MECHANICAL EQUIPMENT FUEL SYSTEMS FUEL FEEDING SYSTEM: Fuel Unloading System Fuel Reclaiming System Fuel Preparation System Fuel Crusher System Fuel Storage System Silo Dust Control Silo Silo Isolation Valves Fuel Conveyors Fuel Spreaders Piping / Feed Chutes to Furnace «x «x KKK OX { x XK KX LIMESTONE FEEDING SYSTEM: Limestone Unloading System Limestone Crusher System Limestone Storage System Silo Dust Control Silo Limestone Bin Isolation Valves Rotary Feeders Blowers Piping To Injection Points Including Supports x KK OK «— KKK XK \ \ SAND FEEDING SYSTEM (IF FIRING PET COKE) NR Sand Unloading and Storage System Silo Dust Control Silo Isolation Valve Blower Piping to Injection Points Including Supports PAGE 2 FI-CIRC (OR) FBB SCOPE VERIFICATION LIST (DIVISION OF WORK) NR = Not Required FURNACE LOOP EQUIPMENT: Fluidized Bed Combustor Refractory Lined Freeboard Evaporator Surface Cyclone Risers Recycle Cyclone System and Support Structure Outlet Manifold Solid System End Wall Water Cooled Distribution Plate Air Distribution Tuyeres Start-Up Burner System BACKPASS EQUIPMENT: Drum /Connecting Tubes/Piping Backpass Tube Panels/Headers Backpass Heat Absorbing Surface: - Economizer - Reheater / Fluidized Bed Heat Exchanger - Superheater Superheater / Desuperheater (S) Desuperheater Valve Stations Desuperheater Piping Economizer Piping To Drum Superheater / Interconnecting Piping Feedwater Stop And Check Valves Safety Valves With Vent Piping And Silencers Electromatic Relief Valve With Vent Piping And Silencer Boiler Trim Valves, Double Valves Drum Level Gauge And Indicators SOOTBLOWING SYSTEM: Retracts/Rotaries As Required Integral Control Panel (S) Valves Field Run Piping Material SUPPLIED SUPPLIED BYCE BY OTHERS x «KK KK OK OK OK OK OK xxx x KKK KKK KK EX x X< <x * &*K O&K PAGE 3 FI-CIRC (OR) FBB SCOPE VERIFICATION LIST (DIVISION OF WORK) NR = Not Required SUPPLIED SUPPLIED BYCE BY OTHERS AIR SYSTEM: Primary Air Fan With Drive Bed Media Transfer Blower Inlet Silencers For Fans And Blowers Airheater Air Ducts - Hangers And Supports - Expansion Joints Steam Coil Air Preheaters, If Required Dampers With Operators «KK KK KK OK OK OK FLUE GAS SYSTEM: Baghouse - Inlet And Outlet Plenums - Controls - Supports Induced Draft Fan With Drive Gas Ducts: Air Heater To Baghouse Baghouse Outlet to ID Fan ID Fan to Stack Dampers with Operators KK KK KK KOK OK OK = a NOx REDUCTION SYSTEM (SCR/SNCR) ASH HANDLING SYSTEM: Ash Drain Valves Ash Drain Piping Ash Coolers Bottom Ash System: - Conveyors From All Collecting Points - Bottom Ash Storage Silo - Controls - Hangers And Supports - Insulation And Lagging <x * & x «KK XK NR = Not Required Fly Ash System: - Piping From All Collecting Points - Fly Ash Storage Silo - Controls - Hangers And Supports - Insulation And Lagging CIVIL Site Preparation For Total Plant: Demolition And Grading Roads, Parking And Fencing Site Drainage Waste Water Ponds Sanitary Systems Preparation For Laydown Areas Site Access Roads Rail Spurs And/Or Upgrades FOUNDATIONS Pilings For Boiler Island Pilings For Balance Of Plant Concrete Foundations And Elevated Slabs Anchor Bolts For Boiler Island And Balance Of Plant Underground Piping System Underground Electrical Cable Ducts Complete Grounding System ARCHITECTURAL Permits Boiler Island Building - Complete Turbine Island Building - Complete Office Building — Complete Plant Control Room- Complete Maintenance Building — Complete Guard House — Complete Pump House — Complete HVAC As Required DIVI PAGE 4 SUPPLIED SUPPLIED BYCE BY OTHERS x «KK KK OK OK «x KK KK KK OK OK OX x «KKK OK x «KK KK OK OK OK OK PAGE 5 BYCE BY OTHERS Steam Generator Structural Steel Steam Generator Platforms System Steam Generator Internal Grid Steel Balance Of Plant Structural Steel Boiler Island Elevator Boiler Building / Siding / Roofing / Doors / Windows/ PIPING AND DUCTING «x * &* x x &* Oil Piping To Boiler Column Oil Storage Tanks And Associated PV&F/Pumps Instrument Air Piping To Boiler Column High Pressure Steam Piping Cooling Water System Pipe To Boiler Column Plant Service Air System Pipe To Boiler Column Feedwater Piping To Feedwater Check Valve Inlet Balance Of Plant Piping «— «KKK KK OK OK ELECTRICAL Motor Control Centers Switchgear As Required High And Low Voltage Wiring Cable Trays Conduit Lighting For Boiler Island Conduit Lighting For Balance Of Plant Substations As Required INSTRUMENTATION AND CONTROL SYSTEMS Burner Management System FBB Steam Generator Field Inst. Desuperheater Control Valves And Thermocouples Distributive Control System (DCS) Conceptual SAMA’s (Boiler Process Control) SAMA For Implementation Controls to DCS xX «x «KK KK OK OK «x KKK FI-CIRC (OR) FBB SCOPE VERIFICATION LIST (DIVISION OF WORK) : REFRACTORIES Refractory Material For FBB Steam Generator Installation Of Refractory Material For FBB Steam Generator Refractory Curing Including Dry Out Fuel Indoor Heated Refractory Storage Building INSULATION AND LAGGING Insulation And Lagging For Heat Conservation Of AAP Equipment PAINTING Shop Prime Painting For C-E Supplied Equipment Shop Prime Painting For Balance Of Plant Equipment Finish Painting For Boiler Island, Including Touch-Up Finish Painting For Balance Of Plant Equipment TURBINE Turbine, Generator, Condenser, Oil Lube System, And Control Sage Guard System, BOP For Turbine Generator MISCELLANEOUS EQUIPMENT / SERVICES Spare Parts (Start-Up) Steam Sampling System Main Feed Pumps And Drives Emergency Feed Pumps And Drives Feedwater Heaters & Treatment System Deaerator System Blowdown And Flash System Chemical Feed System / Injection / Dosing Stack Fire Protection Piping, Hose Stations & Racks First Fill Of Lubricants Compressed Air System Services Of Erection And Startup Personne! For Consultation Training Of Operating & Maintenance — Field PAGE 6 SUPPLIED SUPPLIED BYCE BY OTHERS x X< x x XK x &* x KKK KK KKK PAGE 7 PE V | Vi NR = Not Required a : Erection Of AAP equipment Erection Of Balance Of Plant Equipment Freight — Coastline Port Xx Receiving, Unloading At Dock And Inland Transportation Protection Of Equipment During Storage . Boiler Hydrostatic Testing, Incl. All Temperature. Equip. & Piping Boil Out And Acid Clean Including Chemicals Disposing Of Chemical Wastes Steam Blow Of Lines, Including Temporary Piping & Materials Performance Tests, Advisory Personnel Only Performance Tests, Incl. Test Personnel, Equip., & Materials Fuel, Water, And Power For Commissioning & Erection Plant Operators Office Or Trailer For CE Site Personnel Washrooms / Toilets Camp Housing Site Transportation Instruction Manuals - CE Equipment Xx KKK KKK KK «x «x KK KK OK TAX AND DUTIES EXCLUDED INSURANCE Workers Comp. For CE Employees Employees Liability For CE Employees Auto For CE Employees Comprehensive General For CE Employees Liability For CE Employees Builders All Risk x x «KK OK ALSTOM Power Inc. Turbine Generator Division Industrial Turbines Carl A. Stendebach Delivery-Mail-P. O. Box 73444, Houston, TX 77273 (281) 583-9444 - Phone Courier-~-1118 Manatee Lane, Houston, TX 77090 (281) 583-1910 - Fax TELEFAX: e-mail address cari.stendebach@power.alstom.com Precision Energy Services Inc. September 13, 2000 Hayden Lake, ID Rafal Berezoski > 208-762-1113 Brad Thompson Sven Erlandsson Soren Olsson Budgetary Proposal for Unknown User Bethel, Alaska Our Reference Y00087 Dear Mr. Berezoski We are pleased to provide our Budgetary Performance for the conditions submitted in your facsimile of August 30 (but adjusted inlet conditions), along with Approximate pricing as follows. Please see the attached for performance related information as may be appropriate for this current study phase. For these conditions we have selected our ATP4C Steam turbine generator, with pricing estimate of $13,500,000 for two units. Price is FOB Port of Export, Norrkoping Sweden. No Import duties, Federal, state or local sales or use taxes are included. Current first unit shipment, Ex Port of Export is 14 months from full funded release and mutually agreed purchase documentation. Unit two would follow in approximately 5-6 weeks. Delivery is subject to prior sale. Included in our budgetary pricing is the following scope. We shall be pleased to provide more accurate details and/or specification commentary when a formal is submitted. e Turbine—Unit is provided with axial exhaust orientation, for direct connection to condenser flange (condenser by others), requiring no expansion bellows. Insulation blankets, provided without sheet metal lagging are provided, however miscellaneous piping and valves are to be insulated by others. Emergency stop valve and extraction non-return valves are included as Tequired, but shipped loose to be installed in customer piping. © We include a complete stand-alone digital control system handling all required turbine generator controls (closed and open loop), and monitoring (power output, pressures, temperatures, vibrations, etc.) of the steam turbine generator unit. There is a coordinating controller plus separate control units for (1) the turbine governor function, (2) the steam turbine safety trip functions and (3) the generator voltage regulator functions, connected via a high speed bus. Generator protection relays can be offered as an option. All man-machine © ALSTOM Power Inc. Turbine Generator Division Page 2 Budgetary Quotation Y-00087 9/13/00 interface, as well as all measurements, status and alarm displays are handled from an Operator Station with Color Monitor, Keyboard and Trackball, supported by an event and alarm printer. A Modbus interface for information exchange with the plant DCS can be provided. Generator—TEWAC, 13.8 kV, 60 HZ, 3600 RPM, 0.85 P.F., with brushless excitation, and coolers sized for water temperature of 85 ° F. water. RTDs are provided in each phase windings and in air ducts and bearings. Water leak detection is provided. Shaft is monitored for vibration and is grounded. Oil Systems—Separate baseplate mounted lubrication and control oil systems are included, with interconnecting piping between modules and steam turbine generator. Coolers are sized for water temperature of 85 ° F. Dual coolers and filters are provided on the lube system. Two main oi] pumps are provided, along with one emergency DC pump. Soleplates are included for mounting the separate modules on a concrete foundation. Foundation bolts are not included. Unit is designed for indoor installation with noise attenuation for 85 dBA levels. We trust that this information satisfies your current need and we shall look forward to this becoming a fully funded approved project. Please don’t hesitate to request additional information if necessary to support your effort. Best Regards, nl ONiadteL. Car] A. Stendebach Business Development Manager mre ee revo weer ew ee ee eee See ere Unknown/Precision En.Serv. ABB sATP4C247 Given Pgen: 50000kW 21.15m = 1195.7h UNITS: FLOW:m (kib/h) ENTH:h (Btu/b) PRESS:p (psia) TEMP:t (*F) SIEMENS Westinghouse Siemens Westinghouse Power Corporation A Siemens Company Fax To: PES Sam Fuiton From: Nicholas J. Harbilas Phone: 407-736-2080 ~S~CS~S Fax. 208-762-1113 Fax: 407-736-3171 Phone: 208-772-4457 E-Mail: Nick harbila: c.siemens.com Date: September 11, 2000 Pages to Follow: 1 Message: Budgetary Steam Turbine Information Thank you for your interest in Siemens Westinghouse Power Corporation. We have evaluated your inquiry dated August 31 and are please to provide you with the following: Steam turbine generator set designed for 346,000 pph with a maximum capacity of 390,000 pph. - We have allowed for an extraction flow to the DEA tank of 30,000 pph. This results in an output of approximately: Design 43,200 KW Max 48,810 KW The standard scope of supply would include the turbine generator and associated instrumentation and controls, separate lube oi] system, generator with brushless excitation and AVR. Excluded from our scope are any duties, taxes, shipping and commissioning. Delivery period is approximately 13 months ex-works. Budget price is $ 5,500,000. | hope this information meets your satisfaction. If you require additional information or a more detailed proposal, please contact me at the address above. me Z Nicholas J. Harbilas DB-Regional Marketing Manager This message is intended anty for the use of the individual or entity to which it is addressed and may contain information that is privileged, confidential and exempt from disclosure under applicable law. If the reader ot this message is not the intended recipient, or the employee or agent responsible for delivering the message to the intended recipient, you are hereby notified that any dissemination, distribution, or copying of this communication is strictly prohibited. tf you have received this communication in error, please notify us immediately by telephone and return the original message to us at the address below via your Postal Service. 4400 Alataya Trail 1 1pes091100.doc Ortando, Fl. 32826-2399 i. DRESSER-RAND Casey Spa ies Terry 382 S.E. Washington Sireet Turbocyne P.O. Box 9 Hitisboro, Oregon 97123-0009 $03/693-1221 FAX: 503/640-8424 August 31, 2000 Precision Energy Services, Inc, PO Box 1004 Hayden Lake, ID 83835 Attention: Mr. Sam Fulton Subject: Dresser-Rand Steam Turbine Generator Alaska Mine Application C&N Reference: 00-W-421 Dear Sam: We are pleased to provide our budgetary proposal for a Dresser-Rand Steam Turbine-Generator in response to your August 30, 2000 faxed request. The enclosed data sheets and descriptive literature describe our offering in detail. Please note that the Estimated Performance stated herein assumes that the total steam flow passes through the turbine, since the DA and heater extraction flow and pressure were not specified. Once the flow and pressure arc determined, revised performance can be quoted. The budgetary price for the turbine generator as quoted herein, FOB Wellsville, NY is seseeesse eee ee7,000,000.00, The estimated weight for the complete system is 400,000 Ibs. ‘The estimated envelope dimensions are 47 feet long by 13 feet tall by 16 feet wide. We welcome the opportunity to work with you on this project and look forward to submitting a firm price proposal when this becomes a contract for Precision Energy. Very truly yours, Vf; J. Wold c: Pred Bender c: Brook Tolman 382 SE Washington, PO Box 9 Hillsboro, OR 97123 Phone: (503) 693-1221 Fax: (503) 640-8424 Courtney & ess Teted | . Te: Sam Fulton — Precision Energy From: Don Wold Fac 1-208-762-1113 Pages: 1 of 7 Phone: 1-208-772-4457 Date: August 31, 2000 Re: Oresser-Rand Steam Turbine Generator O Urgent OO ForReview OU Please Comment (Please Reply O Please Recycle Dear Sam: Sent herewith is a copy of our Dresser-Rand Steam Turbine Generator quotation in response to your August 30, 2000 faxed request. Regards, Don FEATURES AND ACCESSORIES (STEAM TURBINE ) Continued STEAM GAUGES MOUNTED ON GAUGEBOARD INITIAL PRESSURE 6" DIAMETER FIRST STAGE PRESSURE 6" DIAMETER EXHAUST PRESSURE 6" DIAMETER GLAND SEAL PRESSURE 6" DIAMETER OIL PRESSURE GAUGES MOUNTED ON GAUGEBOARD GOVERNOR OIL BEARING OIL FEATURES AND ACCESSORIES (STEAM TURBINE ) Continued MOTOR OPERATED ROTOR TURNING GEAR - AC INSULATION WITH PAINTED STEEL JACKET HEAVY STEEL BASEPLATE UNDER TURBINE HEAVY STEEL SOLEPLATES UNDER GENERATOR ELECTRICAL TACHOMETER WITH INDICATING INSTRUMENT VIBRATION PROBES AND PROXIMITORS VIBRATION MONITORING AND READOUT EQUIPMENT ~_ REMOTE BEARING TEMPERATURE DETECTION INCLUDING READOUT MONITOR. NO INTERCONNECTING WIRING INCLUDED LOCAL READING THERMOMETERS FOR MAIN BEARINGS SET OF SPECIAL WRENCHES GAUGEBOARD FOR LOCAL MOUNTING FEATURES AND ACCESSORIES THE FOLLOWING FEATURES AND ACCESSORIES WILL BE SUPPLIED IN ACCORDANCE WITH THE LATEST NEMA STANDARDS: * STEAM TURBINE COMBINED TRIP AND THROTTLE VALVE WITH INTEGRAL STEAM STRAINER - OIL OPERATED WOODWARD “S05” ELECTRONIC GOVERNOR TRIP AND THROTTLE VALVE EXERCISER EXTRACTION PORT (UNCONTROLLED) SEPARATE EMERGENCY OVERSPEED GOVERNOR TILT PAD HORIZONTALLY SPLIT JOURNAL BEARING TILTING PAD THRUST BEARING LABYRINTH INTERSTAGE PACKING LABYRINTH SHAFT PACKING AUTOMATIC GLAND SEAL SYSTEM INCLUDING GAUGES AND PIPING STAINLESS STEEL WHEEL BLADING STAINLESS STEEL DIAPHRAGM NOZZLES SENTINEL WARNING VALVE ON EXHAUST DOWN EXHAUST ORIENTATION OPERATING CONDITIONS AND SPECIFICATIONS GENERATOR DATA RATED KW OUTPUT - 48,500 RATED KVA - 53,890 POWER FACTOR - 90 NUMBER POLES -2 PHASES -3 HERTZ - 60 VOLTAGE - 13800 INSULATION CLASS - “F” ROTOR TEMPERATURE RISE (°C) - 85 (BY RESISTANCE) STATOR COILS TEMPERATURE RISE (°C) - 70 (BY DETECTOR) EXCITATION TYPE - Brushless VOLTAGE REGULATOR TYPE - Static COOLING TYPE - TEWAC COOLING MEDIUM - Water/Air TEMPERATURE - 80°F STEAM TURBINE FLANGE SIZES Inlet: 10 Inch 900 # Extraction (Uncontrolled) Will be determined when Pressure/Temperature are defined Exhaust: 130 Inch Condensing (Down) OPERATING CONDITIONS AND SPECIFICATIONS RATED STEAM CONDITIONS INLET PRESSURE (PSIG) - 900 INLET TEMPERATURE (°F) - 800 EXHAUST PRESSURE (inHgA) -2.0 ESTIMATED PERFORMANCE DATA al MAXIMUM FLOW - 48,500 EKW* NORMAL/DESIGN FLOW - 43,100 EKW* ¢ *Note - the quoted performance is basis straight through with no steam extracted for DA and heater. Once pressure and flow is made available, revised performance can be quoted. RATED TURBINE SPEED (RPM) GENERATOR SPEED (RPM) 3600 3600 STRAIGHT CONDENSING DIRECT COUPLED TURBINE GENERATOR ONE (1) Dresser-Rand, steam turbine generator unit consisting of the following major components: ONE (1) Nominal 48,500 EKW, 3600 RPM multistage condensing steam turbine with a single extraction port for DA steam. Turbine will be baseplate mounted with a down exhaust. ONE (1) 53,890 KVA, 0.90 P.F., 3 phase, 60 hertz, 13800 volts, 3600 RPM electric generator complete with direct connected brushless exciter, voltage regulator system and TEWAC (totally enclosed water to air cooling) construction suitable for 80°F fresh cooling water. Set of soleplates under the generator for mounting. —_ ONE (1) Coupling for connecting the steam turbine to generator. ONE (1) Complete lubrication system baseplate mounted (Console type). ONE (1) Electro-hydraulic control system. ONE (1) Local turbine gaugeboard. ONE (1) Turbine/Generator control panel. 382 SE Washington, PO Bax 9 Hillsboro, OR 97123 Phone. (503) 693-1221 Fax: (603) 640-8424 Courtney & Nee Inc. To: Rafal Berezowski — Precision Energy From: Don Wold Fax: = 1-208-762-1113 Pages: 1of / Phone: 1-208-772-4457 Date: September 15, 2000 Re: Bethel, Alaska Turbine Generators Dear Rafal: We are pleased to provide the following responses regarding the Dresser-Rand Steam Turbine Generators previously offered for this project, in response to Sam Fultons 9-5-00 fax. First, we want to reconfirm the steam conditions as you and | discussed on the telephone. Total steam flow to each turbine:...340,420 Ib/hr at 900 PSIA, 900°F. Altemate for 1300 PSIA, 900°F. Extraction flow from each turbine:...65,200 ib/hr at 20 PSIA, of which 37,100 Ib/nr goes to DA and balance goes to district heating. Steam to condenser, each turbine:.....275,200 Ib/hr at 2 inHgA 1) The estimated power output with 900 PSIA, 900°F steam is 40,200 ekw. With zero extraction and all the steam going to the condenser, output would be 42,900 ekw. 2) The estimated power output with 1300 PSIA, 900°F steam is 41,300 ekw. With zero extraction and all the steam going to the condenser, output would be 43,900 ekw. 3) The breakout cost for controls and instrumentation is approximately $90,000 per unit. 4) The estimated cost for installation is $250,000 per unit. 5) The heaviest piece for lifting after the unit is installed is the turbine upper casing half, which will weigh approximately 52,000 Ibs. 6) Aswe discussed earlier today, | am working on a condenser and cooling tower selection for you at this time. Dresser-Rand offered the budgetary cost for each condenser of $600,000 but I will try to get you a more accurate price. Please advise if you should require any additional information at this time. Don Wold fc: Dale Jonnson fc: Fred Bender 382 SE Washington, PO Box 9 Hillsboro, OR 97123 Seg. . See Courtney & Nye, Inc. To: Rafal Berezowski — Precision Energy From: Don Wold Fac 1-208-762-1113 Pages: 1 of 2 Phone: 1-208-772-4457 Date: September 22, 2000 Re: Bethel, Alaska Project, Alstom Steam Surface Condensers Dear Rafal: As the local Manufacturers Representative for Alstom Power, we are pleased to provide our budgetary proposal for two steam surface condensers for the Bethe! Project. Sent herewith is a data sheet confirming the design performance and physical data for each condenser. Our offering is for quantity (2) two single shell, single pressure surface condensers each containing 34,871 sq. ft. of condensing surface. Construction includes 7/8" - 22 BWG 304L SS tubes (shop installed), solid 304L SS tubesheets, coal tar epoxy coated waterboxes, two (2) 100% capacity liquid fing vacuum pumps sized for 10 SCFM and a rubber dogbone style expansion joint. The budgetary price for quantity (2) two condensers as described above, FOB Easton, PA is..$1,240,000. Shipment will be 34-36 weeks after order receipt. Please advise if you should require any additional details regarding this condenser selection. Regards, Don -_ SANLAAAA Oni sae ae “ALSTOM POWER cE SURFACE CONDENSER PERFORMANCE gee aot. JE Ref 2019.00-302HT e on ECE a Job tie, . is, Date: Q9/2000° THERMAL DATA: : HEAT LOAD (milllons):) =»: BTUHR: = 2658 TOT. CONDENSER PRESS: ‘: ai HAL cH) goo STEAM TEMPERATURE . deg. F 2401.13 ‘COOLING WATER TEMP... deg,F 5!) 75.00: INITIAL TEMP. DIFFERENCE “deg.Fo 2613 TEMPERATURE RISE’ | i (COOLING WATER...) (ed! WATER SIDE FRICTION “2 fof H20. 72 18.24 NUMBER OF WATER PASSES : h2: TUBE DIAMETER). patties ie i D872 ie TUBE GUAGE HBG i 1, 12 wid gat ieniaicieerst st TUBE MATERIAL | tbe ste 304 sis: ane : TUBE CLEANLINESS FACTOR (%) Woctis @ sQQah fi MBs. tiie TUBE VELOCITY: °°: RS Sb eggp gs SE Ou ies. m EFFECTIVE TUBE LENGTH ft. $ORQIR EP bs NUMBER OF TUBES > «> pee hE M62 eee TONDENSING.SURFACE - : Sq.Ft. 3: 34.874 | NUMBER QF SHELLS ‘': Dehadey 4. WATER GCIRCUITSPER'SHELL: 5 2; “. Pestormance information ig based on the Ninth Edition of the HE]... 382 SE Washington, PO Box 9 Hillsboro, OR 97123 Phone; (S03) 693-1221 Fax (503) 640-8424 Courtney r Nye, Inc. To: Rafal Berezowski — Precision Energy From: Don Wold Fax: 1-208-762-1113 Pages: 1of 5 Phone: 1-208-772-4457 Date: September 22, 2000 Re: Bethel, Alaska Project, PS! Cooling Tower, PSI! Ref: 00I-NB366 Dear Rafal: As the local Manufacturers Representative for Psychrometric Systems Inc. Cooling Towers, we are pleased to provide our budgetary proposal for the tower for the Bethe! Project. The complete budgetary proposal with data sheets, drawings and budgetary pricing is included herein. Notice that we have quoted an even number of calls. This will allow you to pipe each condenser to three cells to facilitate operating each turbine separately and alone, if necessary. Please advise if you should require any additional details regarding this condenser selection. Regards, Don SEP-22-00 FRI 10:49 AM PLS. I. FAX NO. 3032155298 P, 02/08 Psychrometric - Systems, Inc. Wet Hybric « Ory Cooling Towers Scptember 22, 2000 Precision Energy : Now Psychrometric Systems, Inc, (PSI) Bethel Power Plant Cooling Tower Solutions Bethel, Alaska PSI Proposal No. 00I-NB366 P AL D) LED W Fumish one Psychrometric Systcms 6 cell, counterflow cooling tower 216’ long by 42’ wide by 28? high to the fan deck. (ODE! . -61-28 guaranteed to cool 55,000 gpm from 95°F HWT to 75°F CWT ata 63°F IWBT with a pump head height of 24° and a BHP/cell of 184.4. The tower consists of the following features: High strength, fire retardant, pultruded fiberglass structure Stainless siecl connecting hardware (300 Scries) Heavy duty PVC film pack fill supplied as nested sheets Cellular PVC drift eliminators Non skid FRP fan deck Partidons: 12 oz. fire retardant FRP Windwalls: 12 oz. fire retardant PRP Casing: 12 oz. fire retardant PRP PVC header with PVC lateral distribution system Composite drive shaft with 316 SS couplings Amarillo gear boxes SPDT vibration switches 28’ diameter 10 blade high efficiency fans 6’ high fire retardant PRP fan cylinders - velocity recovery 200 hp high efficiency, 2 specd mators (480 volt, 3 phase, 60 Hz, 1800/900 rpm) One FRP escape ladder One fiberglass stairway Louverless design eeoererereoereeeevere7%+ ee & Materials FOB Shipping Point $802,871 Freight to Job Site $105,234 Open Shop Installation Labor £11688) TOTAL $1,024,986 All Information Contained Herein is Proprietary and Confidential SEP-22-00 FRI 10:49 AM PLS. I. FAX NO. 3032155298 P. 03/08 2 Psychrometric Systems, Inc. Precision Energy - Bethel Power Plant ee (1) Electrical Power (2) Switch Gcar and Staricrs (3) Wiring and Controls (4) Tower Lighting (5) Lightning Protection System (6) _ Fire Protection System (7) Circulating Water Systems, including: pump, hed pips, risers, and valves (8) Blow Down System (9) | Makeup Water Piping (10) Basin with Anchor Bolts SITE CONDITIONS: Auy physical sile conditions varying significantly from those described below, will result in equitable adjustment to the contract price und schedule. Assumed sile conditions, available at no expense to the Seller, are as follows: (1) A minimum 60 foot wide safety buffer around the structure which will be {rec of other contractor's personnel or equipment and bo reasonably Icvel aad solid. (2) A material lay down/storage urca will be provided, no more than 200 fi from the structure, and be as a minimum, twice the basin area. (3) Access roads and work arcas will be provided, and be solld enough in any weather to support a 35-ton mobile crane. Acccss roads shall be reasonably levcl, compacted and maintained by Others. (4) Connections for adequate clecirieal power (120 VAC with a minimum of 100 AMP service) and potable water supply shall be provided to the Seller within 50 fect of the structure. (5) An employce parking arca within 400 yards of tho tower construction site shall be provided, (6) The top of the basin curb is assumed {o be ono foot above grade, unless otherwise noted. PROPOSAL NOTES (1) Prices do not include sales/use tax and purchaser is responsible for any and all applicable (axes. Any applicable sales/use tax imposed upon seller will be invoiced for separately, and in addition to, contract price. (2) Prices do not include any permits, certificates or special licenses that may be required. (3) Pricing is valid until 60 days afler September 22, 2000. (4) PSI payment terms: 15% for Engineering and Design due upon submittal of customer engineering package (gencral arrangement drawings, basin drawings end load drawings); materials billed upon shipment Net 30 Days. Bi-monthly progress billing for labor, less 5% retainage on final invoicc. All invoices due Net 30 Days from invoice date. (5) PSI standard warranty is 18 months after shipment or 12 months after start-up whichever occurs first. (6) PS} General Terms and Conditions are attached hers(o and are incorporated as part of this documont. These tenns shall apply unless otherwise agreed upon. (7) Three copics of reproducible drawings are supplicd; additional copies can be supplied for an 001-NB366 Paye 2 of 3 ‘September 22, 2000 All Information Contained Herein is Proprictary and Confidential SEP-22-00 FRI 10:50 AN PSL, FAK NU. SUSZ1b>298 Yr. u4avus ee Psychrometric Systems, Inc. Precision Enorgy — Bethel Power Plant additional cost. (8) Four copics of Operation and Maintenance manuals aro supplied; additional copies can bo supplied for additional cost. Submitted by, PSYCHROMETRIC SYSTEMS, INC. £0 Steven D. Adams Vice President, Applications Engineering SDA/tss 0 peed pean Ober ama A on i IT OOI-NNI6G Page 3 of 3 Septemtor 22, 2000 All Information Contained Tere is Proprietary and Co! vidential SEP-22-00 FRI 10:50 AN PLS. I, FAX NO, 3032155298 P, 05/08 CFF ~364226—61-28 ER O Psychrometic [oom #8 Systema, ino. Th mm heel 6 oy tanks Some Coal Information PRECISION ENERGY SERVICES INC. 8. COAL INFORMATION }oraing Coal Limited Page 1 of 2 is) fording Corporate Profile @ View Jab Opportunities Fording Coal Limited, a wholly owned subsidiary of Canadian Pacific Limited, is Canada's largest export-coal producer, competing with other international coal producers for sales of metallurgical and thermal coal products to Asia, the Pacific Rim, North and South America, Europe and the Mediterranean region. Fording's three British Columbia mines collectively have more than one billion tonnes of reserves. These mines chiefly produce high-quality metallurgical coal used to make coke for the international steel industry. Thermal coal is also exported to power utilities worldwide. Fording ships more than 14 million tonnes of cleaned coal annually, almost all of it by Canadian Pacific Railway. In west-central Alberta, Fording operates two thermal coal mines - Genesee and Whitewood - which supply coal to electric utilities for power generation. The company's third Alberta operation - Mildred Lake - removes overburden from oil sand for Syncrude Canada Ltd., Canada's largest producer of synthetic crude oil. Fording, through its wholly owned subsidiaries NYCO Minerals, Inc. and Minera NYCO S.A. de C.V., is the world's largest producer of the industrial minerals wollastonite and tripoli. Wollastonite is a non-metallic industrial mineral used in the manufacture of ceramics, plastics, coatings, refractories and construction materials. NYCO also produces tripoli, a finely ground form of silica used in several applications including mild abrasive soaps and cleansers, and buffing and polishing compounds. 1999 $850+ million Revenues: Employees: 1,900+ Mining Canada, United States, Mexico Operations: Head Suite 1000, Fording Place Office: 205 - 9th Avenue S.E. Calgary, Alberta, Canada T2G OR4 Fax: (403) 269-9863 http://www. fording.ca/ 9/13/00 Cee! Association of Canada - Maps P +lof2 Cogiin Canéeca the COAL Association o Site | About ; Info | Coalin The. Heke TT FT pen Cr : Map | theCAC’ Centte | Canada Classroom ‘Feedback | conferenceonCoal News Contacts Coal and the Econom aa Click Here to See the Power Plants Map | Principal Coal _ Mines in Canada wowon @ Mines © Coal Ports NORTHWEST TERRITORIES _ -_ j o* allway Lines | oe a BRITISH ste oe 4 ws “ene NEWFOUNDLAND Saisosj oie SASK. Horde oe MANITOBA QUEBEC Curae ears Sanat oe oP “a Sanaion gor Be 3 ch i: rts theprer Sea iss PED ] 8Q eremnascom Pe teandvanene eee ONTARIO = Oe Cod Uowten So eunnsee Oey e Pvcaiter tuk Coe Morven. 0 Seana Toreme http://www.coal.ca/coalmap.htm 09/13/00 yituminous Coals in the southern part of the lignite in the northern, and subbitumin- iu the center. The fields are scattered and ted in area. mates of U.S. coal production in the year v from 1200 to 2000 million tonnes per .spending upon the amount of nuclear- generation and the extent of coal ex- 3. Appalachia, which now produces about f the nation’s coal, will decrease to 30 it; the Midwest will produce 11 percent the West, 50 percent; the balance will be -mined Gulf lignite. Surface mining ».edominate at that time and is expected to ‘er 60 percent of the total output. e V of Chapter 2 gives analyses of some coals. Ash analyses of representative U.S. are included in Tables IV, V, and VI of ir 3. le TV (Page A-10) gives detailed analyses ~ bituminous coals, with free-swelling in- MS Bituminous E22 Subbituminous Lignite a Do? S ew> -val Map of Alaska A-11 ASTM and International classifications. ALASKA Coal is distributed widely throughout Alaska in fields differing greatly in size and in geologic environment; much of it is lignitic or subbituminous in rank. Its total reserves are es- timated to be 15 percent bituminous coal and 85 percent subbituminous coal and lignite. Only fields close to main lines of transportation have been developed; major reserves occur in more remote parts of the State. The most impor- tant fields, in terms of production and known reserves, are the lower Matanuska Valley, northeast of Anchorage, and the Nenana, southwest of Fairbanks. In addition to coal, Alaska has a greater area of peat than all the contiguous states combined. Alaskan coal deposits are in several regions (Fig. 3). The Northern Alaska and Seward Peninsula regions contain mostly subbitumi- nous and bituminous coal. The biggest Alaskan COMBUSTION Coats of the Worid ss Table V. Analyses of Typical Alaskan Coals Region, Moisture- and ash-free District —— As received __ HHV Ash ST And Mine % Ash % HO % VM %S Btu/lb Mj/kg Red., °F Northern Region Wainwright 3.2 20.7 41.8 0.4 12,830 29.8 u Yukon Region SN Broad Pass Field 2 Costello Creek 13:3 14.3 49.0 0.7 13,080 30.4 oe 3 Eagle 24.4 19.8 59.3 0.4 11,240 26.1 tan al Nenana Field Pa Suntrana 6.5 22:3 52.2 0.1 12,130 28.2 2140. Kuskokwin Region eS Nelson Island 18.2 3.9 30.6 0.5 14,690 34.2 2710. Southwestern Region - Chignik Bay 21.8 7.1 44.3 1.8 13,850 32.2 : Cook Inlet Region 3 Matanuska Field * Chickaloon 10.4 1.9 23.7 0.8 15,120 35.2 2060' Coal Creek 5.8 1.6 24.7 0.7 15.530 36.1 2450 11.6 4.1 16.4 0.7 14,950 34.8 2240 3 Eska 10.9 3.7 48.0 0.6 14,530 33.8 2570.5 Jonesville 21.3 3.5 48.9 0.3 13,900 32.3 2370 Moose Creek 6.4 3.9 44.6 0.2 14,400 33.5 2660 _ Gulf Region j Bering River Field "7 Katalla 3.8 5.0 15.0 1.0 15,560 36.2 2240- Southeastern Region 1 Admiralty Island ‘ Harkrader 21.4 3.8 47.1 ded 14,210 33.0 2250 | deposits are in the Arctic slope region, in an area 300 miles long (east and west), and 75 miles wide; the coal is low-volatile bituminous to lignite. The Yukon basin coal, lignite and bituminous, occurs in small, scattered areas that have been inadequately explored. The Nenana deposits are subbituminous high-rank lignite. primarily strip-mined. The Cook Inlet-Susitna region contains some of the most important fields of lignitic and sub- bituminous rank. in thicknesses up to 40 ft. The Matanuska Valley is divided into the lower field. containing the Moose Creek and Eska fields, and the upper field, comprising the Chickaloon and Anthracite Ridge. The Mat- anuska fields produce high-volatile B bitumi- nous coal from beds 18 to 20 ft. in thickness. Technical Paper 682 of the U.S. Bureau of A-12 Mines (1946), Analyses of Alaska Coals, pre: sents proximate and ultimate analyses, and fusibility data. for coals from all the majo: Alaskan coal deposits. Table V gives analyses of some typical Alaskan coals. 4 MEXICO Mexico has coal deposits in 16 of the 38 Fed3} eral States (Fig. 4). Estimated production by the" year 2000 is 55 million tonnes. Only three de; posits presently have economically recovery able coal reserves: Barrancas basin (Cen Sonora), Oaxaca basin and Coahuila basin. In the Coahuila basin, the most significant coal, deposits are located within the two largest dissé tricts of Sabinas and Rio Escondido. Brown coals and hard coals are deposited in the Sabinas basin, which is about 35 miles long Dandi oe At left is the Unit 3 coal yard. Several long con | transfer the coal from the rotary car dumper to t | le Feeders below these piles load other belts | deliver the coal to the bunkers in the power plan | | | | | | | | | | : Units 1 and 2 share a coal yard. Long conveyors | deliver the coal to this area from the rotary car : dumper or the Unit 3 coal yard. REFERENCE, SAMPLE OF VARIOUS COAL HANDLING FACILITIES THROUGHOUT THE WORLD lof1 9/6/00 1:32 PM Coal continues to be an important factor in the generation of electricity. Reliable transport, storage and beneficiation of coal is essential for power generation. Krupp has achieved a recognised market position in the construction of coal handling facilities for power plants, from new installations to the modernization and expansion of existing installations. Krupp equips power plants with complete handling systems from the unloading points for delivered coal, through stockyard and boiler house bunker feeding systems to ash and slag handling. Included are a multitude of components such as ship unloaders, belt conveyors, stockyard and blending equipment, crushing and screening stations, dosing and weighing equipment and if necessary vacuum belt filters and dryers. Moneypoint power station in Ireland - a perfect example of a full turnkey project. Ship unloaders, belt conveyors, stockyard equipment, boiler house bunker feeding, blending bunkers, crushers and screens, as well as the complete electncal system for control and automation. lof 1 9/6/00 2:01 PM Krupp Férdertechnik - The comprehensive range of equipment and systems for loading, unloading, stockpiling, blending and transporting. This includes the planning, projection, production and installation of complete handling installations for ports and stockyards, industrial plants and power stations as well as the design, manufacture and installation of individual machines. Krupp installations in all parts of the world are the proof of economical and efficient systems. The Program: Port Handlin Shiploaders Ship Unloaders Complete Terminals Stockyard Handling Reclaimers Stackers Conveyors Coal Handling Plants for Power Stations Fertilizer Handling Plants Cable Cranes Deck Cranes Krupp Fast Handling System (KSU) lofl 9/6/00 2:14 PM Krupp Férdertechnik offers an extensive program for all sectors of port handling. Right from the beginning, Krupp takes every factor and criterion into consideration to work out the best solution for the individual machine or complete installation. The selection of a particular system depends not only on the material to be handled, but also on the actual conditions to be encountered on site. Shiploaders and unloaders are the centrepieces of today's modern terminals where they ensure accurate, rational and sensitive movement of materials. Shiploaders 1 of 6 9/6/00 2:19 PM All around the world, sea-going and coastal ships are constantly being loaded with coal, ore, bauxite, alumina, fertilizers, phosphates, sulphur as well as many other bulk materials. Krupp shiploaders for all capacity ranges and areas of application permit the selection of economic systems: travelling shiploaders with slewing and luffing booms, radial travelling with a fixed pivot point, combined shiploader/stacker and various other customized, special designs. Ships up to 150,000 DWT can be loaded, or coal and iron ore can be stockpiled by this combined shiploader/stacker. Two radial-travelling shiploaders at East Kalimantan, Indonesia, load coal at a rate of 4,200 th. 2 of 6 9/6/00 2:19 PM 3 of 6 This shiploader loads 25, 50 and 100 kg sacks of rice via its spiral chute and telescopic bett. Ship Unloaders Krupp ship unloaders for ocean-going and inland waterway vessels are built in different designs and either as grab-type or continuous unloaders. The offloading of high density bulk goods and heavy loose goods at fast flow rates is the classical domain of the grab crane. The majority of applications call for the gantry-type of cranes. Krupp gantry grabs achieve throughputs of up to 5,100 t/h in ore and 4,200 t/h in coal, with grab payloads of up to 85 tonnes. Slewing and luffing cranes are frequently employed for smaller capacities, especially when the nature of goods varies widely and a high level of flexibility is required. Continuous unloading systems are increasingly entering into the medium-to-large capacity range for unloading bulk materials. Krupp has developed the self-digging "L-type" bucket elevator for effective, dust-free and almost noiseless unloading of coal, ores, phosphates, sulphur, fertilizers and even products such as sticky raw sugar. A further step in the development was the commissioning of continuous ship unloaders for inland vessels. 9/6/00 2:19 PM High capacity grab-type unloaders for iron ore and coal on the Maasviakte terminal in Rotterdam: Two gantries with 50 tonne grabs as well as the world's largest grab unloader with grab payloads of 85 tonnes and a throughput of 5,100 t/h. pee pre ee One of Europe's largest double-level luffing/slewing cranes for grab and hook lifts with a capacity of 65 tonnes at 31m or 20 tonnes at 65 m outreach. 4 of 6 9/6/00 2:19 PM Continuous ship unloader for inland vessels on the Datteln-Hamm Canal. Complete Terminals Krupp offers a whole range of economic terminal designs for the handling of coal and ore, bauxite and cement, limestone, sulphur and potash, as well as for boxed goods, loose goods and containers. Depending upon the type of material concerned, the terminals are built with buffer stores, stockyards and stockpile areas, stackers, bucket wheel reclaimers and /or blending equipment, belt conveying systems, wagon or truck loading facilities, as well as ship loading and unloading facilities. Krupp also modernises, converts and extends existing systems to new standards of output and efficiency. The EMO terminal at Maasviakte, Rotterdam. It was designed and built with extensive loading and unloading systems, stocking and transporting facilities, among others with two 50 t and two 85 t grabbing unloaders, three loaders for barges, one shiploader/stacker for ocean-going vessels, four combined bucket wheel Stacker/reclaimers and a wagon loading station. 9/6/00 2:19 PM 5 of 6 Continuous ship unloader for coal in a power station in Northern Ireland. Capacity: 1,100 t/h. Continuous ship unloader for coal and limestone in the port of Ferrol/Spain. Besides unloading ships the unloader is also able to stockpile coal fully automatically up to a height of 16 m. Capacity: up to 2,300 th. 9/6/00 2:19 PM Stockyard Handling A "Rollgurt" conveyor used as the main coal transporter in a power plant. The 210 m long belt negotiates a 90° curve at 43 m radius directly to the boiler house. Sof 5 http://www.csp-engineering.com/KRUPP/e/what/mathand/subs/stockyardb.htm 9/6/00 2:34 PM Rail mounted stacker with belt tripper and blending bed scraper operating in a coal stockyard. Conveyors Conveyors in stockyards are the logical connection between loading, unloading and storing and blending. Multi-conveyor systems, long distance conveyors and a whole range of specialised conveyor belt systems - all of them have their own particular application. Enclosed conveyors are in ever-increasing demand, e.g. when materials have to transported through or near residential areas, or when the materials themselves are sensitive. For these applications Krupp has developed the "Rollgurt" conveyor for dust free transport of loose materials such as limestone, cement or coal. Extensive belt conveying systems in one of the world's largest stockyards inSpain. 4 of 5 9/6/00 2:34 PM Combined bucket whee! stacker/reclaimer for coal at a power station. Circular store with bridge scraper for the homogenization of coal. A major part of any large-scale stockyard operation is the stacker that deposits the bulk materials in pre-set patterns and systems. Stackers are designed in a wide variety of configurations depending upon the required throughput and extent of mobility: rail-mounted or crawer-mounted, with single or twin booms, with semi or fully-automatic control and with many other features dependent on the application. 3 of 5 9/6/00 2:34 PM Krupp scraper-type reclaimers, designed as bridge or side scrapers and semi- or full portal scrapers, guarantee a constant flow of homogeneous materials such as coal, limestone, marl, clinker, fertilizer, wood chips and many more. Bucket wheel reclaimers are the ideal means of handling and moving large amounts of bulk materials in the shortest possible time and can be designed as reclaimers or as combined stacker/reclaimers for handling huge volumes of coal, ores and other materials in ports, power plants,stockyards or in steel plants. Drum reclaimers and bridge-type bucket wheel reclaimers are robust sytems for the high-performance handling and blending of bulk materials, especially wnen the materials are semi-hard to hard. One of the world's largest portal scrapers in operation in an Australian coal stockyard. The world's largest covered circular blending bed in a Canadian power plant with a diameter of 139 m. 7 of 5 9/6/00 2:34 PM Stockyards have a central function in the field of materials handling. They serve as material buffers, reserve or blending storage between mining, processing and transhipping. They balance out fluctuations in the quantity and quality of raw materials. Krupp has a major share in the development of blending bed and stockyard equipment for circular or longitudinal storages, such as reclaimers, stackers, wagon or truck loading and unloading systems and belt conveyor systems. Reclaimers lof 5S 9/6/00 2:34 PM ( suuecT ConAC EI RED GCeNisraTiInG NOTES BY: = PROJECT FILE # OF -/Z-Zooo _ppce customer Monum Min DATE Phone: (208) 772-4457 Fax: (208) 762-1113 PRECISION ENERGY SERVICES INC. P.O. Box 1004 Hayden Lake, ID 83835 OF. CemtnsaTine PROJECT FILE # Down Munim SUBJECT Co aL Fine CUSTOMER Phone: (208) 772-4457 Fax: (208) 762-1113 PRECISION ENERGY SERVICES INC. P.O. Box 1004 Hayden Lake, ID 83835 SE NOTES BY: Combustion Turbine Information Stewart & Stevenson International, Inc. Meese ey eT Trl mel | PCC i tT Direct-Drive Advantage - Now the LM2500+ is the newest member to the family of Te aH at LM2500 products. LM2500 PC..... 20 MW LM2500 PE (Basic) ...... Pa PSTD tL Aras i lie Introductory ... 27.6 MW a ati Mature ........ 29 MW Best of all, the APA arly ATH packaged and full- load string tested RCE a4 By CAT) MRS ec A MORE PO Standard Combustor, Dry Low Emissions (DLE) New “Stage Zero” Combustor also available 2-Stage Inlet Bellmouth New Stage 1 High-Pressure Direct Drive Wide-Chord Blade LM2500+ Evolves from LM2500 The simplest way to envision the LM2500+ is to think of the basic LM2500 with an additional compressor stage called “stage zero.” The technique of adding “stage zero” before stage | is commonly used in the turbine industry to boost airflow, pressure ratio and power. Several stages of blades and stationary airfoils have also been upgraded to allow 20% additional airflow. In the compressor section, 3-dimensional airfoils from the LM6000 will replace 2-dimensional airfoils in the basic LM2500. In the turbine section, the blades for the first Stage and last stage have been reshaped to optimize performance. Finally, to handle the additional pressure ratio and power, the casings and shafts have been strengthened. Key mechanical components, such as bearings, accessory drive and engine mounts, remain the same. In fact, the LM2500+ can be retrofitted on an exchange basis to boost power output at many existing LM2500 job sites. Turbine (HPT) Flange |__—«-17-Stage a Compressor Turbine Gas Generator LM2500 Heritage @ 25 years of industrial experience @ 1300 LM2500 turbines delivered for marine & industrial service @ 18 million industrial hours @ 28 million flight hours @ Documented performance — Availability 96.5% — Reliability 99.6% Quick delivery, fast start-up Stewart & Stevenson has built more LM2500 generator sets than any other manufacturer. Standardized designs shorten the Stewart & Stevenson manufacturing schedule. A large number of essentially identical packages are always under construction, giving us the flexibility to meet your delivery requirements— often in less than 100 days. Your unit arrives ready to work. All major components are baseplate- mounted, a design that simplifies transportation and installation. No lengthy field setup is required . . . no surprises. maida LM2500_ Factory full-load testing All packages are factory-assembled and tested at full load before shipment. The test uses the contract control panel and auxiliary systems to minimize field start-up and debugging time. This demonstration of power output and heat rate significantly reduces performance risks for owner, constructors and lenders. Superior customer training Training begins in our factory as part of the full-load test. Your operators learn to run your LM2500 before it is shipped. The experience gained from Stewart & Stevenson technicians helps ensure smooth operations, even during start-up. Stewart & Stevenson can also provide supplemental training and refresher courses at the job site. High availability, high profitability Aeroderivative technology makes possible the quick removal and exchange of gas turbine engines without extended downtime for repair. If an unexpected major repair becomes necessary, we can immediately send you a replacement engine to get your plant on-line. For on-site Operations and Maintenance (O&M), call on Stewart & Stevenson Operations, Inc. (SSOI). We operate more than 30 facilities that consistently outperform the power industry in efficiency, availability and reliability. An O&M contract with SSOI streamlines your organization, allowing managers to focus on new opportunities instead of everday supervision of personnel and equipment details. Your bottom line is improved profitability. LM2500+ Package Design Since 1980, Stewart & Stevenson has delivered more than 100 LM2500 direct-drive turbine generators for 60 Hz, 50 Hz and STIG applications. Because the basic LM2500 package was built with growth in mind, upgrading to the LM2500+ can be handled within the existing design framework: Structure Zone 4 earthquake criteria from basic LM2500. Split baseplate, shorter |-beam to allow air transport of the package. Turbine Compartment Sameas basic LM2500 including mounts, built-in maintenance crane, fire protection and ventilation system. Additional 13° length of engine recessed into “clean room.” Generator Compartment Larger generator to handle 7MW boost fits easily into basic 2500 generator compartment. Redundant ventilation system unmodified. Air Filtration LM2500+ breathes 20% more air. Filter house grows 2 ft vertically and 2 ft in length. Larger, high-capacity elements and low-restriction silencer added. Lube Oil Systems Separate lube system for GT and electric generator. Duplex filters and coolers on each system. All stainless piping, reservoir and valve trim. Identical to basic LM2500. Starting System —Electrohydraulic system identical to LM6000, LM5000 and basic LM2500. Control Solid-state digital contro! with fiber-optic link and remote 1/0 to minimize field wiring requirements. Uses best features of LM6000 and basic LM2500. Sa TeV 60 Hz or 50 Hz Dimensions Baseplate Length Baseplate Width Enclosure Height Overall Length* Overall Width* i= Overall Height* Baseplate Foundation Load* Panels a IO O11 Od) “Includes air filter 71'0° 13'7" 13' 6" 78' 6" 212° 340° 420,000 Ib Stewart & Stevenson COC Le ee P.0. Box 1637 ; Houston, Texas 77251-163 Tel: (713) 868-7700 Fax: (713) 868-7697 (UuM2s00 (ums5000 M1600 LM2500 LM2500+ STIG5O LMS5000 STIG 80 ISO Continuous kW" 13440 22800 27,050 28050 34400 48100 Btu/kWH (LVH)* 9545 9280 9330 8325 9180 8070 Exhaust Flow (#/sec) 100 152 183 168 268 324 Exhaust Gas Temp. (°F) 909 975 926 926 813 766 ISO Continuous kW* 13440 21960 26,000 27020 34500 46360 Btu/kWH (LVH)* 9545 9550 9830 8620 9290 8340 Exhaust Flow (#/sec) 100 148 185 168 275 330 Exhaust Gas Temp. (°F) 909 1008 952 941 811 767 “Includes generator and gearbox losses. Ratings at 59 °F, sea level, no inleV/exhaus! losses, natural gas fuel Aeroderivative Industrial Gas Turbine Generator Sets uso000 STIG 120 LM6000 51620 40760 7790 8590 339 277 741 864 49600 40270 8110 8695 344 277 752 864 LM2500+ Gas Turbine 60-Hz Generator Set Performance Site Conditions: 60% rh, sea level, 3600 rpm No inlet/exhaust losses Natural gas fuel, dry engine 32 MW @ Generator Terminals Exhaust gas flow, |b/sec Exhaust gas temperature, °F Fuel Flow, MMBtu/LHV S&S Energy Products A GE Power Systems Business Now with SPRINT ~ Power Boost © ae Gas'Turbine Generator Sets LM6000 Gas Turbine: Simply the World's Most Efficient Efficient Delivering more than 43 MW of electrical power at 42% thermal efficiency, the powerful LM6000 is the most fuel-efficient, simple-cycle gas turbine-generator set in the world. For projects needing more power, the LM6000 Sprint uses SPRay INTercooling to produce up to 20% more output. Serving a wide range of applications, S&S Energy Products offers the field- proven LM6000PC with conventional combustion, the LM6000PD with dry-low emissions (DLE) and the LM6000 Sprint that has spray intercooling for power boost. High thermal efficiency, low cost, and installation flexibility make the LM6000 the ideal choice as a prime driver for utility peaking, mid-range, and baseload operations, as well as for industrial cogeneration. The LM6000 delivers: = the highest simple-cycle and combined-cycle efficiency = low installed cost = dual-fuel capability @ inlet and exhaust flexibility = high availability # reliable starting and fast loading a high reliability = excellent part load efficiency ® flexibility - baseload - dispatchable - cogeneration - peaking - mechanical drive = low exhaust emissions a dry-low emissions technology = simple on-site maintenance LIM6000 Gas Turbine: Reliability by Design The LM6000 is derived from the core of the CF6-80C2, GE's high thrust, high-efficiency aircraft engine which has logged more than 46 million flight hours with over 2,500 engines in service. With a shop visit rate of one-half that of other engines in its class, it has become the standard for reliability in aircraft service. Both engines have a common design and share about 90% of the same parts. Taking advantage of the CF6-80C2 low-pressure system's normal operating speed of 3,600 rpm, the LM6000 couples loads directly to the low-pressure turbine (LPT) shaft, allowing the commonality of the CF6-80C2 and LM6000 to be maintained. The result is low cost and field-proven parts for the LM6000. All LM6000 components incorporate corrosion-resistant materials and coatings to provide maximum parts life and time between overhaul, regardless of the unit's operational environment. The low-pressure compressor (LPC) features variable inlet guide vanes to modulate airflow, ensuring fast, easy startup/shutdown and maximum efficiency — even under partial loads. The high-pressure compressor (HPC) is mated to an efficient annular com- bustor for maximum fuel economy. Gas, distillate, or dual-fuel capability is available. Incorporation of advanced airflow and cooling technologies helps the LM6000 provide unprecedented power, efficiency, low fuel consumption, and low NOx, carbon monoxide (CO) and unburned hydrocarbon emissions. LM6000 Gas Turbine: Configuration Flexibility Flexibility The LM6000's inherent configuration flexibility makes it the ideal choice for baseload, mid-range, and peaking operations. Industrial processes needing cogeneration or mechanical drive capabilities also benefit from the gas turbine's simple installation requirements and unprecedented efficiency. Cost-Effective Power You Can Profit From In a wide range of applications, the LM6000 delivers its power at the lowest cost per kWh of any gas turbine in the world. Platforms or pipelines Utility peaking, mid-range, and baseload operations industrial cogeneration LM6000 Gas Turbine: World Standard for High Performance Sprint Output: Over 43 MW at Over 42% Thermal Efficiency One of the highest outputs available in the aeroderivative gas turbine marketplace today, the LM6000's effi- ciency in simple-cycle configuration is the highest available in the industry. The LM6000 also features excellent combined-cycle performance over 55 MW at more than 52% thermal efficiency. . Environmental Compatibility The LM6000 was GE's first aero- derivative gas turbine to employ the new Dry-Low Emissions premixed combustion system. This system is retrofittable to LM6000s already in operation. Water or steam injection can also be used to achieve low NOx emissions. NOx can be reduced by 90% — guaranteed to 25 ppm when burning natural gas, while maintaining low emissions of CO and unburned hydrocarbons. A dry dual-fuel (DLE) combustion system is available. It provides fuel flexibility for gas or liquid fuel operation. Im imei 9% POWER BASIC LM6000 ryt IIE LM6000 Sprint: The Intercooled Engine That Increases Output The LM6000 Sprint combines the best simple-cycle heat rate of any industrial gas turbine in service today, with a spray intercooling design that significantly increases the mass flow by cooling the air during the compres- sion process. The result is more power, a better heat rate and a really cool engine. The Perfect Baseload Engine The high thermal efficiency, low cost and installation flexibility make the LM6000 the ideal choice for utility peaking, mid-range, cogeneration and baseload operations. The addition of GE's proprietary Sprint technology increases the power output by 9% at ISO and by more than 20% on 90°F days. 1608°F Sed The Hotter It Gets, the More Effectively It Runs Sprint's effectiveness is even more pronounced in hot weather. It is like having an evaporative cooler built within the gas turbine. As ambient temperature rises, the benefits of a Sprint engine become more significant. A Cool Solution The system is based on an atomized water spray injected through spray nozzles located between the high-pressure and low-pressure compressors. Water is atomized using high-pressure air taken off of eighth- stage bleed. The water-flow rate is metered, using the appropriate engine control schedules. The Sprint Solution at Work On high-pressure ratio gas turbines, such as the LM6000, the compressor discharge temperature is controlled because compressed air is used to cool the hot section components. By inject- ing an atomized water spray in front of the LM6000 high-pressure compressor, the compressor inlet temperature is significantly reduced. Utilizing the same compressor discharge temperature control limit, the compressor is able to pump more air, achieving a higher pressure ratio. The result is higher output and better efficiency. LM6000 Sprint: Technology demonstrator in Ft. Lupton, Colorado. LM6000 Gas Turbine: Customer Service Ensures Long-term Retums Support Full-load string testing before shipment reduces risks and speeds delivery. Worldwide Capability S&S Energy Products offers a variety of comprehensive services for GE, Alstom, Allison and Solar gas turbines, concentrating on quick turnarounds. Repairs are performed “on-site” when- ever possible, significantly reducing downtime and total costs. Complete field engineering services are available for upgrades, retrofits and overhauls of most manufacturers’ packages. These services include the individual exhaust gas temperature monitoring systems and inlet air heating and chilling systems. Exchange Option Reduces Costs S&S Energy Products has rotatable inventory of engines and hot sections that are available for outright field exchange. Only one period of down- time is required while the exchange takes place. Parts on Demand Quick response is demanded for repair and overhaul. Our large parts invento- Ty is available 24 hours a day for ship- ment anywhere in the world. Our rotatable inventory of new and exchanged parts is constantly moni- tored to eliminate long lead times. Worn or damaged components are exchanged “on-site” and returned to our factory to be rebuilt. These items are then returned to inventory, keeping parts on the shelves at all times. This system allows you to specify new parts or rebuild components for necessary replacements, including: = High pressure turbine rotors = Compressor assemblies « Nozzles and assemblies « Complete gas generators = Blades = Complete gas turbines « Combustion liners Factory Full-Load Testing S&S Energy Products has the capability to full-load test new, repaired or rebuilt GE, Alstom, Allison and Solar gas turbines, ranging from 500 to 67,000 hp. Our GE test facility is the only com- mercially available dynamometer in the world for full-load testing of LM2500 (including the power turbine) and LM6000 gas turbine engines. Using a power turbine combined with a load imposed by an electric generator, this configuration provides a true measure of performance, horsepower, heat rate and kilowatt output. Advanced Control Center A computerized control system for each cell is used to operate, monitor and provide complete documentation of tests for in-house and customer evaluations. In addition, two high- resolution remote control color video cameras are located in each cell for visual monitoring from the control panel. LM6000 Gas Turbine: 50 Hz Cost-Effective Power maT 1 ct) aaa <| Dimensions 50 Hz 60 Hz Base Plate Length 64" 7" = (19.69 m) 56° 6° = (17.22 m) Base Plate Width 13° 6" — (4.11m) 13° 6 (4.11) Enclosure Height 4° «6 (4.42 m) 4 ¢ (4.42 m) Overall Length 64° 10° (19.76 m) 56° 9" = (17.30 m) Overall Width* 49° 3 (15.01 m) 49 9 (15.16 m) Overall Height* ~ 37° 11" (11.56 m) 36° 2 = (11.02 m) Base Plate Foundation Load* 522,0001b (234,900 kg) 476,000 Ib (214,200 kg) “Includes air filter 60-Hz GENERATOR SET PERFORMANCE 60% RH, sea level, 3600 rpm No inlet/exhaust losses Natural gas fuel, dry engine Fuel Flow, MMBtu/h (LHV) - Exhaust Mass Flew, Ib/s Exhaust Gas Temp., °F S&S Energy Products’ inlet chilling system provides more power output and better fuel efficiency. MW @ GENERATOR TERMINALS m « (16) AMBIENT TEMPERATURE, °F (°C) Aeroderivative industrial Gas Turbine Generator Sets Specifications umn ny Exhaust Flew Exheust Flew ExheustGes Exhaust Gas commen ~ oun uve (tveec) (xp/nec) Temp °C Tomp °F LM1600 13440 10070 9545 = 100 45.4 487 909 LM2500 21960 10076 9550 148 67.1 542 1008 = Lwesoostig 50 27020 9095 8620 168 76.2 505 941 S 1M2500+ 28540 9654 9150 188 85.3 521 969 LM6000PC 43076 8701 8247 = 279 126.6 450 842 LM6000Sprint 46590 8837 8376 «= (288 130.6 455 851 Heat Rate kwh = BtviWh = Exhaest Flew Exheest Flew Exhaust Ges Exhanst Gas ccna wou un (vee) (xprec) Tome °C Tome °F LM1600 13440 10070 9545 = 100 45.4 487 909 rm M2500 22800 9791 9280 152 68.9 524 975 == LM2500STIG 50 28278 8783 8325 =: 168 76.2 497 926 S$ 1m2500+ 28600 9348 8860 183 83.0 510 950 LM6000PC 43400 8737 8281 280 127.0 452 846 LM6000Sprint 47300 8704 8250 288 130.6 455 851 * Inclodes generator and gearbex leases. Ratings st 15°C (53°F), sea level, no nlet/exkaust lesses, aataral gas teel. Aftermarket Products and Services S&S Energy Products’ after- market services group is exclu- sively dedicated to support industrial and aeroderivative gas turbine engines—no flight aircraft engines. This has truly made S&S Energy Products the industry's choice in aftermar- ket services Our depots offer world-class overhaul and repair services for General Electric, Nuovo Pignone, Pratt & Whitney, Rolls-Royce, and Solar®* gas turbines—concentrating on quick turnarounds. With worldwide depots and field service support, S&S Energy is positioned to provide fast response to customer needs. S&S Energy Products is the leading provider of integrated engine maintenance services by focusing on world-class quality, quick turn-times and excellent customer service. Our aftermarket products and services include: e Depot Maintenance, Repair & Field Service Support e Long Term Service Agreements e Extended Engine Warranties e Engine Exchange Programs e Used & Repaired Engines e Lease Engine Programs e Engine Upgrade Kits e Package Conversion Modification and Upgrade Kits e Hot-Section & Component Exchanges e Testing e Spare Parts Installation Services Systems S&S Energy Products has been involved in the Engineering, Procurement, and Construction Management of the Balance of Plant equipment on a turnkey basis for over ten years. We have installed thousands of megawatts in more than 20 countries. As the industry leader in fast- track power generation, S&S Energy Products has devel- oped pre-engineered modular- ized equipment packages to quickly meet customer require- ments. Whether a customer's requirements are limited to re- assembly and startup or full turnkey—S&S Energy Products can provide a quality project at a competitive price for your power generation or gas tur- bine mechanical drive project, anywhere in the world. Services e Detailed Design e Procurement e Construction Management e Logistics/Transportation e Re-assembly e Startup/Commissioning e Quality Control e Environmental Health & Safety e Testing e Permitting Assistance Fuel Systems (Gas, Liquid) Water Treatment Substations Compressed Air Heat Recovery Steam Turbines Foundations Piping Waste Systems Chilled Water Buildings LM2500-—Marine Aeroderivative gas turbines are intrinsically lightweight, compact, efficient, and very reliable. They are used exten- sively on military ships where the mission of the ships must not be compro- mised by a need to carry large propulsion equipment requiring significant spares and crew. Over 325 naval vessels utilize in excess of 850 LM2500 gas turbines. The LM2500 generator pack- age for marine propulsion has accumulated over 6 million hours of operation. It has also found applications in remote areas which demand extremely high reliability and little maintenance such as off-shore platforms. Most recently, the LM2500 has been used for powering high- speed ferries that dramatically reduces the time to transport passengers and cargo. S&S Energy Products also builds an efficient COGES System for cruise ship cus- tomers. COGES is an acronym for combined gas turbine and steam turbine electric and steam production plant for cruise ship propulsion using an integrated electric drive system configuration. The COGES System replaces diesel engines with gas tur- bines and provides the follow- ing advantages: More square meters of space on ship — more room for customers Reduced engine room crew - maintenance provided by S&S Energy Products’ land-based depots Reductions in Sox, NOx, particulates and no sludge disposal required - environ- mentally friendly More reliable and available ship - easy maintenance Improved productivity and efficiency of engine room personnel - no need for diesel inventory manage- ment COGES SYSTEM Service Condensate Return t 7 | Services Steam Supply Heat Recovery Boiler Steam t Turbine(s) Evaporators, HVAC Laundry, Galley & Etc Propulsion * Drives & Motors Electrical > Service Power LM2500 and LM2500+ or enn im - es — GE builds two versions of the LM2500 gas turbine: e Basic LM2500 Model: 22.8 MW ISO e@ LM2500+: 28.6 MW ISO Aeroderivative Heritage Translates into Unsurpassed Reliability. Derived from flight engines used on DC-10 wide- body jetliners and C-5A trans- ports, the LM2500 is a hot-end drive, two-shaft industrial gas turbine with unsurpassed relia- bility. More than 1,500 LM2500s have amassed an excess of 18 million operating hours in marine and industrial applica- tions. Maintaining a high degree of parts commonality with its flight-tested forerunners, the LM2500 continues to build a reputation as the most reliable industrial gas turbine generator set in its class Reliability Exceeding 99%. The LM2500 pack- age isa durable and reliable prime mover, capa- ble of produc- ing more than 25 MW of power in the severest of operating environments. With its direct- drive design, the LM2500 has become the industry standard for 20 to 25 MW gas turbine generator packages. Direct-Drive Reliability with STIG Power and Efficiency. The LM2500’'s power turbine oper- ates at 3000 or 3600 rpm, allowing for direct, gearless coupling to 50 Hz and 60 Hz generators. This operation eliminates the gearbox " required by most industrial gas turbine generator sets. Leading its power class with a simple-cycle efficiency greater than 37%, the LM2500 generator package can be used in combined-cycle con- figurations, increas- ing the overall plant efficiency to more than 50%. To increase power and to match cogenerated steam loads, the LM2500 STIG5O can be injected with up to 50,000 lb/hr of high-pressure steam to produce more than 28 MW, often eliminating the need to purchase combined-cycle equipment such as steam tur- bines, condensers and cooling towers. LMG S&S Energy Products also offers the LM2500+ gener- ator package, which is the latest addition to the LM2500 fleet. Providing more than 28 MW of power, this workhorse is already operating in mechan- ical-drive, power-generation, and marine applications world- wide. More output, high reliability and a lower initial capital invest- ment on a $/kW installed base are just a few of the benefits contributing to the customer value delivered by the LM2500+ generator package. LM6000 SPRINT” LM6000 SPRINT™: The Inter- cooled Engine that Increases Power Output. The LM6000 SPRINT™ combines the best sim- ple-cycle heat rate of any indus- trial gas turbine in service today. It has a spray inter-cooling design that significantly increas- es the mass airflow by cooling the air during the compression process. The result is more power, a better heat rate and a really cool engine. The Hotter It Gets, The More Effectively It Runs. SPRINT™'s effectiveness is even more pro- nounced in hot weather— power output Is increased by 9% at ISO and is increased by more than 20% on 90° days. It is like having an evaporative cooler built within the gas turbine. As ambient temperature rises, the benefits of a SPRINT™ engine become more significant. A Cool Solution. GE has devel- oped a new solution for the SPRINT™ inter-cooling system. compressor with a mico-mist of The system is based on an water, the compressor inlet tem- atomized water spray injected perature and outlet temperature through spray nozzles located are significantly reduced. Thus, between the high-pressure and the compressor outlet tempera- ture limitation is reduced allow- ing the LM6000 to operate on its low-pressure compressors. Water is atomized using high- pressure air taken off of eighth natural firing temperature con- stage air bleed. The water-flow trol. The result is higher output and better efficiency. rate is metered, using the appro- Priate engine control schedules. The SPRINT™ ro Solution at et = a Work. On high- as > pressure ratio gas turbines such as the LM6000, the compressor discharge tem- perature is often the criteria that limits power output because compressed air is used to cool the hot sec- tion components. By pre-cool- ing the LM6000 high-pressure LM6000 The LM6000 is derived from the core of the CF6-80C2, GE's high thrust, high-efficiency air- craft engine which has logged more than 46 million flight hours with over 2,500 engines in service. The flight version of the LM6000 powers approxi- mately 2/3 of the world’s fleet of Boeing 747 and 767 wide- body aircrafts. Delivering more than 43 MW of electrical power at 42% thermal efficiency, the LM6000 is the most fuel-efficient, simple-cycle generator package in the world. For projects needing more power, the LM6000 SPRINT™ uses SPRay INTer-cooling to produce up to 30% more output during hot weather with no sacrifice of engine lifetime Serving a wide range of appli- cations, S&S Energy Products offers the LM6000 conventional annular combustor or a lean pre-mix dry low emissions combustor. When reduction of NOx emissions is required, customers can choose the best technology for their applica- tion: Water injection - low cost solution Steam injection - ideal for cogeneration projects Dry low emissions combustor - no water or steam required High thermal efficiency, com- petitive pricing, and installation flexibility make the LM6000 the ideal choice as a prime driver for utility peaking, mid-range, and base-load operations, as well as for industrial cogenera- tion. The LM6000 package delivers: e@ The highest simple-cycle efficiency for any gas turbine, regardless of size @ The highest combined- cycle efficiency in the 50 MW gas turbine class e Low installed cost e@ Dual-fuel capability Optimal evaporative cool- ing or chilling of air inlet High availability Reliable starting and fast loading High reliability Excellent part load efficiency @ Flexibility - Base-load - Dispatchable - Cogeneration — Peaking - Mechanical drive @ Simple on-site maintenance S&S Energy Products A GE Power Systems Business The Power of the Package FACTORY BUILT GAS TURBINE PACKAGES | POWER GENERATION | MECHANICAL DRIVE Factory Packaging Our shops in Houston, Texas and Florence, Italy fabricate, assemble and test each pack- age utilizing procedures certi- fied to ISO 9000 standards. Extensive research and devel- opment, modern manufactur- ing techniques and on-site experience are behind the suc- cess achieved by S&S Energy Products. We provide single source responsibility to the customer for package design, manufac- turing, operations, training and support. S&S Energy Products provides single source respon- sibility so customers do not have to qualify hundreds of vendors and prepare specifica- tions for all of the components in a generator package or mechanical drive unit. In addi- tion, we provide an overhaul guarantee and warranty for the complete package S&S Energy Products’ factory packaging concept ensures quick delivery and fast startup. Standardized designs shorten our manufacturing schedule. A large number of essentially identical packages are always under construction, giving us the flexibility to meet your delivery requirements —often less than 100 days. Your unit arrives ready for startup. All major components are base-plate mounted, a design that simplifies trans- portation and installation. No lengthy field setup required... no surprises. Factory packaging advantages include: e Single lift module - easily transportable e Stainless steel lube and fuel systems —- reduces mainten- ance e@ Redundancy on critical sys- tems - higher reliability and availability e Full factory test - reduces project risk e Better training - operators learn at our factory with fol- low-up at your site e Faster field erection —- reduces startup time and costs e Integral support systems — reduces installation costs Designed for the Long Term. S&S Energy Products’ gas tur- bine packages use an earth- quake-qualified structural design, durable electrical sys- tems and all stainless steel fluid systems and reservoirs. Redundant, oversized fans keep turbine compartments cool while generators sized larger than the turbine output accommodate future rating increases. This conservative design philosophy reflects the expectations of our customers to operate the package for 20 to 30 years Factory Full-Load Testing. All packages are factory assem- bled and tested at full-load before shipment. Customers are encouraged to witness and participate in the full-load test- ing. This approach allows a true measure of power output, heat rate and vibration as well as to check on control soft- ware and safety devices. The test uses the customer's con- tract generator (compressor for mechanical drive pack- ages), control panel and auxil- iary systems to minimize field startup and debugging time. Advanced Digital Control Systems. S&S Energy Products’ control systems utilize a mod- ular digital architecture: e Rugged GE Mark VI micro- processor control for engine monitoring with integrated fuel management GE Fanuc programmable logic controller; ladder logic control for automatic sequencing of auxiliary equipment during start/stop High-speed digital process- ing with integrated data log- ging/trending capability Operator-friendly interface with PC, color CRT and on- line diagnostics Easy expansion for future needs e Optional capability to con- trol simple-cycle balance-of- plant equipment without distributed control Superior Customer Training. S&S Energy Products offers complete classroom and hands- On operator training at our facility or your job site—no matter where you are located around the world. Operators will learn valuable information, which will help to eliminate costly mistakes during startup or operation. Initial training can even begin at our factory during full-load testing of the turbine package. The training improves operator confidence and trouble-shoot- ing capability during the project startup. SWGR TRANSMISSION SYSTEM Single Wire Ground Return Minimum Cost Transmission System Single Wire Ground Return (SWGR) transmission can best be described as single phase — single wire transmission of electricity that uses the earth as the return conductor. The SWGR transmission concept suggested here is point-to-point with a carefully established grounding system at each point. The substation established at each grounding point would connect to the village multi-grounded neutral distribution through a step-down transformer. The SWGR system proposed herein would in no way create an operating system with a lesser safety than the “conventional” system now in use throughout Alaska. A SWGR transmission line demonstration project was constructed in 1981 to intertie the village of Napakiak with Bethel. The 8.5 miles of line interconnecting the two communities extends over tundra covered terrain which is underlain with permafrost and dotted by numerous small lakes. This demonstration project has operated reliably for 11 years and has proven that a SWGR transmission system is both economically and technically feasible. The SWGR transmission concept described in this proposal has evolved from a recognition of certain basic facts-of-life concerning electric energy in remote western and interior Alaska, which facts are: 1. Small electric loads and the geographic distribution of villages presently limit electric energy supply to small, inefficient fossil-fueled generating plants. 2. Conventional three-phase electric transmission/distribution systems to intertie the outlying communities to more efficient generating plants are mostly impratical because high initial costs penalize the transmitted energy rates. 3. A transmission system using a Single Wire Ground Return (SWGR) line promises good electrical performance and a substantially lower initial capital cost and therefore a lower transmitted energy cost than conventional transmission. 4. The incentive to develop new, alternative energy sources (such as appropriate scale hydroelectric power in the area) is dependent on an economically viable electric transmission scheme that can feasibly deliver such energy to the villages. The SWGR transmission concept is one, which proposes to deal with these realities. While the use of a single energized wire and earth return circuit is unconventional in the sense that applications are not common, it is an accepted system of proven use in several areas of the world. Three-phase equipment can also be successfully operated from this system by using phase converters. The SWGR transmission system or, single-wire-earth-return (SWER) as it is referred to in other countries, is not a new concept. It was first proposed by R.W. Retherford, in 1975, as a means of interconnecting the regional villages to a centralized power generation facility.’ A SWGR transmission line demonstration project was constructed in 1981 to intertie the village of Napakiak with Bethel. The 8.5 miles of line interconnecting the two communities extends over tundra covered terrain, which is underlain with permafrost, and dotted by numerous small lakes. This demonstration project has operated reliably for 20 years and has proven that a SWGR transmission system is both economically and technically feasible. Presently, well over 100,000 miles of SWER power lines are in use in Australia alone. (See attached articles). SWER systems are also in use in New Zealand as well as many other countries, which are confronted with the problem of serving small electric loads, located at great geographical distances from power generation supplies. SWGR Transmission Line Lack of road systems, permafrost, and limited accommodations for construction crews throughout most of the region being studied has established certain limitations as to construction techniques which may be utilized. Two alternative transmission structures have been investigated for use in constructing a SWGR transmission line. Both designs have been developed with the intended purpose of minimizing construction costs. The two alternatives investigated are discussed in more detail in the subsequent paragraphs. "A Regional Electric Power System for the Lower Kuskokwim Vicinity, Robert W. Retherford Associates, July 1995. A-Frame Transmission Structure — The A-Frame transmission structure utilizes the same basic design developed for the Bethel to Napakiak SWGR transmission line and would consist of two 30’ Class 5 poles connected by an angle iron hair pin, a 69 kV post insulator and a full width 30’ Class 5 bog-shoe. The bog-shoe is necessary to prevent overturn in high wind conditions. The conductor selected for use with the A-Frame is 1/0-3/4 AWAC. Maximum span length is approximately 600-700 feet and is limited by structure overturn resistance in high wind conditions. A sketch of the A-Frame structure is attached. Single Pole Transmission Structure, Long Span Construction — A single pole would be utilized for this structure. A 69 kv post insulator would be mounted vertically to the top of the pole. The structure would be bolted to a driven pile foundation. Maximum span length will typically be limited by the strength of the conductor, and conductor clearance requirements. Electric Performance The electrical performance of the proposed 40 KV-to-earth SWGR transmission system has been evaluated and is presented in a series of calculations attached to this section. The analysis examines Feeder 1, which proceeds north from Bethel and extends to the mouth of the Yukon River. See Section 5 for SWGR transmission system map. This is the most heavily loaded and longest feeder of the four SWGR feeders. The results of this analysis indicate that satisfactory electrical performance can be obtained if the feeder is built using 556 ACSR conductor between Bethel and Kalskag, a distance of approximately 80 miles, and 4/0 ACSR for the remainder of the feeder. It is assumed that satisfactory electrical performance can be obtained from the other three feeders, since they are not as long nor as heavily loaded as Feeder 1. A more detailed load flow analysis will be conducted on the entire SWGR system in Phase II of the study. Single-Phase to Three-Phase Conversion in SWGR Power Transmission Single Wire Ground Return transmission scheme is an attempt to develop an economical method of electrically interconnecting small communities with low energy demands to a lower cost generation source(s), such as a centralized power plant at Bethel. However, when transmitting power using the SWGR transmission scheme, it will be necessary to convert single-phase power into three phase power when supplying three phase loads. This can readily be accomplished installing single-phase to three-phase rotary or static conversion equipment. These are standard off-the-shelf equipment, which would be installed at the location of each three-phase load. (See attached information). This type of conversion equipment has been used for many years to supply three-phase loads from single-phase power lines. The size of these converters ranging from a few kW up to 45 MVA. It is also anticipated that existing village distribution systems can readily be re-phased such that the majority of the village load can be supplied from single-phase power. This was accomplished at Napakiak in 1981, as part of the SWGR demonstration project, when the village distribution system was easily reconfigured to operate on either single phase or three-phase power. The single-phase configuration is used when the village is supplied from the SWGR transmission line. The three-phase configuration is used when the village if supplied power from its three phase generators during periods the transmission line is out of service. This was accomplished by installation of a transfer switch at the power plant, which allows the power plant operator either to supply the village from the SWGR transmission line or the three phase village generators. Where 3-phase is required it can be provided by small rotary phase converter equipment, such as installed at the Napakiak school in 1981 as part of the SWGR demonstration project. A 52.5 kVA rotary phase converter was installed at the Napakiak school to demonstrate the feasibility of utilizing such equipment. This unit operated unattended and reliably for a number of years on a continuous basis converting single phase power to three phase power to supply the needs of the school. Unbalanced Generator Loading Three-phase generators are designed for operation under balanced load conditions. That is, the electrical load on all three-phases is equal or approximately equal. If the loading on all three-phases are not equal, circulating currents will flow within the generator windings, which may cause the generator to overheat. When serving single-phase loads from a three-phase generator, it is necessary to connect an equal amount of single-phase load to each of the three-phases to achieve a balanced loading condition. If a centralized power plant is built at Bethel, to supply the SWGR system alone, it may be somewhat difficult to equally balance the phase loading of the generator. However, if the centralized plant supplies power to Bethel Utilities, in addition to the SWGR system, a preliminary review has determined that it will be possible to obtain an acceptable balanced loading condition. Generator loading conditions will be more fully addressed in Phase II of the study. Future Reflections Although the Bethel to Napakiak SWGR line has been in service for more than twenty (20) years, it should be realized that SWGR construction in Alaska is in its infancy stage and many improvements in design and construction techniques are possible. For instance, a prototype aluminum “A” — frame structure has already been designed and manufactured and is awaiting installation in the proposed Bethel-to-Oscarville SWGR transmission line. The aluminum structure is lightweight, weighing only 200 pounds, which will allow for delivery of a complete structure by a single snowmachine. A concrete shoe weighing between 50-100 pounds will be attached to each leg to prevent overturn while simultaneously providing adequate surface area to prevent structure settlement. This approach should allow standardization of structures which can be used in varying geographical regions in Alaska with only the weight of the concrete shoe being altered, for various wind regimes. Other possibilities for improving structure design could employ the use of fiberglass poles and/or fiberglass standoff insulators. The use of lightweight structures will also significantly affect line construction techniques. Lightweight structures will make possible the use of lightweight, portable electrically or hydraulically operated scissor lifts for erecting structures, thereby significantly decreasing construction costs. In addition, the lightweight aluminum structure, using only four connecting bolts, can be assembled in the field by two men in a matter of a few minutes. Life expectancy of a SWGR transmission line is believed at least comparable to conventional constructed lines. This assumption is based primarily on the fact that the Bethel to Napakiak line has been in service for over 20 years. It should also be noted that due to the unique gravity stabilized construction of the SWGR line, the structures are not subject to the “frost heave” action which commonly occurs in conventionally constructed lines built in a permafrost area. This alone could increase the potential life expectancy of the SWGR line in comparison to a conventional line. Construction of SWGR system within the State should not however, be allowed to proceed in an uncontrolled manner. Because of possible problems associated with ground return currents such as corrosion, communication interference, etc., each project should require licensing by the State after careful, but timely review. To prevent personal injury, it is imperative that the State require all earthing systems associated with SWGR systems meet or exceed the standards as set forth in IEEE guide for substation grounding. Cr — 5" DIA. POST INSULATOR 10'x4"x4"x V4" ANGLE IRON | 4.75" DIA. wooD POLE 3i'-8" 30'-o" 10" DIA. La. 27'-0" | "A" FRAME TANGENT STRUCTURE POST INSULATORS worldaware - business awards Page 1 of 2 2001 2000 1999 1998 1997 1996 1995 1994 1993 1992 1991 1990 1989 features sitemap contact us Donate Now! what's this? worldaware = worldaware business awards [ Awards 1997 ] Shell Technology for Development Award GIBB Africa Four hundred homes in Southern African villages now have mains power, thanks to an old technique reworked by GIBB Africa. It will soon provide power for thousands more homes. The technique is single wire, earth return (SWER): in other words, the power goes out along a single wire, mounted on simple poles with long spans, and then uses the earth as return. GIBB has shown SWER can transmit power to small users in outlying areas more cheaply than conventional transmission with three conductor wires. Eskom, the South African power company, expects to save about £10 million in 1998 by using SWER. Power is one of the modern amenities that many South Africans yearn for. SWER means more of them can have it soon. Householders will use the same 230-volt lighting and appliances as those supplied conventionally; but the lines that carry power to their local transformer will be SWER. Australia and Brazil have used SWER for years to take power long distances to outlying farms. Eskom and the Botswana Power Corporation need to supply customers who are closer at hand and greater in number, but for whom they cannot justify a conventional supply. GIBB looked at the science and showed that SWER could take higher currents and voltages than those used in Australia, and that suitable switchgear and other equipment were available. A GIBB system is able to provide 500 kilowatts of power. The 19,000 volts of the SWER line helps overcome one of the problems of SWER, that of distinguishing the normal return flow of power through the ground from the abnormal flow when a conductor wire has fallen and needs to be repaired. The voltage, and South Africa's insulation co-ordination standards, also mean that SWER performs well even in the presence of lightning. GIBB has further had to show it can protect people and animals from high voltages in the electrodes connecting the SWER system to earth. SWER is safer than conventional systems in one important respect. If a conductor wire breaks, the wire on the far side of the break cannot be alive and unsafe. http://www. worldaware.org.uk/awards/awards 1 997/gibb.html 02/19/2002 worldaware - business awards Page 2 of 2 So GIBB was able to persuade Eskom and Botswana Power to adopt an unfamiliar technology. Botswana, which had to change its regulations on the earthing of power systems, decided on a £500,000 pilot scheme, now nearly complete, for five villages near its eastern border. It expects to use SWER for 60 more villages. Eskom, where GIBB has trained staff, expects to use SWER for more than half the 500,000 power connections it plans for 1998. http://www. worldaware.org.uk/awards/awards 1 997/gibb.html 02/19/2002 EFFECTIVE RURAL ELECTRIFICATION THE ESKOM DISTRIBUTION (SOUTH AFRICAN) EXPERIENCE R. STEPHEN, I. SOKOPO* 1 SYNOPSIS The South African utility, Eskom, has electrified over 1,75 million households in the past five years the majority of which have been in rural areas. As the program was self-funded as part of social investment, it became critical that both the cost per connection as well as the achievement of the connection numbers were met. As the number of connections was the more important target, if the cost was allowed to increase, it could have seriously affected the financial viability of the company. Due to a number of interventions which included social, technical, and project management, it was possible to perform 300000 connections in areas that were increasingly rural, simultaneously reducing the cost per connection in real terms by more than 50%. This paper describes those interventions and their successful implementation. 2 INTRODUCTION In the early 90s, Eskom Distribution, driven by lack of electrification of formerly Black Townships, decided to start a programme that was geared to address this and by the end of 1993 a total of 380 000 households were electrified as a result. In order to meet the compact entered into with Government in 1994, Eskom faced a daunting task of electrifying some 300 000 houses per year to achieve around 1,75m house connections by the year 2000. Eskom had limited experience in this field having only electrified farms in the early 1970s and the.380 000 households as mentioned above. It was not clear where to start - was this part of normal business or should it form a totally separate business ? Only one aspect was very clear - there was expectation that Eskom Distribution had to deliver effectively and efficiently at an unprecedented pace. The programme had to be tackled on a number of fronts - the process had to be formulated and the technology had to be perfected. The project management aspect was the key component in the construction process. In order to meet the target it meant that a connection had to be made every 30 seconds for 5 years. A pole had to be placed in the correct position every 10 seconds. Two hundred metres of cable had to be strung and attached every minute. In addition, invoices and payments had to be made to the value of R6 000 per minute or approximately R300 000 per day. In the course of one year over 200 individual electrification projects had to be planned, designed and executed with the precision of an expensive Swiss watch [1] *R. Stephen and I. Sokopo are Corporate Consultants in Eskom Distribution email: stepherg@eskom.co.za 3. DESIGN AND CONSTRUCTION PROCESS It was necessary to decide whether the electrification program was to be part of normal business or a separate aspect of the business to be staffed separately. It was decided to manage this separately which provided for the correct focus but did lead to problems in co-ordination of network plans The main change was from previously reactive program acting only on applications, to a "target" driven approach ensuring strict compliance to numbers and costs per connection. This necessitated a process to be set up whereby villages were identified at least 18 months in advance, communities were approached and interim designs were tabled. This process was also controlled strictly from a centralized point. The business planning, which determined the target cost per connection as well as the number of connections was completed annually 10 months before the next year commenced and included targets for the next three years. In addition it was found necessary to review the plan every three months whereby the target numbers and cost per connection would be redetermined for each of the seven Regional authorities. This was necessary due to the dynamic nature of rural electrification e.g.: - the population of the village may vary enormously in a relatively short period of time, - political considerations may change priorities at short notice, contractors operating in deep rural areas may find projects extremely difficult to complete on time - the number of connections may vary when it is discovered that what were considered to bc dwellings turn out to be sheds or deserted shacks. In order to meet the annual target numbers and costs it was critical that connections could moved between Regions. It was also critical that the decisions by the central planning function were strictly adhered to, no matter what the hardships it brought to the Regions, e.g., consultants were adamant that the cost per connection in the Eastern Region (Kwa-Zulu Natal Province) could not be brought below R6000 in 1995. The connection numbers for this Province were reduced and connections that were of a lower cost supported in other Regions. This implied consultants and contractors were left without work in many instances. It also meant villages had to wait longer for electrification. This forced the consultants and contractors to .sharpen their pencils" and come up with innovative ways of reducing the cost per connection. The consultants worked well with the Eskom staff in recommending changes to the design standards and specifications. This resulted in the same connections in Eastern Region costing under R3000 per connection similar to other areas. A reduction in real terms of over 50% was achieved when inflation was taken into account. 4 OVERALL PROGRAM DESCRIPTION In 1994, when the Democratic Government came to power, it was under pressure to deliver, hence the Government of National Unity embraced the ambitious Reconstruction and Development Programme. Consequently, the electricity industry in South Africa was required to deliver 2,5m domestic connections by the year 2000 and that they should fund the programme. Eskom's share of this compact was achieved at the end of 1999, a year ahead of schedule. At the end of 1999, Eskom alone had electrified 1,750,750 households the bulk of which were in rural areas. This achievement has increased the total number of electrified rural households in South Africa from 12% in 1994 to 46% as at the end of 1999. 5 SOCIAL INTERVENTIONS A programme of the magnitude as described above should be carried out with minimal delays but one of the lessons learnt is that, despite all the haste, the stakeholders must be involved. - failure to so leads to delays which at the end increases the connection costs. Initially, we negotiated projects with existing structures on the ground only to be told later that they were not recognised by the community. We later operated through "electrification committees" which were elected by the communities for that particular project - this carried on until the new Local Authorities were formed. The concept of community based construction became an issue and new people were employed and trained per project to do some of the identified tasks. As the programme unfolded, it became clear that the communities wanted to be involved more in the construction process - which desire led to the training of people to carry out service connections - the buzz word being the transfer of skills. We had to train negotiators to handle the conceptual stages of each project and help solve problems as the project developed. 6 TECHNICAL INTERVENTIONS The technical interventions were tackled on four fronts. The first was to determine the realistic load requirements of the rural dweller, the second was to determine the supply options in terms of single phase or three phase or combinations of these and the third was to ensure the equipment used was utilised to the full. The fourth intervention was the critical one of revenue management and metering. 6.1 Realistic Load Requirements Initially the networks were designed in rural areas using the same parameters as in the urban areas. A design of up to 3kVA per household was applied. In addition, it was discovered that a building might have more than one tenant. Each tenant was therefore connected at 3kVA providing in some cases a network capable of supplying in excess of 4kVA per household. Over time it was discovered that the rural areas did not consume power anywhere near the level at first thought. The load requirements were therefore brought down from 3kVA to 1,5kVA initial and 3kVA final design. Load research was conducted over a number of years in different environments. This resulted in further reductions to 0,6 kVA initial and 1,5 kVA final and eventually to 0,4 kVA initial and 0,8 kVA final for rural areas. In order to protect the networks it was necessary to limit the current to be used by the consumer. Initial limits of 20 A and 60 A were used which were later reduced to 2,5A, 20A and 60A. No flat rate or breaker tariff was used for reasons described in 6.4. 6.2 ‘Type of electrical supply. Although each supply was at low voltage and had to comply with 230V +/- 10%, the technology to supply the LV from the transformers could vary from three phase to dual and single phase. It is not the purpose of this paper to describe the detailed differences between the systems, it suffices to state that the three phase was the most expensive followed by the dual or bi-phase and then the single phase supplies were the lowest cost. The three-phase technology was utilised in designs of 1,5 kVA to 3 kVA per household. It is suitable for higher loads but expensive for lower loads as in the case of electrification. The aim was therefore to reduce the amount of three-phase circuitry to an absolute minimum. Supplies into villages were designed as dual or single phase or single wire earth return (SWER) systems. The difference in the three phases to SWER line costs was six to one. Although the three-phase supply could transfer more power, the SWER was in most cases adequate for the load. The monitoring of the type of supply was performed via indicators that showed the percentage three-phase line to single and dual phase line. 6.3 Utilisation of equipment In the initial stages the mechanical and electrical utilisation of equipment was very poor. This was basically due to the poles being placed equidistant and at property boundaries, transformers were expected to reach their full load at the end of the second phase to prevent having to change transformers. Little overload of transformers was allowed. This under utilisation was one of the main reasons for high cost of connections. The use of indicators to increase the utilisation of equipment realised an approximate 25% reduction in the cost per connection. These indicators focused on span length, which is the distance between two supporting poles on a line as well as the transformer capacity initially, installed divided by the number of connections. This figure should be in the range of the design specifications i.e. 0,4 kVA. The span length for aerial bundle conductor was to be in excess of 60 m and that of medium voltage line around 100 m. Before the use of the indicators and focus on this aspect of the design, the poles were spaced 30 m and 60 m respectively. 6.4 Revenue Management and Metering. The main concern in the start of the program for rural areas was to ability to bill customers and receive payment for service. It was soon realised that with the low demand of the customer at 30 kWh initially, that revenue collection needed to be kept to a minimum. The cost of sending and processing a bill by mail would in many cases exceed the revenue collected. In addition most rural areas have no roads or postal addresses. To mail a bill was not possible. This meant visiting each customer at least once a month in order to deliver the bill and at the same time obtain the revenue. The problem with this was that the customers were seldom at home and repeat visits were required. It was clear early on in the program that any method of billing was not feasible. A method of prepayment was thus developed with a magnetic card being issued from a vendor that enabled an amount of units to be purchased as and when the customer could afford it. The card could only be used by the particular meter. In this way it was possible to determine which customers had not purchased power for a while and they could be visited to ensure that no bypassing of meters was taking place. In addition meters were installed at each village to determine the technical losses and balancing the remaining energy transmitted with the energy purchased. It was thus possible to determine the percentage of non-technical losses in the village. In spite of these devices non-technical losses still pose a problem. The problem, however, is far less than if another type of system was used. At present the revenue received covers the operating costs of the connection. As the capital is a social investment this state of affairs is satisfactory. 4 7 RESULTS We can now take stock of our position, look back and say When we broke in Alamein we were there". Without necessarily beating our own drums, we can proudly say that have invented the wheel when it comes to low cost rural electrification. The 1,75 m homes mentioned above were electrified at a cost of R5,5b and the cost per connection has been coming down all these years to a figure of R2,800 in 1999. There are 9,6 m household in South Africa of which 66,2% have been electrified. Of the electrified households, 46,3% are in rural areas and 79,7% in urban areas. Of the remaining 3,2 m unelectrified households, 2,2 m are in rural areas and some in deep rural areas where innovative means of achieving "universal access" will have to be explored. In the process, we electrified close to 5000 schools and about 150 clinics as part of Eskom's social responsibility programme. 8 CONCLUSION The success of the program in Eskom, South Africa was achieved by continuously learning from the mistakes of the past and implementing best methods nationally from a central office. The up front planning, initially thought impossible, was the key factor that enabled the program to be both efficient and flexible. It is our opinion that strict control from a central point with clear indicators and a well-defined project management approval and management process is paramount to the success of any electrification program. REFERENCES I J. Matsau - "Eskom Distribution's Contribution to Rural Development and Strategy for Future Growth" - Presented May, 2000. Domestic Use of Energy Conference 2001 - Abstract Page 1 of 1 A Visitors | Search [| Staff | Students | News | Contact us | Cam a CAPE TECHNIKON Apobeo Scences : wonmen: & Design: Business informatics ¢ ni Engineering: & THE USE OF SWER (SINGLE WIRE EARTH RETURN) AS A POTENTIAL SOLUTION TO REDUCE THE COST OF RURAL ELECTRIFICATION IN UGANDA \zael Pereira Da Silva, Patrick Mugisha, , Philippe Simonis, G.R. Turyahikayo Makarere University, Uganda The rural electrification process in Uganda is going to face an enormous challenge following the ongoing process of Privatisation/Liberalisation of the Power Sector. The Electricity Act enacted in 1999 provides for more power utilities in the generation, transmission and distribution of electricity in the country, ending a more than 40 years of monopoly of the Uganda Electricity Board, a government parastatal. The Rural Electrification (RE) has passed to the responsibility of the Ministry of Energy who issued a document called the RE strategy and Plan with an overall objective of increasing electricity accessibility in the rural areas from the actual less than one per cent to 10%. No subsidy for energy consumption, and openness to the private sector looks like a wrong formula for facing rural communities with sparse distribution of households and low level of consumption. This paper looks at a technical way of reducing the cost of the extension of the grid using SWER (single-wire earth return). This technology has been used with success in other developing countries. With a cheap transmission system and a varied ways of generating energy (Photo-voltaic systems, mini-hydros, multi-fuel turbines, etc) chances are that the implementation will take place. Regulations and standards for construction of LV lines and safety considerations are reviewed and, where necessary, modifications are proposed. Students | Visitors | Campus | Staff | News | Search | Intranet | Webmaster Page 2 of 2 http://www.ctech.ac.za/conf/due/200 1 /abstracts/ab13.html 02/19/2002 ESAA infoPOWER - Information Services - Data Page 1 of 4 INFOPOWER sean: socin newsissues | informationservices | links | environment | sitemap About | Data | Publications | Prices Data ESAA is the principal supplier of electricity market data in Australia. As part of our commitment to provide members with the facts they need to increase organisational effectiveness, we undertake constant research into the changing state of the Australian electricity industry. When you access ESAA market data, you gain invaluable insight into the purchasing habits of your customers, infrastructure and production statistics, and the trends affecting your business and the electricity market as a whole. Further information on industry statistics is available in ESAA's annual journal Electricity Australia. The 2000 edition is now os or | [ _|wswaact| vic | ato [Residential __||_18,456|[10,631][ 9,638|[_3,814]/ 3,605]1,759 Other [_[_41,069)25,689)23 620] 6,62] 7, 802)7,466) [Total 1998|| —_58,713]/34,855][32,210]| 9,939]|1 1,063]/8,985] | ———Jis99] —59,544)36,314)23,200] 0,456] 11 407)9,225]1,540]_ 161,762] [Change on previous year (%) el 1.4% 4.2%]| _3.3%|| 5.2%] 3.1%] 2.7%] 1.6%], 2.8% i ERMC PRC CE geri eget OTR eect Ecce cm a: Figures represent sales from Western Power Corporation only. Electricity consumption of industrial customers who http:// — w.esaa.com.au/head/lite/informationservices/data 03. 2001 Electricity consumption - year ended 30 June 1999 (GWh) ESAA infoPOWER - Information Services - Data Page 3 of 4 joint venture project ot Federal government and State governments of NSW and Victoria. | Last Updated on 7/07/00 [Transmission and distribution system at 30 June 1998 Overhead lines (circuit kilometres) | | i Leeann eee eae ee oe oO NSW& | ACT vic TAS Australia [High voltage transmission, 220 - 500 kV 6,288} 6 ,367|| 5 Soa sat aT =e -||_ 23,904) High voltage distribution, sub-transmission and . transmission, 6.6 - 132 kV 161,673 Sr asa 609)/81 ,021]122,403}/30,099}/17,069)/3,761]] 377,636 [Low voltage distribution, 415 V 59,453 37,968] 968|[27,599||14,943]|11 ,006|| 8,700]|1,944]| 161,613 Single wire earth return, 240 V - 11 kV 29,618 29,403] 60,8311|31,435}/39,026 | 635]| 9] 190,956 al _| Underground cables (circuit kilometres) - NSW & ACT a QLD || SA || WA — (Australia High voltage transmission, 220 - 500 kV I 20/10} [ 5 8 + ji 43) High voltage distribution, sub-transmission and transmission, 6.6 - 132 kV | 12,084] 3,281]] 3,638]| 2,389] 2,003] 734] 556]| 24,685) Low voltage distribution, 415 V I 13,469]|10,964]| 4,677 7 4.418 4,418 8|| 5,261]| 1,000 1,444] 41,233 Single wire earth return, 240 V - 11 kV | 15[_132[ 251[ 43 ft Sta Last Updated on 7/07/00 http:// — w.esaa.com.au/head/lite/informationservices/data 03. 2001 ESAA infoPOWER - Information Services - Data Page 2 of 4 — om eed tome 8 Ce “ ~ ae aeeeeeneeeees t — — Last Updated on 7/07/00 Number of customers - at 30 June 1999 NswaacT| vic || ato || sa || wa | Tas Australia [Residential [_2,513,792][1,800,026]|1,382,747]|636,283]}676,947 nd 205,138 ae 619 Other | 468,461]|_ 353,403] 193,566|| 97,500|| 98,655|| 40,047][11,663]|1,263, 295] Total _|[1998|[_2,947,013][2,088,051][1,532,034][724,531][761,704]|245,498|[66, 126]|8,364,957| S999] 2,982,253][2, 153, 429][1,576,313||733,783||775,602||245,185]|68,349 Change on previous year (%) | 1.2% 3.1%] 2.9%] 1.3%| 1.8%] -0.1%]| 3.4%] 2.0% Last Updated on 7/07/00 Electricity generation by fuel type - year ended 30 June 1999 (GWh) [Australia| | |___|[Nsw][ vic || ap || sa || wa |[Tas|[ NT |sma*|Australia Hydro [|| 232 748 77of | —sejg,ssal| | 4,573]| 16,187 Black coal [_|ssg75{a7,379[_— sf 7,993[ ff] 104,347 Brown cold Ye sea aseef—tag Natural gas |_| sof 107]| 1,397] 4,747]| 3,854] | 12,487 [Oilproducts CCC] [otal —“‘“s*™S™SC™C~CSCC_ ft 998]57,535][48,110]39, 168]| 7,285]11,810]9,692]|1,576 it 99960, 05]/49, 442]40,231] 6, 305]12,152]9,679] Change on previous year (%) | 4.4%l| 2.8%] 2.7%|[14.0%]| 2.9%|| 1.9%] See * Snowy Mountains Hydro-Electric Scheme,a || | | | f yf | | © a wo +b http:// —_ w.esaa.com.au/head/lite/informationservices/data 03, 2001 ESAA infoPOWER - Information Services - Data Page 4 of 4 | To top of page Username Search | Printer friendly page Password High graphics page E | | FLogin Shopping cart Email this page to a friend Exe © Copyright 2001 Electricity Supply Association of Australia Ltd http:// — w.esaa.com.au/head/lite/informationservices/data 03, 2001 When One Wire Is Enough Australia’s rural consumers benefit from single-wire earth return systems. By Neil Chapman, Advance Energy n the early 1950s, Australia saw a need to expand its electrical net- work to provide power to the country's agricultural areas. Be- cause the loads were smal] and spread over a wide area, financial con- straints demanded a network that was economical to construct and maintain, as the return on capital investment would take a lot of time. As a result, Advance Energy, New South Wales, Australia, turned to single-wire earth retum (SWER) systems, which had been successfully tried in New Zealand several years carlier. Initially, the loads nourished by the feeders were small. However, over the years, the loads grew and began creat- ing problems for the existing SWER systems. One of the principal prob- lems was greater voltage variation along the line. A common solution to this problem is to build a new three- phase 22-kV or 33-kV backbone feeder through the area, redesigning the ex- isting SWER system into several smaller systems sustained by the new feeder. Although this approach is cf- fective, it can be expensive—particu- larly for areas where load growth rates are inadequate to justify capi- tal investment on a three- phase feeder. Step voltage regulators (SVR) provide a more eco- nomical solution because they can be inserted in the SWER line to control volt- age both undcr light load and at peak demand. Advance Energy’s Deca design, a project in the western part of New South Wales, illustrates Shunt the effect of regulator appli- cation ina SWER system us- ing the V-CAP software pro- Source @ Arrasters gram for circuit analysis. Fig. 2. A schematic of a single-phase regulator. 56 SWER System Characteristics SWER systems are significantly dif- ferent from the three-phase, three-wire and single-phase, two-wire systems commonly used throughout Austrai#_, As the name implies, it is a single-wire distribution system in which all equip- ment is grounded to earth and the load current retums through the earth. Its loads are light and its lines are long, often causing the current to have a leading power factor. The main features and components of the SWER system are: @ System voltage. Typical SWER voltages are 12.7 kV and 19 kV, al- though they can range from 6.35 kV to 19.1 kV. The 12.7-kV and 19-kV lev- els are convenient because they are the phase-to-ground voltages of a 22-kV and 33-kV system, respectively, and allow the use of standard hardware and equipment. The industry standard for distribution voltages is + -6% from a nominal 240 V. This standard estab- lished criteria for acceptable voltage limits in specifying and optimizing the location of voltage regulators and de- termining the maximum load capacity of the system. Studies allowed 2% for low-voltage regulation and assumed the use of 16- and 25-kVA, 19,000-kV/S00- 250-V @yansformers with an approximate 4% impedance and taps of + -5%, 2.5% and 0%. @ [solation transformer. The isolation transformer iso- lates the earth currents (zero sequence currents) of the Series SWER system from the Arrosters three-phase main supply feeder. This limits the expo- sure to telephone interference and allows the main supply feeder to maintain its sensi- TRANSMISSION & DISTRIBUTION WORLD/www.tdworld.com/April 2001 Fig, Tien itahigs hasidiiendsen 50-50 OUR epehoen meinen iaiion belek Tas, tive earth fault detection protection. The transformer carries all the current of the system, including load current and capacitive charging current. The charging current on long feeders is sig- nificant, therefore, the impedance of the unit must be low. Originally, the carth retum current ‘was limited to 8 A at the isolation trans- former to avoid potential step-and- touch problems for livestock and hu- mans. Although this regulation no ionger strictly applies, currents still are kept relatively low. The typical isola- tion transformer sizes are 50 KVA, 100 kVA, 150 kVA and 300 kVA; however, 1-MVA units have been used on sev- eral occasions. ® Conductor characteristics. Line length varies according to customer distribution, with an average SWER feeder length of 60 kin (37 miles), al- though a 400-lan (250-mile) SWER system is in operation in one state. Therefore, circuit losses because of the high resistance of the SWER conduc- tors, reactive losses in the isolating transformers and resistive losses in the earthing systems can be up to 100% greater compared to those of a single- phase (two-wire) system serving simi- lar loads. Typically, conductors have a small diameter and high strength, and are made of aluminumysteel or steel cable. Sec- tions at the sending end of the line often are 3/4/2.5 ACSR (34mm? [0.053in7}) orare similar Tee-offs and lightly loaded sections often are 3/2.75 SC/GZ (17.8mm? [0.028in?]). These high im- pedance conductors in long SWER lines can cause the total impedance at the end of the feeder to be 1000 ohms. 58 TRANSMISSION & DISTRIBUTION WORLD/www.tdworld.com/April 2001 i HTLTLTUEUAL @ Reactors for compensation. Charging currents are approximately 0,025 A/km for 12.7 kV and 0.04 A/ km for 19-kKV SWER systems. These charging currents, although similar to other types of distribution construc- tion, are a concern because of long line lengths and high impedance of the con- ductors and supplying source. Shunt reactors usually are applied to the line to compensate for the charging current to reduce line losses, provide voltage control and minimize isolation trans- former size. Because the reactors are fixed rather than switched, they cannot automatically regulate the voltage. Because the Peactors are fixed rather than switched, they caunot automatically regulate the voltage. @ Load densities. Load densities for a SWER distribution system typically are Jess than 0.5 kVA per Kilometer (0.31 KVA per mile) of line with a maximum demand per customer of 3.5 KVA. A large system may supply up to 80 distribution transformers with unit ratings of 5 KVA, 10 kVA and 25 kVA. The joad patterns and demands vary greatly from customer to customer and from one season to another, thus, as load growth continues, SWER systems are reaching their technical capability. And with customers keenly aware of supply quality, customer complaints are increasing. @ Earthing. Transformer earthing Nn 3907 762 4617 # must be reliable and have low resis- tance, requiring frequent testing to maintain its reliability. Poor earthing systems reduce safety and supply qual- ity. The maximum earthing resistances are: @A 5-kKVA distribution trans- former—20 ohms @A 10-KVA distribution trans- former—20 ohms @A 20-KVA distribution tans-~ former—-10 ohms @All isolation transformers—2 ohms SWER vs. Conventional Construction Although a number of inherent dis- advantages are associated with the SWER option (for example, load bal- ance on the primary distribution line, restricted load capacity and the inabil- ity to provide a three-phase supply), there are many advantages to using SWER in sparsely settled areas, for instance: @ A low capital cost—through fewer conductors, fewer pole-top fittings, graded insulation on distribution trans- formers, and fewer switching and pro- tection devices. Although every new project will vary, savings of up to 30% per customer are common for long, lightly loaded feeders. ® Simplicity of design, which al- lows for speed of construction. This particularly applies to the stringing of a single conductor @ Reduced maintenance costs, be- cause there is only one conductor and no crossarm. @ Fewer bush-fire hazards, because conductor clashing cannot occur in high winds. Application of Voltage Regulators As load on the SWER system in- creases, voltage regulation becomes an increasingly severe problem. Com- pared with three-phase system rein- forcement, voltage regulators are an economic choice. Their capital expen- diture is minimal, and they provide the control needed for adequate regulation, even at some distance from the send- ing end of the line. The SVR is an autotransformer in which the series winding is tapped and equipped with a reversing switch that permits its voltage to add or subtract from the shunt-winding voltage. The voltage regulator, therefore, is able to boost or decrease (buck) the voltage ao 5-21-01; 4: on the load side as compared to the source-side voltage. A control wind- ing sepses the load-side voltage and supplies this intelligence to the con- trol, which in turn activates an auto- matic tap changer on the series wind- ing to raise or lower voltage. A line-drop compensation feature often is added to enable a constant voltage to be maintained at a load center remote from the regulator despite fluctuations in load. Figures 1 and 2 show the single- phase regulator and its schematic. Darling Electrification Project Figure 3 shows a diagram of the 19-kV SWER system used in Advance Energy’s Deca project. The longest feeder is 161 km (100 miles), with the isolation transformer installed at Bindara Gate. The maximum loading for this lme is 157 kVA, supplying 20 Primary feeder loads via a radial pet- work that comprises three conductor types—3/4/2.50 ACSR (34mm? (0.053in?]), 3/2.75 SC/AC (17.8mm* [0.028in?]) and 3/2.75 SC/GZ (17.8mm? [0.028in?]). This system was simulated using the V-CAP software, a generalized circuit 23PM;Trans&Spcl. Pr jcts. analysis program for radial feeders. It has specialized tools that focus on volt- age regulation and energy-loss evahu- ation, including voltage regulator mod- els with tap-changing controls; shunt- capacitor models with a full range of switching controls; and load models that allow representation of load as constant impedance,. constant kVA, motor load, converter, or mixed motor and impedance. Each load can have a load profile that ts Joad changes over a 24-hr period in increments as small as 15 min. In addition, an annual load profile can be overlaid on the daily profile to account for seasonal load variations. The load modeling features permit a much more accurate annual loss evaluation. Regulator control modeling permits the simulation of voltage set points, time delay, band- width, PT and CT ratios, and maxi- mum and minimum voltage limits. Although the program primarily is used for three-phase circuit analysis, Advance Energy modified it to repre- sent the single-phase system with a 20-ohm ground resistance. Advance Energy used the program Circte 130 on Reader Service Card April 2001/www.tdwortd.com/TRANSMISSION & DISTRIBUTION WORLD 3907 762 4617 TONUEUESTETTTTS {111 for a voltage profile of its SWER sys- tem under various operating conditions. Figure 4 shows the voltage profiles scaled to a 120-V base, the two hori- zontal lines marking the statutory lim- its for the distribution transformer sec- ondary voltage (for example, 126 V to 114 V). The theoretical system voltage profile for the total system of 394 km (245 miles), with 300 kKVAR charging capacitive VARs operated at no load and with no shunt reactors, results in a voltage 25% higher than the system nominal voltage. Shunt reactors usually are added to control the voltage. On this system, 11- to 25-kVAr units are scattered around the circuit to achieve about 90% compensation of the capacitance. While the shunt reactors are neces- sary for maintaining the voltage con- trol during light-load conditions, they continue to hoki the voltage down dur- ing loaded conditions. In this the maximum load of 157 kVA causes voltage depression. The voltage drops below 117 V quite quickly and reaches as low as 109 V at the end of the feeder. Off-load taps at the isolation trans- former are of some help but cannot be 59 a rn a i No load, no shunt reactors. bj mmm No load, shunt roactors In sorvice. = Full load, ehunt reactors in service, one regulator an line == Full load, shunt reactors in service, two regulators on ine. m= Full load, shunt reactors inservice. =m Pui! load, shunt reactors in servios, one regulator on line Fd wine drop comp. i Fig. 4. Voltage profiles over the 161-km (100-mile) portion of the SWER system for various operating conditions. raised too high or the voltage during light loads will be excessive. A voltage regulator can provide the control necessary to maintain voltage Within statutory limits over the range of light and heavy loads. Figure 4 iJ- lustrates the effect of adding a regula- tor to the line. In this example, the 60 PLUMAS regulator is positioned on the network where the voltage approaches the lower limit. The regulator taps up to its set- point of 122 V, and the voltage contin- ues to fall to 115 V at the end of the feeder. This is below the acceptable primary voltage range, but setting the voltage set-point higher could help boost the voltage at the remote end However, this would result in exces- sive voltages during light load. Two solutions to the under-voltage problem are: 1. Position a second regulator down line of the first. 2. Use the li compensation feature of the regulator control. ‘A second regulator can be added to raise the voltage once the voltage drops to the lower limit. The optimum loca- tions for two regulators in series on a conventional feeder are approximatcly 20% and 50% of the entire line length from the source. On the Advanced En- etgy SWER system, the regulators were located at the 12% and 44% positions. In this case, the high source imped- ance of the SWER system required the regulation to be closer to the source. When two regulators are used in se- ries, it is important to adjust the con- trols so they coordinate tap changes. The preferred method is to adjust the time-delay settings of the farthest regu- lator to be greater than the sending- end regulator, allowing the sending- end regulator to respond first. The line-drop compensation feature of a TRANSMISSION & DISTRIBUTION ‘HARDWARE * For OVERHEAD AND LINDERGROUND APPLICATIONS ON ELECTRIC, RAILWAY Systems AND SupsTATION CONNECTORS & CLamps. * For Pore Lint HARDWARE AND TOWER Fiennes. * Harpware Meer ISO, ANSI/NEMA, ASTM, AT&T, DIN, BS, JIS or CUSTOMER SPECIFICATIONS. FAH TEENG INDUSTRIAL CO., LTD. P.C. Box 17-219 Talpei, Taiwan Email: fahteeng@ms2] .hinet.net Tet: 886-2-25235489 - Fax: 886-2-25235779 Cirote 120 on Reader Service Card TRANSMISSION & DISTRIBUTION WORLD/www.tdwarld.com/April 2004 RA er cme co regulator control also can be usexi to | correct the undervoitage. Figure 4 shows the effect of line~<irop compen- sation on the voltage profile—the regu- lator is better used and the voltage is brought within limits. At light load, the extra boost is reduced because the smaller voltage drop of the line results in a smaller subtracted voltage. The use of shunt reactors, voltage regulators and the line-drop compen- sation feature effectively controls the voltage to the end of the feeder. Ad- | vance Encrgy did not consider cither of the other available options for volt- age control in this study, namely, switched shunt reactors and switched shut capacitors, because of the remote- ness of the SWER system. Although these options can be effective for volt- age control and for reducing losses, operations and maintenance for the multiple devices (which must be scat- tered over a broad area), they may make the switching of these devices impractical. SWER Systems—Set to Continue SWER systems now cover extensive areas of Australia. By 1997, New South Wales had about 35,000 km (21,700 miles) of SWER lines and many other states had incorporated SWER into their distribution networks. In addi- tion, Canada, India, Brazil and South Africa all usc the SWER design to supply electricity to thinly populated areas. Through the Advanced Energy project and several other experiences, Australian electricity distributors have gained cxtensive experience in design- ing large-scale SWER systems. And as the project demonstrates, hardware and software is now available to ensure these networks will continue to supply economical, high-quality electrical energy into the future. D Neit Chapman is the overhead develop- ment manager for Advance Energy. He joined the etectricity supply industry in 1974, since which he has held various operations and engineering positions. Chapman has the electrical trade certificate and the associate's diploma in electrical engineer- ing from Orena Community College. He also has the graduate diploma in management from Charles Sturt University T&D World online... www.tdworld.com April 2001/www.tdworld.com/TRANSMISSION & DISTRIBUTION WoRLD Lowers Your #3 Substatios Design |: Costs Nexus 1250 solves your information and control probierns easily and quickly using advanced DSP technology and expertise. eg Metering and Control! rete you how to lower substation design costs while improving data gathering and control functionality. Features: Revenue Power Data — MV90 Compatible Advanced Power Pertect for: Quality Analysis = Substation Power Monitoring = Expandable I/O + Substation Controf Schemes = Mutt-Tier Logical Protection * Utility Tie Lines & Convo! « RTU Applications (Poll-Top or Station) Customer Metering Critical Load Points DNP 3.0 Protocol Simple to Use Software Ethemet Web Access www.electroind.com Hectro industies/Gaugetecn Tel: 516-334-0870 ° Fax: 516-338-4741 1B00 Snarnes Drive * Wostbury. NY 11590 1- B877-EIMETER 11-877-346-38371 Circle 32 on Reader Service Card 61 PHASE-A-MATIC: Rotary Converter Application Notes Page 1 of 2 x On This Page: ROTARY @ Application Notes @ Motor Load Types CONVERTER @ Resistive Loads e Computer, Rectifier & Transformer Loads @ Multiple Motor Application Application Notes Application Notes Application Notes: The Rotary Converter is designed to supply full running current to a three-phase motor normally providing it with full running torque. However, most motors will draw five times their running current during start-up. When used at its maximum HP rating the Rotary Converter cannot deliver the full (5 times) starting current to the motor and therefore cannot provide full starting torque. For heavy start-up loads a larger converter should be used. NOTE: You can always use a larger Rotary converter than the HP of the motor. There is no minimum load requirements for the Rotary converters. Some customers will install a Rotary Converter larger than they need to accommodate any future additions to their equipment. Below are the minimum size recommendations for various applications. 1. MOTOR LOADS A. TYPE 1 LOADS: May be used up to the HP rating of the converter. They include mills* & lathes* with a clutch, drills, metal grinders, etc. *For instant reversing (as for rigid tapping), size according to TYPE 3 LOADS B. TYPE 2 LOADS: These include domestic & European lathes without a clutch, some pumps, wheel balancers, paper cutters, flywheel driven equipment, air conditioners, blowers, woodworking band saws, dough mixers, meat grinders, motors rated below 1000 RPM, etc. Use a converter with HP rating of at least 50% larger than HP of the motor. C. TYPE 3 LOADS: These include Design "E" motors, Taiwanese, Chinese, Brazilian, Mexican motors, pumps starting under load, etc. Use a converter with twice the HP rating of the motor. D. TYPE 4 LOADS: These include laundry extractors, hoists, elevators, etc. For these start-up loads use a converter with three times the HP rating of the motor. E. TYPE 5 LOADS: Often hydraulic pumps, which come under a momentary load during http://www phase-a-matic.com/rappnote. html 03/22/2001 PHASE-A-MATIC: Rotary Converter Application Notes Page 2 of 2 use will be loaded well beyond their rated HP for the brief period of maximum PSI. Examples includes bailers, compactors, paper cutters, shears, pumps, etc. The HP of the converter must be at least as high as the actual HP developed by the motor. To calculate the HP developed, you must first find the actual amperage drawn during maximum PSI. This is different from the rated amps of the motor. Next you would divide the maximum amperage by 2.8 to find the actual HP being developed by the motor. That figure is the minimum size of converter to be used. Example: A 10 HP compactor with a motor rated at 28 amps but draws a peak of 40 amps momentarily at maximum compression. Divide 40 by 2.8 = 14.3 HP being developed, use model R-15 Rotary Converter. 2. RESISTIVE LOADS Resistive loads must use the Rotary type converter, the Static type should never be used because it would be damaged. There are two methods to determine the HP of the converter to be used. One method is to take the amperage rating of the equipment and divide by 2.8 to find the equivalent HP. The other method is to take the KW rating and multiply times 1.34 or divide by .75 to find the equivalent HP of the equipment. 3. COMPUTER, RECTIFIER, AND TRANSFORMER LOADS Transformers and electric equipment (welders, lasers, EDM machines, CNC equipment, computers, plating rectifiers, power supplies, etc.) can operate on the Rotary Converter. Use the same formula as for resistive loads to determine the proper size converter to use. If a 4-wire wye input is required (all lines equal voltage to ground), a three- phase delta-to-wye isolation transformer must be installed between the converter and the equipment to change the Delta power to wye power. 4. MULTIPLE MOTOR APPLICATIONS The Rotary Converter is capable of running up to three times its rated HP providing the maximum starting load does not exceed the HP rating of the converter, and the motors are not running heavily loaded. Home Page || Products Page || Contact Us || How To Order http://www.phase-a-matic.com/rappnote. html 03/22/2001 Kotary Converter Dimensions Page 1 of 1 ROTARY CONVERTER DIMENSIONS Dimension Measurements Shown In Inches LONG HIGH | WIDE jew | a [a Co fel e fel |r Ls [x |e [on | 0 | 2 ER 2 EE ET fea | 9 Poe [ Roe] 4] 5 | 6 foal] Pe va] Sel 62 [94 [50 ae] Pat [9oe [aoef Saal Gor [ef 2s Sedan] Bon 94 [Te 5] on pew [ios fief siel Pe filo om alta oe [ae [one 6 peas | an [Oval ta ve[ Suef 10 valve] rm [Sone] 5 [Soaf vel 111 [oan] er Tafa ef ofa foes fosadibol TD Poe = reel 19 [ose fzoaf om [Sel Safe af al aL] For shipping dimensions see ROTARY CONVERTER PRICES. Home Page Products Page Contact Us http://www. phase-a-matic.com/rotarydimensions. html 03/22/2001 PHASE-A-MATIC: Rotary Installation Instruction Sheet Page 1 of 4 ROTA RY On this page: @ General Instructions CONVERTER @ 220V Electrical Specifications @ 460V Electrical Specifications “ “ @ Single Unit Illustration Installation Instructions @ Multiple Unit Illustration @ Multiple Unit Instructions x CAUTION: Always Start Converter Before Applying Load 1. Magnetic controls or single-phase loads must always be energized by lines T-1 and T-2. Never connect a ground or neutral to line T-3 (Mfg. phase), which can easily be identified as the line with the highest voltage to ground with the converter running. 2. It is essential that careful consideration be given to your wiring length and size to prevent slow starting due to a voltage drop . Consult National Electrical Code for proper wire sizing. 3. When starting a motor of the same horsepower as the " Largest Motor" rating of the rotary converter, some drop in starting torque may occur in heavily loaded applications due to the higher starting current. However, full running torque is usually still obtained. Refer to APPLICATION NOTES for sizing considerations. 4. The tables below show the appropriate idle current at the specified voltage. Higher line voltage will cause idle current to increase. Excessive amperage could also be caused by incorrect installation. 5. Properly ground all electrical equipment. 6. Converter should reach full speed within 2 to 3 seconds. 7. Lubricate every 12 months for normal operation, or every 6 months for continuous (24 hour) operation. Use high temp bearing grease, (Shell "Dolium R" or equivalent, available from PHASE-A-MATIC). 8. Converters are intended for use in clean, dry locations with access to an adequate supply of cooling air. In addition, there should be protection from or avoidance of flammable or combustible materials inthe area of converters as they can eject flame and/or metal in the event of an insulation failure. http://www.phase-a-matic.com/installr.html 03/22/2001 PHASE-A-MATIC: Rotary Installation Instruction Sheet Page 2 of 4 For 220V operation: For 220 VOLT Operation: 230V Models (R Series) & Electrical LARGEST} TOTAL APPROX. | DISCONNECT MODEL | MOTOR }COMBINED IDLE SWITCH FUSE HP CURRENT | (TIME DELAY) ia_| 1aP_| 3H Specifications NEMA STARTER] SINGLE STARTER] HEATER [3H [sans | 10am | 00] 48 wos | 15 avs | [cH _| 2aves | 1oawrs | 0 | 778 [is ans] oHP [04 A [20-anes i i i | | yt wn Q wire YON 5|5 i = wn \o > i a fi ofr Aaa: EE aD 3 : i x —_ 5 Ss N NO | in 4 S oOo es pW oTo I I J ; =le|=|s(3| iR-is_[1sHP | «SHP_| Saws | coawrs [| 3 | 48a 100 avg] R-20_| 20HP | cOHP | 10 ams | soames | 3 | 63a [125 avs] fe-30_[ 30H | o0HP | 12 anrs | 125 aps] 3 | 94.4 200 avrs| fa-ao_| 0HP_| 1201P [13 awrs | 150.ames_[ 4] 117A [250 aver| pei [R-so_ [| 50HP | 150HP * Read APPLICATION NOTES for sizing considerations. eh WN ° Y S o wn 5 w S o 3 45A ** Larger units available through multiple unit connection. Contact Phase-A-Matic. Operating R Series is 208-230V single-phase in and 208-230V 3-phase out. RH Series is 400\ single-phase in and 460V 3-phase out. Higher line voltages or voltage sensitive applications, such as CNC equipment, may require a Voltage Stabilizer If you have single-phase that is 208-230V and you need 460V 3-phase out, or visa- versa. a transtormer can be used to step the voltages up or down as required. Consult factory XX L-1 T-1 THR SINGLE EE PHASE T-3 PHASE INPUT 1.2 1-2 OUTPUT 3-PHASE = FUSED DISCONNECT SWITCH OR MAGNETIC STARTER (Not supplied with converter) ROTARY CONVERTER http://www. phase-a-matic.com/installr.html 03/22/2001 PHASE-A-MATIC: Rotary Installation Instruction Sheet http://www. phase-a-matic.com/installr.html NOTE: co Always use T-landT-2t0 = == operate magnetic controls. = For 460 VOLT Operation: For 460 VOLT Operation: 460V Models ( RH Series) and Electrical Specifications | DISCONNECT ILARGEST}} TOTAL |} APPROX. MODEL || MOTOR ||COMBINED|| IDLE SWITCH FUSE}} NEMA |/STARTER (TIME STARTER |} HEATER HP HP LOAD* |iCURRENT} DELAY) RH-20 || 20HP || 6OHP |[Samps || 40amps || 2 35 AMPS|| 60 AMPS | RH-30 || 30HP || 90HP | 6 amps || ooames || 3 48 AMPS || 100 AMPS| 3 RH-40 || 40 HP || 120HP || 8amps || s0amps | 63 AMPS || 125 AMPS] RH-50 I 50 HP | 150 HP |} 9 AMPS 100AMPS I 3 78 AMPS || 150 AMPS| *Read APPLICATION NOTES for sizing considerations. multiple unit ill. Multiple Units Banked Together R Series is 208-230V single-phase in and 208-230V 3-phase out. RH Series is 460V single-phase in and 460V 3-phase out. Higher line voltages or voltage sensitive applications, such as CNC equipment, may require a Voltage Stabilizer If you have single-phase that is 208-230V and you need 460V 3-phase out, or visa-versa, a transformer can be used to step the voltages up or down as required. Consult factory. XX SINGLE L4 T-1 THREE Reo L-2 7-2 PHASE 3-PHASE FUSED DISCONNECT SWITCH OR MAGNETIC. STARTER {Not supphed wath converter) ROTARY CONVERTER ROTARY CONVERTER NOTE: ALWAYS ENERGIZE MAGNETIC CONTROLS WITH T-1 AND T-2 Multiple Unit Instructions Page 3 of 4 03/22/2001 PHASE-A-MATIC: Rotary Installation Instruction Sheet Page 4 of 4 A. 1,000 HP or more is possible by connecting multiple units together in banks as required. Potential output is limited only by adequate wiring size and your single-phase supply available. Consult factory for these options. B. Caution: Special care must be taken to connect all T-1 lines and all T-2 lines together. Test run the individual units before connecting the T-3 lines together. Carefully measure the voltages between the different T-3 lines. It should not read more than 60V for the R Series, and 220V for the RH Series, but could read much less. This will ensure that you have proper phase rotation. Cross phasing will cause a dead short and possible damage. C. Fuses or magnetic starters should be sized for the individual converters and not for the total load. D. The converters may be started either individually to reduce line surge, or may be started simultaneously depending on the limitations of your single-phase supply available. Home Page Products Page Contact Us How To Order Sizing Assistance http://www. phase-a-matic.com/installr. html 03/22/2001 Page 1 of 1 PHASE-A-MATIC: Voltage Stabilizer Prices VOLTAGE STABILIZER Models & Prices MODEL HP || AMPS PRICE WEIGHT DIMENSIONS iE VS-1 1 3.2 $140.00 7 Ibs. [ 7s. |] axexa | VS-2 2 6 $196.00 = [ exex4 VS-3 3 10 $276.00 [tts | Bx6x4 VS-5 5 s || 33600 | 16 Ibs. 8x6x4 VS-7 7-112 3 | ss7e00 || 19 Ibs. 8x8x6 VS-10 10 2 | $548.00 | 26 Ibs. Bx8x6 VS-15 15 3 | s7as. 00 | 31 ibs. | 8x 8x6 VS-20 20 $1,196.00 [sews |] toxtoxe | VS-30 30 || 100 co nseo | eae [15x 10-12x7-94 | VS-50 50 147 $2,756.00 [ests | 15xt0412x7-04 | VS-60 60 196 $3,240.00 | 102 Ibs. 15 x 10-172 x 7-318 VS-80 ** 80 226 || $4,112.00 | ae vs-100** || 100 || 294 $5,512.00 || aes ™ Multiple Unit Models Home Page Products Page [ Contact Us || How To Order || Sizing Assistance | http://www. phase-a-matic.com/vprices. html 03/22/2001 New Static Phase Converters - three phase power Page 2 of 2 Part# eer RP Raves | [TEMCo - % HSD_|[1/3-t0-3/4 = [TEMCo - 1 % HSD][3/4-to-1-1/2 129.00 [TEMCo - 3 HSD _|[2-to-3 TEMCo - 5 HSD_|-to-5 TEMCo - 7 % HSDjj7 1/2 TEMCo - 10 HSD |/10 94.00 TEMCo - 15 HSD fis 85.00 TEMCo - 20 HSD {20 29.00 TEMCo - 30 HSD 30 778.00 'TEMCo - 40 HSD |/40 890.00 ITEMCo - 50 HSD |/30-to-50 1098.00 Other sizes available call for details. Pricing subject to change, due to industry changes. al * Machinery with Delta wound motors must be run with TEMCo Rotary Phase Converters instead of static converters. * Clich here for more information about how a Static Phase Converter works and how to choose between a Static and a Rotary Phase Converter * Call for more application specific questions in choosing the correct model of TEMCo phase converter. (510) 770-0851. Tower Electric Motor Company has experience selling and maintaining electrical motors and producing single to three phase converters since 1968. All our electrical products are made to the highest quality standards and are backed by industry standard warrantees. When you want an electric motor, phase converter, or quality motor supply, turn to TEMCo. Call To Order: 1 (510) 770-0851 We accept Visa/MasterCard and can ship your order ASAP. mas Home « Order Converter » Rotary Phase Converters Remember to bookmark this page! Feel free to add a link to us! http://www. phaseconverter.com/static-converter.html 03/22/2001 PHASE-A-MATIC: Static Converter Prices ROTARY CONVERTER On This Page: @ 220V (R Series) @ 460V (RH Series) MODELS & PRICES Page 1 of 2 220V Models & Prices 220V "R" Series 220V (R Series) MODELS & PRICES 220V MODELS ee price ||SHIPPING||_ SHIPPING mp | SEENOTE WEIGHT || DIMENSIONS ect ned zt) ae R-l 1 | $408.00]| 33 ibs. | 15x10x10" R2 2 || s496.00] 41 tbs. 15x10x10" R-3 ie | $596.00] 62 Ibs. | 19x12x13" | R-5 | $780.00] 70 Ibs. | 19x12x13" | R-7 71/2 co ono ee R-10 10 || $1328.00 328.00] 1251s. || 16x16x16"_| R-15 15 | $1860.00] 208 ibs. | 31x24x21" R-20 20 || $2256.00][ 240 Ibs. |] 31x24x21" R-30 30 || $3076.00]| 320 Ibs. | 31x24x21" | R-40 40 | $3836.00]] 448 Ibs. 32x24x24-1/2" [R-so [| 50 || $4532.00], a8otbs._ |] 32x24x24-1/2" R-6o* || 60 | $5228.00] s4oms | ---- | [ R-80* so | [ $7148.00] 896 ibs. | eat —= R-100* 100 | $9064.00 960 Ibs. | NOTE: See APPLICATION NOTES for sizing considerations. * Multiple Unit Models http://www. phase-a-matic.com/prices. html 03/22/2001 PHASE-A-MATIC: Static Converter Prices Page 2 of 2 460V "RH" Series 460V Models & Prices 460V (RH Series) MODELS & PRICES 460v | = MODELS RATING || pricg || SHIPPING] SHIPPING "RH" SEE NOTE WEIGHT || DIMENSIONS : BELOW Series RH-20 20 $2256.00}} 240 Ibs. 31x24x21" RH-30 30 $3076.00 320 Ibs. 31x24x21" RH-40 40 $3836.00] 448 Ibs. || 32x24x24-1/2" ‘Tf RH-50 | 50 $4532.00} 480 lbs. 32x24x24-1/2" RH-60* 60 $5228.00} 640 lbs. ---- RH-80* 80 $7148.00]| 896 ibs._| ---- RH-100* 100 $9064.00 ]} 960 lbs. eee | NOTE: See APPLICATION NOTES for sizing considerations. * Multiple Unit Models Home Page Products Page Contact Us How To Order | Sizing Assistance http://www. phase-a-matic.com/prices. html 03/22/2001 New Static Phase Converters - three phase power Page 1 of 2 New Static Phase Converters Run three phase equipment on single phase with a TEMCo New Static Phase Converter. Quality Guaranteed. eaclick here to po 1 Pricing Guide | Rotary Phase | Converters Light Starting DUTY NEW STATIC PHASE CONVERTERS Motor H.P. Range 7 ITTEMCo - % LSD 1/3-to-3/4 TEMCo=1 LSD TEMCo-31SD_| TEMCo - 5 LSD Is Call for this month's TEMC ‘0 - 7 % LSDII7 1/2 Reduced Price = Specials!! 1 (510) 770-0851 * Light Starting Duty Static Phase Converters are intended for use with machines that are started infrequently such as drill presses or bench grinders and are ideal for the Home shop. | Rotary Converter | Sizing Charts | a * Heavy Starting Duty Static Phase Converters are intended for use in the industrial environment where frequent starting/stopping occur and are designed for long service life under these conditions. HEAVY STARTING DUTY NEW STATIC PHASE CONVERTERS http://www. phaseconverter.com/static-converter.html 03/22/2001 http://www. phase-a-matic.com/vdescrpt.html PHASE-A-MATIC: Voltage Stabilizer Description & Installation VOLTAG E On This Page: @ Description STAB 1 LIZE R @ Installation Illustrations Designed to reduce voltage phase imbalance on Rotary Phase Converter Systems. xX Description: The normal operating voltage of the Rotary Phase Converter is 208-230VAC. The output voltage of a Rotary Phase Converter is normally higher than the input voltage under no-load and light-load conditions. In applications with high single-phase voltage (greater than 230V), the no- load or light-load output voltage may be excessive. Some CNC equipment will not work properly at the higher output voltage. The Phase-A-Matic Voltage Stabilizer is designed to reduce this higher voltage to near the input voltage. It will also help keep the output voltage stable during peak loads, thus helping CNC and other voltage-sensitive equipment to operate properly. Supplied in a NEMA type 1 enclosure with various sizes of knockouts. Intended for indoor use only in dry locations, but can be placed in a rain tight enclosure for use in wet or damp applications. Select a Voltage Stabilizer at least as large as the load it will operate. It does not have to be as large as the Rotary Phase Converter being used. Installation: INSTALLATION ILLUSTRATION PHASE Ll 3-PHASE NOTE: > FUSED Always use DISCONNECT SWITCH OR T-1 and T-2 MAGNETIC to operate STARTER magnetic NOT SUPPLIED WITH controls. CONVERTER ROTARY Page 1 of 2 03/22/2001 PHASE-A-MATIC: Voltage Stabilizer Description & Installation Page 2 of 2 CUR VYERIER VOLTAGE STABILIZER Home Page Products Page Contact Us How To Order http://www. phase-a-matic.com/vdescrpt.html 03/22/2001 Static phase converter, what is a static phase converter. When to select static and when to s.. Page 1 of 2 What is a static phase converter? Understanding the static phase converter can help you to choose between rotary and static phase converters. A static phase converter makes it possible to run a three-phase motor on single-phase power. The static phase converter does not actually generate three-phase power continuously as a rotary phase converter does, but uses capacitors to start the motor much like a single-phase motor does. Once the motor has started the capacitors are disconnected and motor continues to run on single-phase power, but because only two of three windings get power during running, power output is reduced to 2/3. A fifteen horsepower motor will start with the power of a fifteen but run as a ten for example. The high starting torque with reduced running power is an important factor when considering the use of a static phase converter. Static phase converters are often used with air compressors because of the high starting torque characteristics. In most of these applications the pulley diameter is reduced to accommodate the loss of horsepower after the compressor has started. Static phase converters are not well suited to machines that operate continuously close to the maximum rated horsepower of the motor that operates them. Gear head lathes are a good example of this. Although the static phase converter works fine on these lathes in the slower speeds, in the higher speeds the converter is able to start the lathe turning but the lack of rated horsepower makes these higher speed settings useless. A rotary phase converter is best suited for this application. Duty cycle (The percentage of time a motor is fully, or close to fully loaded during the time it runs) is another consideration when operating a three-phase motor on a static phase converter. If the machine is operated close to its full load for any length of time it is much more likely to over heat when using a static phase converter compared to running on three-phase power from a rotary phase converter, so this should also be taken into account. The two most common ‘pes of motors are Wye and delta wired. Some motors will not operate on a static phase converter because of the internal wiring of the motor are delta. Most domestic motors up to fifteen horsepower are usually Wye connected and can be run on a static phase converter. Domestic motors above fifteen horsepower are usually Wye connected but there are some which are delta connected. Delta winding is more common as the horsepower rating increases. Many imported motors are de/ta connected and will only work on a rotary phase converter. click on the product type to go to; Static Phase New Rotary Phase || Re-Manufactured Rotary Rotary Converter Converter Order Phase Converters Converters Converters Sizing Charts Converter If you have additional questions about your specific equipment after reading through our website please call (510)770-0851. We are always happy to assist you in choosing the correct model. Tower Electric Motor Company has experience producing single to three phase converters since 1968. TEMCo uses the latest proven technology to manufacture industrial grade rotary and static http://www. phaseconverter.com/what-is-static. html 03/22/2001 Static phase converter, what is a static phase converter. When to select static and when to s.. Page 2 of 2 converters. Our products are AC, single to three phase, 220v and 440v converters. All our phase converters are built to last using the highest quality standards and are backed by our warranty. When you want a phase converter that will run like clock work, turn to TOWER. Charts » Static Phase Converters * ReManufactured Rotary Converters Remember to bookmark this page! * Feel free to add a link to us! Site content Copywright 1999 Tower Electric Motor Company http://www. phaseconverter.com/what-is-static. html 03/22/2001 Choosing the right size TEMCo Rotary Phase Converter ye NS Page 1 of 2 Superior Rotary Phase Converters Choosing the right size TEMCo Rotary Phase Converter What is the HP of the largest three phase motor you will need to start? Is it Easy, Medium or Hard to start? (Click here for starting load help) Find the appropriate column and motor hp. (Easy, Medium or Hard) Consider your Total Motor Group Load. Chose the TEMCo Rotary Converter size that accommodates the power you will need by following the horizontal line to the right. 6. Be sure you have a large enough single phase supply breaker, if you don't you may need to rewire. Largest Motor to i Sar [otalMoiog) Gomer | Single rhwe | Acta Roe Easy [Medium “Hard | ep See Fuses Breaker Rating 2 [L415 1 5 10 [ 2 | 3 | 3 | 2 1.5 8 15 30— | 5 12 20 [ 4 [| 75 | 7.5 || 5 15 30 60 10 10 | 7.5 [25 40 Oe Ce is | 10 | 7.5 35 60 100 20 20 | 15 45 80 150 25 | 35 || 25 15 70 100 i5 | 4 = | 45 || 30 || 20 90 125 200 50 50 || 40 30 100 150 250 60 | * Call for further details or specific application questions. * Click here to determine if your specific application is Easy, Medium or Hard to Start. * Remember- using a larger phase converter than you currently need is safe, but one that is too small will not work. Also getting a size larger will help you plan for the future, in case you need http://www. phaseconverter.com/rotary-converter.sizing/ 03/22/2001 Choosing the right size TEMCo Rotary Phase Converter Page 2 of 2 additional power as you add new equipment. Call To Order! (510) 770-0851 Click here to return to the TEMCo Home Page Click here to send us a letter by email to info@phaseconverter.com. About Phase Converters * Electric Motors * Rotary Phase Converters * Rotary Converter Sizing Charts * Static Phase Converters * ReManufactured Rotary Converters Remember to bookmark this page and please add a link from your home page to: www. phaseconverter.com http://www. phaseconverter.com/rotary-converter.sizing/ 03/22/2001 Electrical Characteristics of SWGR Transmission Lines for Selected Conductors A. Series Impedance Zg = 1c + 0.00159-f + j-0.004657-f- Jog, Hl Yet) winnie. rc = resistance of conductor per mile f= frequence in Hz p = earth resistiavity in ohm meter GMR = geometric mean radius of conductor Conductor 4/0 ACSR Tc := .352 f := 60 p := 1000 GMR := .01826 P f zg4/0 := (rc + 0.00159-f) + .004657-f-log} 2160- *j f) Be” GMR zg4/0 = 0.447 + 1.588: Conductor 2/0 ACSR TC := .706 f := 60 p := 1000 GMR := .01451 P f zg2/0 := (re + 0.001598-f) + .004657-f-log] 2160- ‘j 2 t ) 6 GMR zg2/0 = 0.802 + 1.616i Conductor D220-124/25 Tc := 37 f := 60 p := 1000 GMR := .0217 P GMR ) Zgd220 := (re + 0.001598-f) + .004657-f-log} 2160- zgd220 = 0.466 + 1.567i B. Shunt Capactive Reactance xc=xatxe/3 in Megohms per mile xa=0.0683*60/f*log1/r Capacitive Reactance at 1 ft. spacing xe= 123/¢*log2h Zero Sequence Shunt Capactivie Reactance Factor where: h = conductor height above ground f = frequency r = radius of conductor in feet Conductor 4/0 ACSR h := 35 f := 60 12 60 xa ‘= eocss--oa( =) xe (= f r 12.3 -log(2-h f og(2-h) xc4/0 := xat+ = xc4/0 = 0.237 j Conductor 2/0 ACSR h := 35 f := 60 447 "EB 60 1 : Xa := 0.0683-—- log} — |xe := > 10g(2-h) f r f xc2/0 := xat+ ~ xc2/0 = 0.244 Conductor D200-124/25 h := 35 f := 60 - te xa ‘= 0.0683: Jog = xe = 3 jog(2-h) f r f xcd220 := xa+ = xcd220 = 0.212 SWGR North Feeder -] Kotlik Sheldon's Point | |_|77))__g ) Wind Turbine Farm =] Aniak Loy | Os SZ | 4 ots 44+ __;__,___,_| {"] Upper/Lower Kalskag mono oo" Bethel Frank J. Bettine, P.E., Esq. Project : Calista Region Energy Needs Study Prepared by : Frank Bettine Circuit File : C:/Program Files/MegaSys/PVlite/SWGR North Feeder alt1.cir GEN1__- Generator - Wind Turbine Farm - Fixed Load Rated kVA 1500 Terminal Voltage 6800 Voltage Rating 7200 Current in Amps 247 Volt Reg % 0 kVA 1677 kW Output Setting 1500 Device kW -1500 kVAr Output Setting -750 Device kVAr 750 Generator % R 0 Generator % X 0 Transient Reactance % 0 Subtransient X, % 0 GEN2__ - Generator - Bethel Generation - Variable Loadt Rated kVA 25000 Terminal Voltage 7181 Voltage Rating 7200 Current in Amps 1857 Volt Reg % 5 kVA 13337 kW Output Setting 0 Device kW -13287 kVAr Output Setting 0 Device kVAr -1163 Generator % R 0 Generator % X 0 Transient Reactance % 0 Subtransient X, % 0 T1i___- Transformer - - Delta - Delta, Rated kVA 2000 Primary Voltage 6800 Primary Voltage 7200 Secondary Voltage 77211 Secondary Voltage 80000 Primary Current 247 Percent Resistance 0 Secondary Current 22 Percent Reactance 5 Voltage V21 320 % Secondary Tap OO Voltage Drop % 2 kVA 1677 kW Flow 1500 kVAr Flow -750 T2___- Transformer - - Delta - Delta! Rated kVA 10000 Primary Voltage 7181 Primary Voltage 7200 Secondary Voltage 80388 Secondary Voltage 80000 Primary Current 1146 Percent Resistance 0 Secondary Current 103 Percent Reactance 5 Voltage V21 297 % Secondary Tap 0 Voltage Drop % 7 kVA 8230 kW Flow 8121 kVAr Flow -1339 Li___- Load - Kotlik! Load Rating, kVA 880 Terminal Voltage 77001 Voltage Rating 80000 Current in Amps 11 Power Factor 1 kVA 880 Device kW 748 Device kVAr 464 - Load - Emmonak~> Load Rating, kVA Voltage Rating Power Factor - Load - Alakanuk— L3 Load Rating, KVA Voltage Rating Power Factor - Load - Sheldon's Point-. Load Rating, kVA Voltage Rating Power Factor - Load - Aniak— Load Rating, KVA Voltage Rating Power Factor L6___- Load - Mt. Villaget Load Rating, KVA Voltage Rating Power Factor L7___- Load - St. Mary'st Load Rating, kVA Voltage Rating Power Factor - Load - Pilot Stationt Load Rating, kVA Voltage Rating Power Factor - Load - Marshallt Lo Load Rating, kVA Voltage Rating Power Factor 1490 80000 860 80000 300 80000 1380 80000 1290 80000 700 80000 800 80000 500 80000 Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr 76994 19 1490 1267 785 77034 11 860 731 453 77211 300 255 158 79423 17 1380 1173 727 77894 17 1290 1097 680 78130 700 595 369 78331 10 767 652 404 78910 425 263 Load Rating, kVA Voltage Rating Power Factor L11__- Load - Kalskags<- Load Rating, kVA Voltage Rating Power Factor L12__ - Load - Tuluksak> Load Rating, kVA Voltage Rating Power Factor L13___- Load - Akiak> Load Rating, kVA Voltage Rating Power Factor L14___- Load - Akiachak> Load Rating, kVA Voltage Rating Power Factor L15___- Load - Bethelt Load Rating, kVA Voltage Rating Power Factor 440 80000 650 80000 350 80000 540 80000 625 80000 5740 80000 Terminal Voltage Current in Amps kVA Device kw Device kVAr Terminal Voltage Current in Amps kVA Device kw Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kw Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr 79373 440 374 232 79773 650 342 80101 350 298 184 80167 540 459 284 80233 625 531 329 7181 799 5740 5166 2502 Frank J. Bettine, P.E., Esq. Project : Calista Region Energy Needs Study Prepared by : Frank Bettine Circuit File : C:/Program Files/MegaSys/PVlite/SWGR North Feeder.cir GEN1__- Generator - Wind Turbine Farm - Fixed Load - Disconnected Rated kVA Voltage Rating Volt Reg % kW Output Setting kVAr Output Setting Generator % R Generator % X Transient Reactance % Subtransient X, % 1500 7200 0 1500 -750 0 0 0 0 Terminal Voltage Current in Amps kVA Device kW Device kVAr GEN2__- Generator - Bethel Generation - Variable Load Rated kVA Voltage Rating Volt Reg % kW Output Setting kVAr Output Setting Generator % R Generator % X Transient Reactance % Subtransient X, % 25000 7200 eocoooon - Transformer -_- Delta - Delta 11 Rated kVA Primary Voltage Secondary Voltage Percent Resistance Percent Reactance % Secondary Tap 2000 7200 80000 0 5 0 - Transformer - - Delta - Delta T2 L1 Rated kVA Primary Voltage Secondary Voltage Percent Resistance Percent Reactance % Secondary Tap - Load - Kotlik Load Rating, KVA Voltage Rating Power Factor 10000 7200 80000 0 5 0 880 80000 Terminal Voltage Current in Amps kVA Device kW Device kVAr Primary Voltage Secondary Voltage Primary Current Secondary Current Voltage V21 Voltage Drop % kVA kW Flow kVAr Flow Primary Voltage Secondary Voltage Primary Current Secondary Current Voltage V21 Voltage Drop % kVA kW Flow kVAr Flow Terminal Voltage Current in Amps kVA Device kW Device kVAr eoooo eooooo esoooeooooo ecooooooogo eoooo L2 - Load - Emmonak Load Rating, kVA Voltage Rating Power Factor L3___- Load - Alakanuk Load Rating, kVA Voltage Rating Power Factor - Load - Sheldon's Point Load Rating, kVA Voltage Rating Power Factor - Load - Aniak L5 Load Rating, kVA Voltage Rating Power Factor L6___- Load - Mt. Village Load Rating, kVA Voltage Rating Power Factor L7___- Load - St. Mary's L8 Load Rating, kVA Voltage Rating Power Factor - Load - Pilot Station Lg Load Rating, kVA Voltage Rating Power Factor - Load - Marshall Load Rating, kVA Voltage Rating Power Factor 1490 80000 860 80000 300 80000 1380 80000 1290 80000 700 80000 800 80000 80000 Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kw Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr eoooo soooo soooo eoooo seoooo soooo soooo esoooo Load Rating, kVA Voltage Rating Power Factor 440 80000 L11__- Load - Lower/Upper Kalskag Load Rating, kVA Voltage Rating Power Factor L12___- Load - Tuluksak Load Rating, kVA Voltage Rating Power Factor L13___- Load - Akiak Load Rating, kVA Voltage Rating Power Factor L14___- Load - Akiachak Load Rating, kVA Voltage Rating Power Factor L15___- Load - Bethel ' Load Rating, kVA Voltage Rating Power Factor 650 80000 1 350 80000 540 80000 625 80000 5740 80000 Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kw Device kVAr eoooo soooo eoooo seoooo eoooo soooo Frank J. Bettine, P.E., Esq. Project : Calista Region Energy Needs Study Prepared by : Frank Bettine Circuit File : C:/Program Files/MegaSys/PVlite/SWGR North Feeder.cir GEN1__- Generator - Wind Turbine Farm - Fixed Load— Rated kVA 3000 Terminal Voltage 6993 Voltage Rating 7200 Current in Amps 457 Volt Reg % 0 kVA 3195 kW Output Setting 3000 Device kW -3000 kVAr Output Setting -1100 Device kVAr 1100 Generator % R 0 Generator % X 0 Transient Reactance % 0 Subtransient X, % 0 GEN2__ - Generator - Bethel Generation - Variable Loadt Rated kVA 25000 Terminal Voltage 7193 Voltage Rating 7200 Current in Amps 1621 Volt Reg % 5 kVA 11656 kW Output Setting 0 Device kW -11650 kVAr Output Setting 0 Device kVAr -376 Generator % R 0 Generator % X 0 Transient Reactance % 0 Subtransient X, % 0 T1___- Transformer - - Delta - Delta Rated kVA 2000 Primary Voltage 6993 Primary Voltage 7200 Secondary Voltage 80205 Secondary Voltage 80000 Primary Current 457 Percent Resistance 0 Secondary Current 41 Percent Reactance 5 Voltage V21 592 % Secondary Tap 0 Voltage Drop % 3 kVA 3195 kW Flow 3000 kVAr Flow -1100 T2___- Transformer -_- Delta - Delta! Rated kVA 10000 Primary Voltage 7193 Primary Voltage 7200 Secondary Voltage 80811 Secondary Voltage 80000 Primary Current 949 Percent Resistance 0 Secondary Current 85 Percent Reactance 5 Voltage V21 246 % Secondary Tap 0 Voltage Drop % 1 kVA 6823 kW Flow 6484 kVAr Flow -2126, L1___- Load - Kotlik! Load Rating, KVA 880 Terminal Voltage 80097 Voltage Rating 80000 Current in Amps 11 Power Factor 1 kVA 880 Device kW 748 Device kVAr 464 L2 - Load - Emmonak~> Load Rating, kVA Voltage Rating Power Factor - Load - Alakanuk— Load Rating, KVA Voltage Rating Power Factor - Load - Sheldon's Point L4 L5 Load Rating, kVA Voltage Rating Power Factor - Load - Aniak— Load Rating, kVA Voltage Rating Power Factor L6___- Load - Mt. Villaget Load Rating, kVA Voltage Rating Power Factor L7___- Load - St. Mary'st Load Rating, kVA Voltage Rating Power Factor - Load - Pilot Stationt Load Rating, kVA Voltage Rating Power Factor - Load - Marshallt Lo Load Rating, kVA Voltage Rating Power Factor 1490 80000 860 80000 300 80000 1380 80000 1290 700 80000 800 80000 Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr 80035 19 1490 1267 785 80062 11 860 731 453 80205 300 255 158 81244 17 1380 1173 727 80743 16 1290 1097 680 80908 700 595 369 81050 10 821 698 433 81463 425 263 Load Rating, kVA Voltage Rating Power Factor 440 80000 L11___- Load - Lower/Upper Kalskag— Load Rating, kVA Voltage Rating Power Factor L12__ -Load - Tuluksak— Load Rating, KVA Voltage Rating Power Factor L13___- Load - Akiak Load Rating, kVA Voltage Rating Power Factor L14___- Load - Akiachak> Load Rating, kVA Voltage Rating Power Factor L15__- Load - Bethelt Load Rating, kVA Voltage Rating Power Factor 650 80000 1 350 80000 540 80000 625 80000 5740 80000 Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kw Device kVAr Terminal Voltage Current in Amps kVA Device kw Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr 81708 440 374 232 81577 676 575 356 81246 350 298 184 80979 540 459 284 80877 625 531 329 7193 798 5740 5166 2502 SWGR West Feeder _ Wind Turbine Farm | GENT | ay + CO [4 | — 1 + | ! — a r 6 LJ LE} LJ u Ls Ls uw Newtok Frank Bettine, P.E., Esq. Project : Calista Energy Needs Study Prepared by : Frank Bettine Circuit File : C:/Program Files/MegaSys/PVlite/SWGR West Feeder.cir GEN1__- Generator - Wind Turbine Farm - Fixed Load! Rated kVA 1500 Terminal Voltage 7457 Voltage Rating 7200 Current in Amps 201 Volt Reg % 5 kVA 1500 kW Output Setting 1500 Device kw -1500 kVAr Output Setting 0 Device kVAr 0 Generator % R 0 Generator % X 0 Transient Reactance % (a) Subtransient X, % 0 GEN2_ - Generator - Bethel - Variable Load— Rated kVA 25000 Terminal Voltage 7190 Voltage Rating 7200 Current in Amps 1216 Volt Reg % 5 kVA 8744 kW Output Setting 0 Device kW -8720 kVAr Output Setting 0 Device kVAr -641 Generator % R 0 Generator % X 0 Transient Reactance % 0 Subtransient X, % 0 T1___- Transformer - - Delta - Deltat Rated kVA 2000 Primary Voltage 7457 Primary Voltage 7200 Secondary Voltage 82909 Secondary Voltage 80000 Primary Current 201 Percent Resistance 0 Secondary Current 18 Percent Reactance 5 Voltage V21 261 % Secondary Tap 0 Voltage Drop % 0 kVA 1500 kW Flow 1500 kVAr Flow 0 T2___- Transformer - - Delta - Delta— Rated kVA 10000 Primary Voltage 80854 Primary Voltage 80000 Secondary Voltage 7190 Secondary Voltage 7200 Primary Current 57 Percent Resistance 0 Secondary Current 629 Percent Reactance 5 Voltage V21 1811 % Secondary Tap 0 Voltage Drop % 1 kVA 4575 kW Flow -3841 kVAr Flow 2485 L1__- Load - Scammon Bay! Load Rating, kVA 1370 Terminal Voltage 81842 Voltage Rating 80000 Current in Amps 17 Power Factor 1 kVA 1370 Device kw 1165 Device kVAr 722 L2___- Load - Bethel Load Rating, kVA 5740 Terminal Voltage 7190 Voltage Rating 7200 Current in Amps 798 Power Factor 1 kVA 5740 Device kW 4879 Device kVAr 3024 L3___- Load - Hooper Bay» Load Rating, kVA 1530 Terminal Voltage 81781 Voltage Rating 80000 Current in Amps 19 Power Factor 1 kVA 1530 Device kW 1301 Device kVAr 806 L4___- Load - Chevakt Load Rating, KVA 1030 Terminal Voltage 82166 Voltage Rating 80000 Current in Amps 13 Power Factor 1 kVA 1030 Device kW 876 Device kVAr 543 L5__- Load - Newtokt Load Rating, kVA 300 Terminal Voltage 82909 Voltage Rating 80000 Current in Amps 4 Power Factor 1 kVA 322 Device kW 274 Device kVAr 170 L6___- Load - Kasigluk/Nunapitchukt Load Rating, kVA 1520 Terminal Voltage 81388 Voltage Rating 80000 Current in Amps 19 Power Factor 1 kVA 1520 Device kW 1292 Device kVAr 801 L7___- Load - Atmautluakt Load Rating, kVA 360 Terminal Voltage 81243 Voltage Rating 80000 Current in Amps 5 Power Factor 1 kVA 371 Device kW 316 Device kVAr 196 Frank Bettine, P.E., Esq. Project : Calista Energy Needs Study Prepared by : Frank Bettine Circuit File : C:/Program Files/MegaSys/PVlite/SWGR West Feeder.cir GEN1__- Generator - Wind Turbine Farm - Variable Load - Disconnected Rated kVA 1500 Terminal Voltage 0 Voltage Rating 7200 Current in Amps 0 Volt Reg % 5 kVA 0 kW Output Setting 1500 Device kW 0 kVAr Output Setting 0 Device kVAr 0 Generator % R 0 Generator % X 0 Transient Reactance % 0 Subtransient X, % 0 GEN2_- Generator - Bethel - Variable Load Rated kVA 25000 Terminal Voltage 7184 Voltage Rating 7200 Current in Amps 1437 Volt Reg % 5 kVA 10323 kW Output Setting 0 Device kW -10272 kVAr Output Setting 0 Device kVAr -1025 Generator % R 0 Generator % X 0 Transient Reactance % 0 Subtransient X, % 0 T1___- Transformer - - Delta - Deltat Rated kVA 2000 Primary Voltage 7344 Primary Voltage 7200 Secondary Voltage 81603 Secondary Voltage 80000 Primary Current 0 Percent Resistance 0 Secondary Current 0 Percent Reactance 5 Voltage V21 0 % Secondary Tap 0 Voltage Drop % 0 kVA 0 kW Flow 0 kVAr Flow 0 T2___- Transformer - - Delta - Delta Rated kVA 10000 Primary Voltage 80649 Primary Voltage 80000 Secondary Voltage 7184 Secondary Voltage 7200 Primary Current 72 Percent Resistance 0 Secondary Current 801 Percent Reactance 5 Voltage V21 2306 % Secondary Tap 0 Voltage Drop % 1 kVA 5811 kW Flow -5393 kVAr Flow 2165 L1__- Load - Scammon Bay! Load Rating, kVA 1370 Terminal Voltage 80418 Voltage Rating 80000 Current in Amps 17 Power Factor 1 kVA 1370 Device kw 1165 Device kVAr 722 L2___- Load - Bethel Load Rating, kVA 5740 Terminal Voltage 7184 Voltage Rating 7200 Current in Amps 799 Power Factor 1 kVA 5740 Device kW 4879 Device kVAr 3024 L3___- Load - Hooper Bay> Load Rating, kVA 1530 Terminal Voltage 80357 Voltage Rating 80000 Current in Amps 19 Power Factor 1 kVA 1530 Device kW 1301 Device kVAr 806 L4___- Load - Chevakt Load Rating, kVA 1030 Terminal Voltage 80756 Voltage Rating 80000 Current in Amps 13 Power Factor 1 kVA 1030 Device kW 876 Device kVAr 543 L5___- Load - Newtokt Load Rating, kVA 300 Terminal Voltage 81603 Voltage Rating 80000 Current in Amps 4 Power Factor 1 kVA 312 Device kW 265 Device kVAr 164 L6___- Load - Kasigluk/Nunapitchukt Load Rating, kVA 1520 Terminal Voltage 80828 Voltage Rating 80000 Current in Amps 19 Power Factor 1 kVA 1520 Device kW 1292 Device kVAr 801 L7___- Load - Atmautluakt Load Rating, kVA 360 Terminal Voltage 80777 Voltage Rating 80000 Current in Amps 5 Power Factor 1 kVA 367 Device kW 312 Device kVAr 193 Frank Bettine, P.E., Esq. Project : Calista Energy Needs Study Prepared by : Frank Bettine Circuit File : C:/Program Files/MegaSys/PVlite/SWGR West Feeder.cir GEN1__- Generator - Wind Turbine Farm - Fixed Load! Rated kVA 3000 Terminal Voltage Voltage Rating 7200 Current in Amps Volt Reg % 5 kVA kW Output Setting 3000 Device kW kVAr Output Setting 0 Device kVAr Generator % R 0 Generator % X 0 Transient Reactance % 0 Subtransient X, % 0 GEN2__- Generator - Bethel - Variable Load— Rated kVA 25000 Terminal Voltage Voltage Rating 7200 Current in Amps Volt Reg % 5 kVA kW Output Setting 0 Device kW kVAr Output Setting 0 Device kVAr Generator % R 0 Generator % X 0 Transient Reactance % 0 Subtransient X, % 0 T1___- Transformer - - Delta - Deltat Rated kVA 2000 Primary Voltage Primary Voltage 7200 Secondary Voltage Secondary Voltage 80000 Primary Current Percent Resistance 0 Secondary Current Percent Reactance 5 Voltage V21 % Secondary Tap 0 Voltage Drop % kVA kW Flow kVAr Flow T2___- Transformer - - Delta - Delta— Rated kVA 10000 Primary Voltage Primary Voltage 80000 Secondary Voltage Secondary Voltage 7200 Primary Current Percent Resistance 0 Secondary Current Percent Reactance 5 Voltage V21 % Secondary Tap 0 Voltage Drop % kVA kW Flow kVAr Flow L1__- Load - Scammon Bay! Load Rating, KVA 1370 Terminal Voltage Voltage Rating 80000 Current in Amps Power Factor 1 kVA Device kW Device kVAr 7515 399 3000 -3000 7192 1003 7210 -7191 -532 7515 83702 399 36 517 3000 3000 80910 7192 43 473 1361 3442 -2312 2550 82705 17 1370 1165 722 L2 - Load - Bethel L3___- Load - Hooper Bay - Load - Chevakt L4 - Load - Newtokt L5 Load Rating, kVA Voltage Rating Power Factor Load Rating, kVA Voltage Rating Power Factor Load Rating, kVA Voltage Rating Power Factor Load Rating, kVA Voltage Rating Power Factor 5740 7200 1530 80000 1030 80000 300 80000 - Load - Kasigluk/Nunapitchukt L6é - Load - Atmautluakt L7 Load Rating, KVA Voltage Rating Power Factor Load Rating, kVA Voltage Rating Power Factor 1520 80000 1 360 80000 Terminal Voltage Current in Amps kVA Device kw Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kw Device kVAr 7192 798 5740 4879 3024 82645 19 1530 1301 806 83022 12 1030 876 543 83702 328 279 173 81679 19 1520 1292 801 81471 373 317 197 Kipnuk SWGR South Feeders Bethel G) [ + L_} Jus rE cress nirnesetercnnane th a c|4 | 2 » |] 2! | 15 5 =A [| Js {| _ | | aa TT | 6 |7f | Lj — | 7 | | Us 7 T fo] fe lo —ts | — 1 oP | Goodnews Bay | 0s G L10 _ ‘ ~/ Wind Turbine Farm 1 | Te “ GEN2 r 1" “112 | : 12 ——113 | i 13 116 | 14 Las Tununak Prepared by :Frank Bettine Circuit File : C:/Program Files/MegaSys/PVlite/SWGR South Feeders alt1.cir GEN1__- Generator - - Variable Load! Rated kVA 25000 Voltage Rating 7100 Volt Reg % kW Output Setting kVAr Output Setting Generator % R Generator % X Transient Reactance % Subtransient X, % esooooon GEN2__- Generator - - Fixed Load— T1 T2 L1 Rated kVA 1500 Voltage Rating 7200 Volt Reg % 5 kW Output Setting 1500 kVAr Output Setting -2000 Generator % R 0 Generator % X 0 Transient Reactance % 0 Subtransient X, % 0 - Transformer - - Delta - Deltat Rated kVA 10000 Primary Voltage 7200 Secondary Voltage 80000 Percent Resistance 0 Percent Reactance 5 % Secondary Tap 0 - Transformer -_- Delta - Delta Rated kVA 2000 Primary Voltage 7200 Secondary Voltage 80000 Percent Resistance 0 Percent Reactance 5 % Secondary Tap 0 - Load - Bethel) Load Rating, KVA 5740 Voltage Rating 7200 Power Factor 1 L2___- Load - Napakiak— Terminal Voltage Current in Amps kVA Device kw Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr Primary Voltage Secondary Voltage Primary Current Secondary Current Voltage V21 Voltage Drop % kVA kW Flow kVAr Flow Primary Voltage Secondary Voltage Primary Current Secondary Current Voltage V21 Voltage Drop % kVA kW Flow kVAr Flow Terminal Voltage Current in Amps kVA Device kW Device kVAr 7106 775 9542 -9530 489 6594 219 2500 -1500 2000 7106 80398 474 43 123 5828 4651 -3513 6594 77706 219 20 284 2500 1500 -2000 7106 466 5740 4879 3024 Load Rating, kVA Voltage Rating Power Factor L3___- Load - Napaskiak> Load Rating, kVA Voltage Rating Power Factor - Load - Kwethluk— Load Rating, kVA Voltage Rating Power Factor - Load - Tuntutuliak— L6 Load Rating, kVA Voltage Rating Power Factor - Load - Eek Load Rating, KVA L7 Voltage Rating Power Factor - Load - Kongiganak> L8 Load Rating, kVA Voltage Rating Power Factor - Load - Quinhagak— Load Rating, kVA Voltage Rating Power Factor L9___- Load - Kwigillingok> L10 Load Rating, kVA Voltage Rating Power Factor - Load - Goodnews Ba 390 80000 490 80000 730 80000 475 80000 340 80000 490 80000 750 80000 285 80000 Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr 80356 390 332 205 80676 490 417 258 80590 730 621 385 79834 475 404 250 82485 340 289 179 79223 490 417 258 83545 750 638 395 78953 285 242 150 Voltage Rating Power Factor L11__- Load - Kipnuk> Load Rating, KVA Voltage Rating Power Factor L12___- Load - Chefornak— Load Rating, KVA Voltage Rating Power Factor L13__- Load - Nightmute— Load Rating, kVA Voltage Rating Power Factor L14__- Load - Toksook Bay Load Rating, kVA Voltage Rating Power Factor L15___ - Load - Tununakt Load Rating, KVA Voltage Rating Power Factor 80000 920 80000 80000 300 80000 750 80000 400 80000 Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr 380 323 200 77706 920 782 485 77704 440 374 232 77592 300 255 158 77426 750 638 395 77401 400 340 211 Prepared by : Frank Bettine Circuit File : C:/Program Files/MegaSys/PVlite/SWGR South Feeders alt1.cir GEN1__- Generator - - Variable Load! Rated kVA 25000 Voltage Rating 7100 Volt Reg % kW Output Setting kVAr Output Setting Generator % R Generator % X Transient Reactance % Subtransient X, % eooooon Terminal Voltage Current in Amps kVA Device kW Device kVAr GEN2__- Generator -_- Fixed Load - Disconnected m1 T2 L1 Rated kVA 1500 Voltage Rating 7200 Volt Reg % 5 kW Output Setting 1500 kVAr Output Setting -2000 Generator % R 0 Generator % X 0 Transient Reactance % 0 Subtransient X, % 0 - Transformer - - Delta - Deltat Rated kVA 10000 Primary Voltage 7200 Secondary Voltage 80000 Percent Resistance 0 Percent Reactance 5 % Secondary Tap 0 - Transformer - - Delta - Deltas Rated kVA 2000 Primary Voltage 7200 Secondary Voltage 80000 Percent Resistance 0 Percent Reactance 5 % Secondary Tap 0 - Load - Bethel) Load Rating, kVA 5740 Voltage Rating 7200 Power Factor 1 L2___- Load - Napakiak— Terminal Voltage Current in Amps kVA Device kW Device kVAr Primary Voltage Secondary Voltage Primary Current Secondary Current Voltage V21 Voltage Drop % kVA kW Flow kVAr Flow Primary Voltage Secondary Voltage Primary Current Secondary Current Voltage V21 Voltage Drop % kVA kW Flow kVAr Flow Terminal Voltage Current in Amps kVA Device kW Device kVAr 7141 931 11512 -11110 3016 seoooo 7141 81817 702 182 8678 6231 eoooeo°o9o 7141 5740 4879 3024 L3 Load Rating, kVA Voltage Rating Power Factor - Load - Napaskiak Load Rating, kVA Voltage Rating Power Factor - Load - Kwethluk— L4 L5 L6 Load Rating, kVA Voltage Rating Power Factor - Load - Tuntutuliak— Load Rating, kVA Voltage Rating Power Factor - Load - Eek Load Rating, KVA L7 Voltage Rating Power Factor - Load - Kongiganak~ Load Rating, kVA Voltage Rating Power Factor L8__- Load - Quinhagak— Load Rating, KVA Voltage Rating Power Factor L9___- Load - Kwigillingok— L10 Load Rating, kVA Voltage Rating Power Factor - Load - Goodnews Ba Load Rating, kVA 390 80000 490 80000 730 80000 475 80000 340 80000 490 80000 750 285 80000 380 Terminal Voltage Current in Amps kVA : Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage 82100 390 332 205 82110 490 417 258 82027 730 621 385 83246 475 404 250 83985 340 289 179 83695 490 417 258 85089 750 638 395 83848 285 242 150 85605 Voltage Rating Power Factor L11__- Load - Kipnuk-— Load Rating, KVA Voltage Rating Power Factor L12__-Load - Chefornak— Load Rating, kVA Voltage Rating Power Factor L13___- Load - Nightmute— Load Rating, kVA Voltage Rating Power Factor L14___- Load - Toksook Bay Load Rating, kVA Voltage Rating Power Factor L45___- Load - Tununakt Load Rating, KVA Voltage Rating Power Factor 80000 920 80000 440 80000 300 80000 750 80000 400 80000 Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr Terminal Voltage Current in Amps kVA Device kW Device kVAr 380 323 200 84065 920 782 485 84136 440 374 232 84108 300 255 158 83972 750 638 395 83951 400 340 211 STAR Way - Fiber Optic Aerial Cables Systems Page 1 of 2 CORNING English Search Contact CablesHome | Discoverinc Beyond Im News & Events Products & Solutions ContactCenter AboutUs Careers Investor Relations Reeder eee e eee ere re ese s nena eeses esses eeeeeseeseesesssessessesesesesene may Fiber Optic Aerial Cable Systems STARWay « STARWay Optical Ground Wire / Optical Phase Conductor OPGW ADSS AD-Lash Accessories Design Optical element: Central aluminium buffer tube, containing single fibers or fiber bundles in a filling compound Armoring: Single or multi-layer design; round wires of Al-alloy and Al-clad steel or galvanized steel Features Central buffer tube design provides ® optimum protection of the fibers against mechanical stresses and lightning High reliability & long lifetime ® less additional loads on towers due to the low weight and small outer diameter of the cable Protection of the towers " a wide range of fiber count within the same cable type Flexibility Experience 20 years design and manufacturing Worldwide 12,000 km cable-km installed or under contract Solutions even for extreme operational conditions http://www.corningcablesystems.de/en/products/starway/opgw/index.htm 03/05/2007 “Col ng Cable Systems CORNING STARWay OPGW SINGLE LAYER DESIGN (DAB) APPLICATION Optical Groundwires to be installed along overhead power lines. FEATURES & BENEFITS @ Central tube design provides optimum protection of fibers against mechanical stresses and lightning ™ Minimized additional loads due to the small outer diameter and low weight Aluminum-alloy wire Aluminum tube § High fiber counts up to 96 and variance in fiber count Aluminum-clad for the same cable type steel wire Filling Compound Fibers or Fiberbundles @ Fiber bundles (12 each) for more than 12 fibers PROPERTIES No. of armoring layers: 1 Standard attenuation values* for the fibers: Armoring material: Al-alloy (AA) and/or 0.36 dB/km @ 1310nm Al-clad steel (ACS) + 0.22 dB/km @ 1550 nm Storage temperature: -40 °C to +80°C Standard fiber counts® are 12/24/36/48/60/72/84/96 Installation temperature: -10 °C to +50 °C Operation temperature: -40 “C to +80 °C * other options on request Corning Cable Systems « P.O. Box 70 03 09 + 81303 Munich + Germany + www.corning.com/cablesystems/europe > aca naan TECHNICAL DATA Urs Lig alc eg 3 ee Sea lk es es ee nse ig fe.g. 012) * '$-20-15/29-100KEQ 'S-20-00/44-0xxEQ S-20-00/49-100E9 'S-20-00/57-xxxEg S-20-25/25-10KEQ S-20-28/28-xxxEg S-20-29/20-xxxEQ S-40-00/81-xxxEQ S-40-42/21-20KEQ S-60-41/41-2XxEQ 'S-60-31/61-200KE9, S-60-51/26-xxxEQ 'S-80-61/20-100KE9 $-100-61/31-xxxEQ, 4 7 4 7 3 23 4 25 a 7 24 30 48 30 36 35 96 35 96 2 36 a 48 41 48 “3 48 58 84 62 60 68 48 B 84 94 pe Bt VERBSYSSLAISK HR SSEVS res Sree Ry 162 162 no no 162 162 no 162 no 92 83 92 a rd ORDER INFORMATION Bee eee ag ee S-40-29/29-10xEQ S-40-34/34-00KEQ S-40-00/81-xxxEg S-40-42/21-xXXEQ S-60-41/41-xxxEQ S-60-31/6190xEQ $-60-51/26-xxxEg S-80-61/20-10xE9 S-100-61/31-xxxEg OE 12, 24, 36, 48 12, 24, 36, 48 12, 24, 36, 48 24, 36, 48, 60, 72, 84 12, 24, 36, 48, 60 12, 24, 36, 48 24, 36, 48, 60, 72, 84 Cul i REEL SIZES AND Max. DELIVERY LENGTHS Reel Size (mm) and max. Cable Delivery Length (m) Alaa eee Pee eee a (rir) 'S-20-15/29-2100KEQ. '$-20-00/44-xxxEQ Srl) Coefficient SIL 45 13,0 Bo 3,0 15,6 15,6 165 13,0 30 15,6 15,6 13,0 ™ 15,6 45 arAl 18,1 7 eS Ry 4 faire esse) Cia PIL SKIP SSSSSVSVSEL © S DE aig S-20-00/49-10xEg 4.200 6.000 : “/ 'S-20-00/57-xxxEg 4.200 6.000 . $-20-25/25-10KEQ 4200 6.000 - - $-20-28/28-xxxEQ 4.200 6.000 - - S-20-29/20-xxxEQ 4.200 6.000 : = 'S-40-00/68-xxxEg 3.500 5.400 6.000 S-40-00/59-00xEQ 3.500 5.400 6.000 - S-40-29/29-xxxEg 3.500 5-400 6.000 . S-40-34/34100E9 3.500 5-400 6.000 - 4 |S-40-00/81-xxxEQ 2.900 4500 4.900 6.090 1S-40-42/21-20KEQ 3.500 5-400 6.000 - S-60-41/4)-xxxEQ 2.900 4500 4-900 6.000 /S-60-31/61-xxxKEQ = 3.700 4100 6.000 S-60-51/26-xxxEQ 2.900 4.500 4-900 6.000 S-80-61/20-200KEQ 2.900 4500 4900 6.000 'S-100-61/31-xxxEQ - 3.700 4.100 6.000 * other options on request Corning Cable Systems « P.O. Box 70 03 09 + 81303 Munich + Germany » www.corning.com/cablesystems/europe |All nghts reserved This pubtcation mus! not be Feproduied oF Copued Wn any way whalonve: withoul the express Consent ‘Subject to avadabilty and technical moddications Corning Cable Systems Gmbr & Ca. KG reserves the sight to wmprove. en of Cornung Cable Systems Combi te Co KC. ermine modity Corning Cable Systems products without priot notihcabon,sncluding {and i particula’ technical Gata and other wtormation soout Wuch products There ns no lex! Obligation Lo supply 2 spect product LO a precise specCthcaton unt 8 Dancing Order» accepted by Cormng Cabbie Systerm, Gripes ke Co. KC Printed in Germany COPYRIGHT ©2001 Orote No C1-B38 1 7600/ CCS 0201x aed fe oun) CORNING STARWay OPGW DOUBLE LAYER DESIGN (DABB) APPLICATION Optical Groundwires to be installed along overhead power lines. FEATURES & BENEFITS ® Central tube design provides optimum protection of fibers against mechanical stresses and lightning ® Minimized additional loads due to small outer diameter and low weight @ High fiber counts up to 96 and variance in fiber count for the same cable type @ Fiber bundles (12 each) for more than 12 fibers PROPERTIES No. of armoring layers: 2 Standard attenuation values* for the fibers: Armoring material: Al-alloy (AA) and 0.36 dB/km @ 1310nm + 0.22 dB/km @ 1550 nm Al-clad steel (ACS) Standard fiber counts® are 12/24/36/48/60/72/84/96 Storage temperature: -40 °C to +80°C Installation temperature: +10 °C to +50 °C Operation temperature: -40 °C to +80 °C * other options on request » Corning Cable Systems + P.O. Box 70 03 09 * 81303 Munich « Germany + www.corning.com/cablesystems/europe TECHNICAL DATA aur Bree gel (20l | ae Load Bearing Le feritetsil4 ier ras Piet: CY ib ssa a D160-103/15-xxxEg Di60-092/44-10xEQ Di60-098/29-xxxEg D180-108/20-10xE9 DiB0-088/59-xxxEg D180-107/29-%0KEQ D180-099/49-xxxEg D200-121/415-100E9 D220-124/25-xxxE9 0240-118/29-xxEQ 1D260-127/42-xxxEQ 10320-148/21-20aKEQ D380-154/51-xxxEg 10460-180/26-20xEQ SSRESELERGERREREL BSSBSARBLegaesy ORDER INFORMATION B33 | eee Pirie eget Be (e.g. 012 ; 096) D120-074/44-10xEQ 1D140-079/49-xxxEg D140-088/29-100E9 D160-103/15-xxxEg D160-092/44-20%EQ 1D160-098/29-xxxEg 12, 24, 36,48 D180-108/20-xxxEg 12, 24, 36, 48 D180-088/59-xxxEg 48, 60, 72, 84, 96 Di80-107/29-xxxEQ 12,24 Di80-099/49-xxxEg 12, 24, 36, 48 D200-121/15-0KEg 12,24 D220-124/25-xxxEg 12, 24, 36, 48 0240-118/29-x0xEQ 48, 60, 72, 84,96 1D260-127/42-xxxEg 12, 24, 36,48 1D320-148/21-.0KE9 12, 24, 36, 48 D380-154/51-xxxE9 12, 24, 36, 48, 60 1D460-180/26-xxxE9 12, 24, 36, 48, 60 REEL SIZES AND Max. DELIVERY LENGTHS Reel Size (mm) and max. Cable Delivery Length (m) yrs Be Dig0-079/49-xxxEg 3.300 4-800 5.600 6.000 D140-088/29-100xEQ 3-700 5-400 6.000 -_s 0160-103/15-xxxEg 3-700 5-400 6.000 - 1D160-092/44-xxxEQ 3.300 4-800 5.600 6.000 D160-098/29-xxxEg 3.300 4.800 5.600 6.000 ¥ D180-108/20-0xE9 3-300 4800 5.600 6.000 . D180-088/59-xxxEg - 4-300 5.100 6.000 01B0-107/29-200KEQ 3.300 4-800 5-600 6.000 \ Di80-099/49-xxxEg : 4.300 5.100 6.000 D200-121/15-x%00KEQ 3.300 4-800 5.600 6.000 \ D220-124/25-xxxE9 - 4.300 5.100 6.000 D2g0-118/29-xxxEQ : 4-300 5-100 6.000 D260-127/42-.0xEg - 3-800 4400 6.000 D320-148/21-100E9 : 3.800 4400 6.000 D380-154/51-xxxEQ : - 3-500 , 6.000 1D460-180/26-2x0xEQ : - 3.500 6.000 * other options on request Corning Cable Systems « P.O. Box 70 03 09 + 81303 Munich + Germany » www.corning com/cablesystems/europe All nghts reserved Thvs publication must not be reproduced oF copied in any way whatsoever without the express convent in witing of Comming Cable Systems Ganbe &e Co. KC. Subject to avadabulty and technucal modifications Corming Cable Systems GmbH & Co KG reserves the right to improve. enhance oF otherwise madity Corning Cable Systems products without prios notification, including, ‘and mn particule’ technical Gata and other information about 4uch products Theve ms no legal ObNgation TO Supply 4 Speci product to 4 Precise specication until a binding order ms accepted by Corrung Cable Systems Crm be Co. KG Printed in Germany COPYRIGHT ©200" Orore No C1839 -1-2600/ CCS 0201 138 KV & 230 KV TRANSMISSION SYSTEM 1. Load Flow Analysis A very basic load flow analysis was conducted to evaluate the electrical performance of the proposed 138 kV power line between Bethel and the mine site built along Route D and of the 230 kV transmission line built along Route E. These analysis were conducted using the PowerWorld Simulator. Results are attached and are summarized in the following paragraphs. e 138 kV Transmission Line Bethel to Mine Site (Route D) This 175 mile long transmission line alternative was evaluated using both 556 and 795 ACSR, under 60 MW and open circuit power transfer conditions. As expected the use of 795 ACSR conductor resulted in lower line losses and superior electrical performance. The results of the evaluation indicate the line will provide acceptable electrical performance. However, substantial capacitive reactance must be added at the mine site to maintain receiving end voltage within acceptable limits under 60 MW transfer conditions, while substantial inductive reactance must be added under open circuit conditions. This suggests that a static var compensation system (SVCS) may be necessary to stabilize receiving end voltage. However, since the mine load is expect to remain relatively constant, voltage regulation might be achieve through the use of switched capacitors and reactors rather the a SVCS. The electrical performance of the transmission line will be examined in more detail in Phase II of the study. The electrical characteristics of the transmission line were also examined using the assumption that the section of the line between Bethel and Lower Kalskag, a distance of approximately 80 miles, was built using 556 ACSR and the remaining 100 miles was built using 795 ACSR. The results of this evaluation indicated this “hybrid” line would provide acceptable electrical performance but that line losses would increase by about 20%. This purpose of this evaluate was to determine that if a SWGR transmission line were built between Bethel and Lower Kalskag using 556 ACSR, could this section of line then be converted it a three phase line, at a later date, to supply the mine load. The result of the evaluation suggests that use of 556 ACSR for the first 80 miles would provide acceptable electrical performance. e 230 kV Transmission Line (Route B) This 175 mile long transmission line alternative was evaluated using and 795 ACSR, under 60 MW and open circuit power transfer conditions. As expected the results of the analysis revealed significant receiving end voltage variations between full load and no load, requiring the addition of inductive reactive compensation at both ends of the line. Also as expected this line is capable of provides satisfactory electrical performance. Donlin Creek - 60 MW load at 0.95 PF 60 MW 14.0 MVR 0 MVR 2 4.61 MWLine Loss 1.00 pu -25.03 Deg 215.00 MVA 138 kV Transmission Line Line Thermal L' 180 miles in length 795 ACSR 1.00 p 0.00 Deg Bethel Bus 1 64.6 MW -6.4 MVR Donlin Creek - Open Circuit Donlin Bus 215.00 MVA 138 kV Transmission Line Line Thermal Limit 180 miles in length 1.00 pu 0.00 Deg 230 kV Transmission Line From Beluga Donlin Creek - 60 MW Load at .95 PF 180.00]MVA Line Thermal Limit 60.0 MW 29,0 MVR 2 Donlin Bus 1.57 MW Line Loss 230 kV Transmission Line 330 miles In length 795 ACSR 0.0 MVR Bethel Bus 61.6 MW -15.0 MVR 230 kV Transmission Line From Beluga Donlin Creek - Open Circuit Donlin Bus Line Thermal Limit 0.0 MW 0.14 MW ss Line Loss 230 kV Transmission Line 330 miles in length 795 ACSR 0.0 MVR Bethel Bus 0.1 MW -46.8 MVR 2. Scoping Report For an Electrical Transmission Line to Serve the Kuskokwim Region Matanuska Electric Association, Inc. (MEA) has, at the request of Calista Corporation, provide Calista with a scoping report that addressed the construction of a transmission line from the MEA service area into the Kuskokwim Region. The report is attached for information purposes. The information and concepts outlined in the MEA report do not differ in any substantive manner from those present in this study. May-30-01 02:21pm = From= 7-382 P.02/08 ~=- F083 Matanuska Electric ZB Association, Inc. P.O. Box 2929 Palmer, Alaska 99645-2929 Telephone: (907) 745-3231 Fax: (907) 745-9328 May 10, 2001 Mr. Matthew Nicolai, President & CEO ’ Calista Corporation 301 Calista Court, Suite A Anchorage, AK 99518 Dear Mr. Nicolai: Enclosed is a copy of the scoping report | received James D. Hall; P.E. regarding an electrical transmission line to serve the Kuskokwim region. | look forward to visiting with you regarding this possiblity. Sincerely, Donne Wayne D. Carmony General Manager prw enclosure May-30-01 02:21pm = From- 7-362 =P.03/08 F083 SCOPING REPORT FOR AN ELECTRICAL TRANSMISSION LINE TO SERVE THE KUSKOK WIM REGION May-30-01 02:22pm = From- T-382 -P.04/08 = F083 May 4, 2001 Wayne D. Carmony General Manager Matanuska Electric Association PO Box 2929 Palmer, AK 99645 Dear Mr. Carmony: Electrical energy is much less expensive in the Railbelt than in the Kuskokwim region. This is due to the availability of low cost natural gas, coal, and hydroelectric sources, as opposed to the diesel fuel required along the Kuskokwim River drainage. If the Federal government funds construction of the Susitna dams on the Susitna River in the Matanuska-Susitna Borough, then more abundant low cost hydroelectric energy will become available in the Railbelt. Any Susitna hydroelectric project that is constructed will be connected to the existing Anchorage-Fairbanks intertie, With this in mind, this report will show lines connecting McGrath, which is a community in the Kuskokwim region within the Calista Native Corporation area, to the Douglas substation near Willow, which is on the existing intertie, A map is attached showing an approximate route for such lines. The transmission lines discussed in this report are all overhead lines, consisting of “XX” shaped steel towers supporting three wires of steel reinforced aluminum. The 138 KV towers are about seventy feet tall and about thirty feet wide. The 345 KV towers are about one hundred ten feet tall and about sixty feet wide. All of the towers would be of weathering steel that has a rusty brown color. The three wires would be suspended below a horizontal cross member on porcelain or epoxy insulators. Many transmission lines, including the existing intertie, have two addition steel ground wires above the three main wires to protect them from direct lightning strikes. The lines proposed in this report do not include these shield wires. This is because of the low incidence of lighting in the area of the proposed line. These lines are the type used on the existing intertie, and many other transmission lines in Alaska. These lines have in general performed well. There are problems with differential snow loading on the existing intertie, but these problems can be mitigated in future lines with proper design consideration. May~30-01 02:22pm = From= T-382-P.05/08 = F083 There are two voltage options that will be discussed for this line. One of these options is 345 KV. Much of the existing Railbelt intertie was designed for future operation at 345 KV. The other is 138K'V, which is the present operating voltage of the existing intertie, and a commonly used transmission voltage in the Railbelt. If the Susitna dams are constructed, then the operating voltage of the existing intertie will almost assuredly be increased to either 230 KV or 345 KV. A 345 KV line provides greater capacity, but the transmission towers become too heavy to be carried in a single helicopter pick, and 345KV class station equipment is much more expensive. If construction relies on helicopters instead of being built in conjunction with the construction of a road into the region, much higher costs can be anticipated. A typical 345KV line could carry 300 megawatts, while a typical 138K line could carry "140 megawatts. Long, lightly loaded, transmission lines, such as a line serving the Kuskokwim region, will need equipment to prevent over-voltages. Ifthe line is to be operated as a radial line, with no online generation in the Kuskokwim region, then voltage control could consist of shunt reactors. If local generation were used as backup for the line, then operationally, the line would have to be turned off before the local generation could be turned on, resulting in a brief outage. If the line is operated along with the local generation, then a much more expensive static var control systems could be required. A line from the Douglas substation near Willow in the Matanuska-Susitna Borough (an area served by Matanuska Electric Association) to McGrath in the Kuskokwim region would be about two hundred twenty miles in length. A cursory estimate of cost for a 138 KV line is $550,000 per mile for a line cost of about $121,000,000. Substations at each end could be expected to add an additional $3,000,000. An estimate for a 345 KV line is about $900,000 per mile for a line cost of about $198,000,000. Substations at each end could be expected to add an additional $5,000,000. These substations would include shunt reactors for voltage control. Static var systems increase cost by an estimated $40,000,000. One-line diagrams for each substation are attached. Taps to the line to serve small communities along the route would be possible. A ground- mounted substation to connect to a town distribution system, and provide three phase power, would cost about $1,000,000. Smaller interconnections of a more limited nature are technically feasible. The area from Rainy Pass Lodge to Rohn Roadhouse is very rugged. Avalanche areas would need to be further considered during design. The route shown on the attached map, and used to assess the length of the line, goes through Goodman Pass, rather than Rainy pass. The route is assumed to have less avalanche danger. May-30-01 02:22pm = From- T-382-P.06/08 «= F~083 Preliminary cost estimates are based on winter construction using tracked vehicles to drive foundation pilings, and summer construction using helicopters to set towers, and string wire. Other types of construction could result in higher costs. No estimates are included for engineering, right of way acquisition, or environmental studies. With cooperation from government, and Native organizations, right of way cost should be minimal. Cost of environmental studies should be assumed to be significant in scope and cost. This report is based on recent cost estimates for transmission lines, and do not reflect actual field conditions that may be encountered on this project. A comprehensive field investigation, engineering design, and construction schedule would be required to prepare a final cost estimate. As previously mentioned, an alternative that could lower overall cost of transmission construction would be to construct a road along the route. In my professional judgment, it is technically feasible using mature technology and existing construction procedures to construct a transmission line from Matanuska Electric’s Douglas substation (Willow) to the Kuskokwim region (McGrath). It is also technically feasible to operate the line using available technology and modern practices. If you require any further analysis, please do not hesitate to contact me. Sincerely, James D. Hall P.E. PROPOSED McGRATH SUBSTATION. 138 kV BUS —-— — -— eee ae i vane 138 kV LINE | ai TO DOUGLAS DISCONNECT DISCONNECT (WILLOW) ni SWITCH a SWITCH oe CIRCU a Ee a i] DISCONNECT iN DISCONNECT SWITCH SWITCH ARRESTORS EU ge] EIST pete 1 &- DISCONNECT La ain SWITCH VY SHUNT REACTOR POWER TRANSFORMER PIs DISCONNECT SWITCH CIRCUIT BREAKER NOTE: IF A 345 kV LINE IS USED, THEN ALL BREAKERS, SWITCHES, ETC. WOULD BE 345 kV. DISCONNECT SWITCH TO McGRATH AREA DISTRIBUTION Wdg2:20 10-98-42 4 -wol4 286-1 80/20'd €80-4 — pe pera 4 PROPOSED ADDITION 10 DOUGLAS SUBSTATION WdE2:20 1 0-08-AEW -woly EXISTING 138 kV eet as BUS DISCONNECT DISCONNECT SWITCH ( SWITCH ky yy NOTE: IF A 345 kV LINE IS USED 138 k 138 k : GRCUIT GRouIT THEN THE 345 kV BUS WOULD BREAKER BREAKER BE EXTENDED AND ALL BREAKERS, SWICHES, ETC. WOULD BE 345 kV. DISCONNECT DISCONNECT DISCONNECT SWITCH SWITCH SWITCH Sf 138 kV ARRESTORS er 138 kV SHUNT & REACTOR » § 138 kV p TRANSMISSION s LINE TO McGRATH SINGLE & COMBINED CYCLE COMBUSTION TURBINE BTU Ae OREN I mee 8) | PES UAEDIET) auiquny sey eel | —— =SICN1 ee —— Se “Ouy ‘JeuoNeUaU] - UOSUTAS}S FY WeMI}S Now the LM2500+ is the newest member to the family of experienced APs ele oe LM2500 PC ..... 20 MW LM2500 PE (Basic) ........ 22 MW LM2500 STIG ... 27 MW LM2500+ Introductory ... 27.6 MW MPa Mature ........ 29 MW Best of all, the Pe aes Ay eC) packaged and full- load string tested RCE a Stevenson... RRS eye 2 PO Lar ar Ae A MORE PC Standard Combustor, Ory Low Emissions (DLE) New “Stage Zero” New Stage 1 Wide-Chord Blade Inlet Bellmouth WUD = Went? | _—s-:*17-Stage Compressor LM2500+ Evolves from LM2500 The simplest way to envision the LM2500+ is to think of the basic LM2500 with an additional compressor stage called “stage zero.” The technique of adding “stage zero” before stage | is commonly used in the turbine industry to boost airflow, pressure ratio and power. Several stages of blades and stationary airfoils have also been upgraded to allow 20% additional airflow. In the compressor section, 3-dimensional airfoils from the LM6000 will replace 2-dimensional airfoils in the basic LM2500. In the turbine section, the blades for the first stage and last stage have been reshaped to optimize performance. Finally, to handle the additional pressure ratio and power, the casings and shafts have been strengthened. Key mechanical components, such as bearings, accessory drive and engine mounts, remain the same. In fact, the LM2500+ can be retrofitted on an exchange basis to boost power output at many existing LM2500 job sites. Gas Generator Combustor also available 2-Stage High-Pressure Direct Drive Turbine (HPT) Flange LM2500 Heritage @ 25 years of industrial experience @ 1300 LM2500 turbines delivered for marine & industrial service @ 18 million industrial hours @ 28 million flight hours @ Documented performance — Availability 96.5% — Reliability 99.6% Quick delivery, fast start-up Stewart & Stevenson has built more LM2500 generator sets than any other manufacturer. Standardized designs shorten the Stewart & Stevenson manufacturing schedule. A large number of essentially identical packages are always under construction, giving us the flexibility to meet your delivery requirements— often in less than 100 days. Your unit arrives ready to work. All major components are baseplate- mounted, a design that simplifies transportation and installation. No lengthy field setup is required . . . no surprises. Matai LM2500_ Factory full-load testing All packages are factory-assembled and tested at full load before shipment. The test uses the contract control panel and auxiliary systems to minimize field start-up and debugging time. This demonstration of power output and heat rate significantly reduces performance risks for owner, constructors and lenders. Superior customer training Training begins in our factory as part of the full-load test. Your operators learn to run your LM2500 before it is shipped. The experience gained from Stewart & Stevenson technicians helps ensure smooth operations, even during start-up. Stewart & Stevenson can also provide supplemental training and refresher courses at the job site. High availability, high profitability Acroderivative technology makes possible the quick removal and exchange of gas turbine engines without extended downtime for repair. If an unexpected major repair becomes necessary, we can immediately send you a replacement engine to get your plant on-line. For on-site Operations and Maintenance (O&M), call on Stewart & Stevenson Operations, Inc. (SSOI). We operate more than 30 facilities that consistently outperform the power industry in efficiency, availability and reliability. An O&M contract with SSOI streamlines your organization, allowing managers to focus on new opportunities instead of everday supervision of personnel and equipment details. Your bottom line is improved profitability. LM2500+ Package Design Since 1980, Stewart & Stevenson has delivered more than 100 LM2500 direct-drive turbine generators for 60 Hz, 50 Hz and STIG applications. Because the basic LM2500 package was built with growth in mind, upgrading to the LM2500+ can be handled within the existing design framework: Structure Zone 4 earthquake criteria from basic LM2500. Split baseplate, shorter |-beam to allow air transport of the package. Turbine Compartment Sameas basic LM2500 including mounts, built-in maintenance crane, fire protection and ventilation system. Additional 13" length of engine recessed into “clean room.” Generator Compartment Larger generator to handle 7MW boost fits easily into basic 2500 generator compartment. Redundant ventilation system unmodified. Air Filtration LM2500+ breathes 20% more air. Filter house grows 2 ft vertically and 2 ft in length. Larger, high-capacity elements and low-restriction silencer added. Lube Oil Systems Separate lube system for GT and electric generator. Duplex filters and coolers on each system. All stainless piping, reservoir and valve trim. Identical to basic LM2500. Starting System —Electrohydraulic system identical to LM6000, LM5000 and basic LM2500. Control Solid-state digital control with fiber-optic link and remote 1/0 to minimize field wiring requirements. Uses best features of LM6000 and basic LM2500. on Se ae Stewart & BY CATT ET] International, Inc. CAT me KE . Houston, Texas 77251-163 Tel: (713) 868-7700 Fax: (713) 868-7697 60 Hz or 50 Hz Dimensions Baseplate Length 71'0° Baseplate Width 13' 7° Enclosure Height 13' 6° Overall Length* 78' 6° Overall Width* 212° Overall Height* 34' 0" Baseplate Foundation Load* 420,000 Ib “Includes air lilter Aeroderivative Industrial Gas Turbine Generator Sets ‘LM2500 (Uts000—- LMS000 LmM1600 LM2500 LM2500+ STIGSO LMSOOO STIG8O0 STIG120 LM6000 1SO Continuous kW" 13440 22800 27,050 28050 34400 48100 51620 40760 Blu/kWH (LVH)* 9545 9280 9330 8325 9180 8070 7790 8590 Exhaust Flow (#/sec) 100 152 183 168 268 324 339 277 Exhaust Gas Temp. (°F) 909 975 926 926 813 766 741 864 1SO Continuous kW* 13440 21960 26,000 27020 34500 46360 49600 40270 Btu/kWH (LVH)* 9545 9550 9830 8620 9290 8340 8110 8695 Exhaust Flow (é/sec) 100 148 185 168 275 330 344 277 Exhaust Gas Temp. (°F) 909 1008 952 941 811 767 752 864 “Includes generator and gearbox losses. Ratings at 59 °F, sea level, no inlel/exhaus! losses, natural gas tuel LM2500+ Gas Turbine 60-Hz Generator Set Performance Site Conditions: 60% rh, sea level, 3600 pm Exhaust gas flow, Ib/sec No inlet/exhaust losses —-— Exhaust gas temperature, °F Natural gas fuel, dry engine -—- Fuel Flow, MMBtu/LHV MW @ Generator Terminals Ambient Temperature, °F A Canueinht 1004 Stowart & Stevencan International Inc S&S Energy Products LIM6000 Gas Turbine: Simply the World's Most Efficient Efficient Delivering more than 43 MW of electrical power at 42% thermal efficiency, the powerful LM6000 is the most fuel-efficient, simple-cycle gas turbine-generator set in the world. For projects needing more power, the LM6000 Sprint uses SPRay INTercooling to produce up to 20% more output. Serving a wide range of applications, S&S Energy Products offers the field- proven LM6000PC with conventional combustion, the LM6000PD with dry-low emissions (DLE) and the LM6000 Sprint that has spray intercooling for power boost. High thermal efficiency, low cost, and installation flexibility make the LMG6000 the ideal choice as a prime driver for utility peaking, mid-range, and baseload operations, as well as for industrial cogeneration. The LM6000 delivers: = the highest simple-cycle and combined-cycle efficiency = low installed cost = dual-fuel capability ® inlet and exhaust flexibility a high availability ® reliable starting and fast loading « high reliability = excellent part load efficiency = flexibility - baseload - dispatchable - cogeneration - peaking - mechanical drive # low exhaust emissions # dry-low emissions technology = simple on-site maintenance LIM6000 Gas Turbine: Reliability by Design The LM6000 is derived from the core of the CF6-80C2, GE's high thrust, high-efficiency aircraft engine which has logged more than 46 million flight hours with over 2,500 engines in service. With a shop visit rate of one-half that of other engines in its class, it has become the standard for reliability in aircraft service. Both engines have a common design and share about 90% of the same parts. Taking advantage of the CF6-80C2 low-pressure system's normal operating speed of 3,600 rpm, the LM6000 couples loads directly to the low-pressure turbine (LPT) shaft, allowing the commonality of the CF6-80C2 and LM6000 to be maintained. The result is low cost and field-proven parts for the LM6000. All LM6000 components incorporate corrosion-resistant materials and coatings to provide maximum parts life and time between overhaul, regardless of the unit's operational environment. The low-pressure compressor (LPC) features variable inlet guide vanes to modulate airflow, ensuring fast, easy startup/shutdown and maximum efficiency — even under partial loads. The high-pressure compressor (HPC) is mated to an efficient annular com- bustor for maximum fuel economy. Gas, distillate, or dual-fuel capability is available. Incorporation of advanced airflow and cooling technologies helps the LM6000 provide unprecedented power, efficiency, low fuel consumption, and low NOx, carbon monoxide (CO) and unburned LIM6000 Gas Turbine: Configuration Flexibility aloal fe The LM6000's inherent configuration flexibility makes it the ideal choice for baseload, mid-range, and peaking operations. Industrial processes needing cogeneration or mechanical drive capabilities also benefit from the gas turbine's simple installation requirements and unprecedented efficiency. Cost-Effective Power You Can Profit From In a wide range of applications, the LM6000 delivers its power at the lowest cost per kWh of any gas turbine in the world. Platforms or pipelines Utility peaking, mid-range, and baseload operations industrial cogeneration LM6000 Gas Turbine: World Standard for High Performance — E a Output: Over 43 MW at Over 42% Thermal Efficiency One of the highest outputs available in the aeroderivative gas turbine marketplace today, the LM6000's effi- ciency in simple-cycle configuration is the highest available in the industry. The LM6000 also features excellent combined-cycle performance over 55 MW at more than 52% thermal efficiency. Environmental Compatibility The LM6000 was GE's first aero- derivative gas turbine to employ the new Dry-Low Emissions premixed combustion system. This system is retrofittable to LM6000s already in operation. Water or steam injection can also be used to achieve low NOx emissions. NOx can be reduced by 90% — guaranteed to 25 ppm when burning natural gas, while maintaining low emissions of CO and unburned hydrocarbons. A dry dual-fuel (DLE) combustion system is available. It provides fuel flexibility for gas or liquid fuel 3 mol 3 9% POWER tne LM6000 Sprint The Intercooled Engine That Increases Output The LM6000 Sprint combines the best simple-cycle heat rate of any industrial gas turbine in service today, with a spray intercooling design that significantly increases the mass flow by cooling the air during the compres- sion process. The result is more power, a better heat rate and a really cool engine. The Perfect Baseload Engine The high thermal efficiency, low cost and installation flexibility make the LM6000 the ideal choice for utility peaking, mid-range, cogeneration and baseload operations. The addition of GE’ proprietary Sprint technology increases the power output by 9% at ISO and by more than 20% on 90°F days. By eu 16350 rpm he a) Cred The Hotter It Gets, the More Effectively It Runs Sprint's effectiveness is even more pronounced in hot weather. It is like having an evaporative cooler built within the gas turbine. As ambient temperature rises, the benefits of a Sprint engine become more significant. A Cool Solution The system is based on an atomized water spray injected through spray nozzles located between the high-pressure and low-pressure compressors. Water is atomized using high-pressure air taken off of eighth- stage bleed. The water-flow rate is metered, using the appropriate engine —— The Sprint Solution at Work On high-pressure ratio gas turbines, such as the LM6000, the compressor discharge temperature is controlled because compressed air is used to cool the hot section components. By inject- ing an atomized water spray in front of the LM6000 high-pressure compressor, the compressor inlet temperature is significantly reduced. Utilizing the same compressor discharge temperature control limit, the compressor is able to pump more air, achieving a higher pressure ratio. The result is higher output and better efficiency. LM6000 Sprint: Technology demonstrator in Ft. Lupton, Colorado. LM6000 Gas Turbine: Customer Service Ensures Long-term Returns Support Full-load string testing before shipment reduces risks and speeds delivery. Worldwide Capability S&S Energy Products offers a variety of comprehensive services for GE, Alstom, Allison and Solar gas turbines, concentrating on quick turnarounds. Repairs are performed “on-site” when- ever possible, significantly reducing downtime and total costs. Complete field engineering services are available for upgrades, retrofits and overhauls of most manufacturers’ packages. These services include the individual exhaust gas temperature monitoring systems and inlet air heating and chilling systems. Exchange Option Reduces Costs S&S Energy Products has rotatable inventory of engines and hot sections that are available for outright field exchange. Only one period of down- time is required while the exchange takes place. Parts on Demand Quick response is demanded for repair and overhaul. Our large parts invento- Ty is available 24 hours a day for ship- ment anywhere in the world. Our rotatable inventory of new and exchanged parts is constantly moni- tored to eliminate long lead times. Worn or damaged components are exchanged “on-site” and returned to our factory to be rebuilt. These items u are then returned to inventory, keeping parts on the shelves at all times. This system allows you to specify new parts or rebuild components for necessary replacements, including: = High pressure turbine rotors = Compressor assemblies « Nozzles and assemblies = Complete gas generators = Blades « Complete gas turbines = Combustion liners Factory Full-Load Testing S&S Energy Products has the capability to full-load test new, repaired or rebuilt GE, Alstom, Allison and Solar gas turbines, ranging from 500 to 67,000 hp. Our GE test facility is the only com- mercially available dynamometer in the world for full-load testing of LM2500 (including the power turbine) and LM6000 gas turbine engines. Using a power turbine combined with a load imposed by an electric generator, this configuration provides a true measure of performance, horsepower, heat rate and kilowatt output. Advanced Control Center A computerized control system for each cell is used to operate, monitor and provide complete documentation of tests for in-house and customer evaluations. In addition, two high- resolution remote control color video cameras are located in each cell for visual monitoring from the control panel. LIM6000 Gas Turbine: Cost-Effective Power WY & S n CO Fe YU 5 SY) 50 Hz 60 Hz Dimensions 50 Hz 60 Hz Base Plate Length 64° 7 == (19.69 m) 56° 6 (17.22m) Base Plate Width 13° 6 (4.11. m) 13° 6 (4.11. m) Enclosure Height 4 & (4.42 m) 4 & (4.42 m) Overall Length 64° 10° = (19.76 m) 56° 9 (17.30 m) Overall Width* 49° 3° = (15.01 m) 49° 9° (15.16 m) Overall Height* > 37° 11" (11.56 m) 36° 2 (11.02 m) Base Plate Foundation Load* 522,000 1b = (234,900 kg) 476,000 Ib (214,200 kg) “Includes air filter 60-Hz GENERATOR SET PERFORMANCE 60% RH, sea level, 3600 rpm No inlevexhaust losses Natural gas fuel, dry engine Fuel Flow, MMBtu/h (LHV) - Exhaest Mass Flow, th/s Exhaust Gas Temp., °F 8 S&S Energy Products’ inlet Chilling system provides more power output and better fuel efficiency. MW @ GENERATOR TERMINALS Asroderivative Industrial Gas Turbine Generator Sets Heat Rate so kikwe = Bhv/kWh = Exhaest Flew Exheust Flew ExhawstGes Exhaust Gas Coationses kW") LTV" uve (ie/eec) (xp/sec) Tomp °C Tome °F LM1600 13440 10070 = 9545 100 45.4 487 909 LM2500 21960 10076 ©9550 148 67.1 542 1008 LM2500STIG 50 27020 9095 8620 168 76.2 505 941 LM2500+ 28540 9654 9150 188 85.3 521 969 LM6000PC 43076 8701 8247 279 126.6 450 842 LM6000Sprint 46590 8837 8376 288 130.6 455 851 Heat Rate so kiAwh = BtwkWh Exhaust Flew Exhaust Flew Exhaust Ges Exhasst Gas Continuows kW LIV une (ia/sec) (xg/eec} Tome °C Tome “F LM1600 13440 10070 «= 9545 100 45.4 487 909 LM2500 22800 9791 9280 152 68.9 524 975 LM2500STIG 50 28278 8783 8325 168 76.2 497 926 LM2500+ 28600 9348 8860 183 83.0 510 950 LM6000PC 43400 8737 8281 280 127.0 452 846 LM6000Sprint 47300 8704 8250 288 130.6 455 851 * Includes gonerater and pearbar leases. Ratings at 15°C (59°F), sea level, ne iniet/exhaus! losses, natural gas fuel. Aftermarket Products and Services S&S Energy Products’ after- market services group is exclu- sively dedicated to support industrial and aeroderivative gas turbine engines—no flight aircraft engines. This has truly made S&S Energy Products the industry's choice in aftermar- ket services. Our depots offer world-class overhaul and repair services for General Electric, Nuovo Pignone, Pratt & Whitney, Rolls-Royce, and Solar®* gas turbines—concentrating on quick turnarounds With worldwide depots and field service support, S&S Energy is positioned to provide fast response to customer needs. S&S Energy Products is the leading provider of integrated engine maintenance services by focusing on world-class quality, quick turn-times and excellent customer service. Our aftermarket products and services include: e Depot Maintenance, Repair & Field Service Support e Long Term Service Agreements e Extended Engine Warranties e Engine Exchange Programs e Used & Repaired Engines e Lease Engine Programs e Engine Upgrade Kits e Package Conversion Modification and Upgrade Kits e Hot-Section & Component Exchanges e Testing e Spare Parts Installation Services S&S Energy Products has been involved in the Engineering, Procurement, and Construction Management of the Balance of Plant equipment on a turnkey basis for over ten years. We have installed thousands of megawatts in more than 20 countries. As the industry leader in fast- track power generation, S&S Energy Products has devel- oped pre-engineered modular- ized equipment packages to quickly meet customer require- ments. Whether a customer's requirements are limited to re- assembly and startup or full turnkey—S&S Energy Products can provide a quality project at a competitive price for your power generation or gas tur- bine mechanical drive project, anywhere in the world. Services e Detailed Design e Procurement e Construction Management e Logistics/Transportation e Re-assembly e Startup/Commissioning e@ Quality Control e@ Environmental Health & Safety e Testing e Permitting Assistance Systems e Fuel Systems (Gas, Liquid) e Water Treatment e Substations e Compressed Air e@ Heat Recovery e Steam Turbines e Foundations e Piping e Waste Systems e Chilled Water e Buildings LM2500-—Marine Aeroderivative gas turbines are intrinsically lightweight, compact, efficient, and very reliable. They are used exten- sively on military ships where the mission of the ships must not be compro- mised by a need to carry large propulsion equipment requiring significant spares and crew. Over 325 naval vessels utilize in excess of 850 LM2500 gas turbines. The LM2500 generator pack- age for marine propulsion has accumulated over 6 million hours of operation. It has also found applications in remote areas which demand extremely high reliability and little maintenance such as off-shore platforms. Most recently, the LM2500 has been used for powering high- speed ferries that dramatically reduces the time to transport Passengers and cargo. S&S Energy Products also builds an efficient COGES System for cruise ship cus- tomers. COGES is an acronym for combined gas turbine and steam turbine electric and steam production plant for cruise ship propulsion using More square meters of space on ship — more room for customers Reduced engine room crew — maintenance provided by S&S Energy Products’ land-based depots Reductions in Sox, NOx, particulates and no sludge disposal required — environ- mentally friendly an integrated electric drive e More reliable and available system configuration. ship - easy maintenance The COGES System replaces e Improved productivity and diesel engines with gas tur- efficiency of engine room bines and provides the follow- personnel — no need for ing advantages: ; diesel inventory manage- ment Exhaust Service 7 1 Condensate Return Services Steam Supply Evaporators, HVAC. Laundry, Galley & Etc Steam Turbinets) Heat Recovery Bouer Propulsion * Orives & Motors Electrical ” Service Power LM2500 and LM2500+ GE builds two versions of the LM2500 gas turbine: e Basic LM2500 Model: 22.8 MW ISO e@ LM2500+: 28.6 MW ISO Aeroderivative Heritage Translates into Unsurpassed Reliability. Derived from flight engines used on DC-10 wide- body jetliners and C-5A trans- ports, the LM2500 is a hot-end drive, two-shaft industrial gas turbine with unsurpassed relia- bility. More than 1,500 LM2500s have amassed an excess of 18 million operating hours in marine and industrial applica- tions Maintaining a high degree of parts commonality with its flight-tested forerunners, the LM2500 continues to build a reputation as the most reliable industrial gas turbine generator set in its class Reliability Exceeding 99%. The LM2500 pack- ageisa durable and reliable prime mover, capa- ble of produc- 5 bs Nf & y fn ie ! ing more than 25 MW of 4 | fi. power in the severest of operating environments. With its direct- drive design, the LM2500 has become the industry standard for 20 to 25 MW gas turbine generator packages. Direct-Drive Reliability with STIG Power and Efficiency. The LM2500's power turbine oper- ates at 3000 or 3600 rpm, allowing for direct, gearless coupling to 50 Hz and 60 Hz generators. This operation eliminates the gearbox ' required by most industrial gas turbine generator sets. Leading its power class with a simple-cycle efficiency greater than 37%, the LM2500 generator package can be used in combined-cycle con- figurations, increas- ing the overall plant efficiency to more than 50%. To increase power and to match cogenerated steam loads, the LM2500 STIG5O can be injected with up to 50,000 lb/hr of high-pressure steam to produce more than 28 MW, often eliminating the need to purchase combined-cycle equipment such as steam tur- bines, condensers and cooling towers. INGE S&S Energy Products also offers the LM2500+ gener- ator package, which is the latest addition to the LM2500 fleet. Providing more than 28 MW of power, this workhorse is already operating in mechan- ical-drive, power-generation, and marine applications world- wide. More output, high reliability and a lower initial capital invest- ment on a $/kW installed base are just a few of the benefits contributing to the customer value delivered by the LM2500+ generator package. [M6000 SPRINT™ M6000 SPRINT™: The Inter- cooled Engine that Increases Power Output. The LM6000 SPRINT™ combines the best sim- ple-cycle heat rate of any indus- trial gas turbine in service today. It has a spray inter-cooling design that significantly increas- es the mass airflow by cooling the air during the compression process. The result is more power, a better heat rate and a really cool engine. The Hotter It Gets, The More Effectively It Runs. SPRINT™'s effectiveness is even more pro- nounced in hot weather— power output is increased by 9% at ISO and is increased by more than 20% on 90° days. It is like having an evaporative cooler built within the gas turbine. As ambient temperature rises, the benefits of a SPRINT™ engine become more significant. A Cool Solution. GE has devel- oped a new solution for the SPRINT™ inter-cooling system. compressor with a mico-mist of The system is based on an water, the compressor inlet tem- perature and outlet temperature are significantly reduced. Thus, atomized water spray injected through spray nozzles located between the high-pressure and low-pressure compressors. Water is atomized using high- the compressor outlet tempera- ture limitation is reduced allow- ing the LM6000 to operate on its natural firing temperature con- trol. The result is higher output and better efficiency. pressure air taken off of eighth stage air bleed. The water-flow rate is metered, using the appro- priate engine control schedules. The SPRINT™ re PoE Solution at RP eet a ae eal a. _, Work. On high- ams _ ee —, pressure ratio gas turbines such as the LM6000, the compressor discharge tem- perature is often the criteria that limits power Output because compressed air is used to cool the hot sec- tion components. By pre-cool- ing the LM6000 high-pressure LM6000 The LM6000 is derived from the core of the CF6-80C2, GE's high thrust, high-efficiency air- craft engine which has logged more than 46 million flight hours with over 2,500 engines in service. The flight version of the LM6000 powers approxi- mately 2/3 of the world’s fleet of Boeing 747 and 767 wide- body aircrafts. Delivering more than 43 MW of electrical power at 42% thermal efficiency, the LM6000 is the most fuel-efficient, simple-cycle generator package in the world. For projects needing more power, the LM6000 SPRINT™ uses SPRay INTer-cooling to produce up to 30% more output during hot weather with no sacrifice of engine lifetime. Serving a wide range of appli- cations, S&S Energy Products offers the LM6000 conventional annular combustor or a lean pre-mix dry low emissions combustor. When reduction of NOx emissions is required, customers can choose the best technology for their applica- tion: Water injection — low cost solution Steam injection - ideal for cogeneration projects Dry low emissions combustor — no water or steam required High thermal efficiency, com- petitive pricing, and installation flexibility make the LM6000 the ideal choice as a prime driver for utility peaking, mid-range, and base-load operations, as well as for industrial cogenera- tion. The LM6000 package delivers: @ The highest simple-cycle efficiency for any gas turbine, regardless of size @ The highest combined- cycle efficiency in the 50 MW gas turbine class e@ Low installed cost @ Dual-fuel capability e Optimal evaporative cool- ing or chilling of air inlet e@ High availability @ Reliable starting and fast loading e@ High reliability e Excellent part load efficiency e Flexibility - Base-load - Dispatchable - Cogeneration - Peaking - Mechanical drive @ Simple on-site maintenance S&S Energy Products A GE Power Systems Business [he Power of the Package FACTORY BUILT GAS TURBINE PACKAGES | POWER GENERATION | MECHANICAL DRIVE Factory Packaging Our shops in Houston, Texas and Florence, Italy fabricate, assemble and test each pack- age utilizing procedures certi- fied to ISO 9000 standards. Extensive research and devel- opment, modern manufactur- ing techniques and on-site experience are behind the suc- cess achieved by S&S Energy Products. We provide single source responsibility to the customer for package design, manufac- turing, operations, training and support. S&S Energy Products provides single source respon- sibility so customers do not have to qualify hundreds of vendors and prepare specifica- tions for all of the components in a generator package or mechanical drive unit. In addi- tion, we provide an overhaul guarantee and warranty for the complete package. S&S Energy Products’ factory Packaging concept ensures quick delivery and fast startup. Standardized designs shorten our manufacturing schedule. A large number of essentially identical packages are always under construction, giving us the flexibility to meet your delivery requirements — often less than 100 days. Your unit arrives ready for startup. All major components are base-plate mounted, a design that simplifies trans- portation and installation. No lengthy field setup required... no surprises. Factory packaging advantages include: ; e@ Single lift module - easily transportable e@ Stainless steel lube and fuel systems - reduces mainten- ance @ Redundancy on critical sys- tems - higher reliability and availability e@ Full factory test - reduces project risk e Better training - operators learn at our factory with fol- low-up at your site e@ Faster field erection - reduces startup time and costs e Integral support systems - reduces installation costs Designed for the Long Term. S&S Energy Products’ gas tur- bine packages use an earth- quake-qualified structural design, durable electrical sys- tems and all stainless steel fluid systems and reservoirs. Redundant, oversized fans keep turbine compartments cool while generators sized larger than the turbine output accommodate future rating increases. This conservative design philosophy reflects the expectations of our customers to operate the package for 20 to 30 years Factory Full-Load Testing. All packages are factory assem- bled and tested at full-load before shipment. Customers are encouraged to witness and Participate in the full-load test- ing. This approach allows a true measure of power output, heat rate and vibration as well as to check on control soft- ware and safety devices. The test uses the customer's con- tract generator (compressor for mechanical drive pack- ages), control panel and auxil- iary systems to minimize field startup and debugging time. Advanced Digital Control Systems. S&S Energy Products’ control systems utilize a mod- ular digital architecture: e Rugged GE Mark Vi micro- processor control for engine monitoring with integrated fuel management GE Fanuc programmable logic controller; ladder logic control for automatic sequencing of auxiliary equipment during start/stop High-speed digital process- ing with integrated data log- ging/trending capability Operator-friendly interface with PC, color CRT and on- line diagnostics Easy expansion for future needs e Optional capability to con- trol simple-cycle balance-of- plant equipment without distributed control Superior Customer Training. S&S Energy Products offers complete classroom and hands- on operator training at our facility or your job site—no matter where you are located around the world. Operators will learn valuable information, which will help to eliminate costly mistakes during startup or operation. Initial training can even begin at our factory during full-load testing of the turbine package. The training improves operator confidence and trouble-shoot- ing capability during the project startup. MICROTURBINES ADVANCED MICROTURBINE SYSTEMS PROGRAM PLAN FOR FISCAL YEARS 2000 THROUGH 2006 Marcu 2000 U.S. DEPARTMENT OF ENERGY OrFIcE OF ENERGY EFFICIENCY AND RENEWABLE ENERGY OFFICE OF POWER TECHNOLOGIES TABLE OF CONTENTS U.S. DEPARTMENT OF ENERGY Orrice oF ENERGY EFFICIENCY AND RENEWABLE ENERGY EXECUTIVE SUMMARY ke his multi-year program plan outlines |= proposed activities of the Department of Energy, Office of Energy Efficiency and Renew- able Energy to develop advanced microturbine systems for distributed energy resource applica- tions. These systems range in size from 25 kilo- watts to 1,000 kilowatts. Since 1994 hundreds of industry executives from various industries have met in dozens of vision and roadmap workshops to discuss the elements critical to success in the global marketplace over the next twenty years. Cleaner and more efficient, afford- able, and reliable heat and power systems is one of the most prominent re-occurring needs raised during these sessions. The rapidly changing marketplace for utility energy services is opening new opportunities for the nation’s heat and power users to reduce energy costs, increase power quality and reliability, and reduce environmental emissions. In addition, over the next twenty years, a significant portion of the nation’s aging stock of boiler and power generation equipment will reach its useful life and need to be replaced. One opportunity is investment in smaller-scale distributed energy resources that can be integrated into overall manufacturing plant or building opera- tions. These technologies can be controlled locally to optimize performance and satisfy needs for both electricity and thermal energy. Energy managers and building operators want to have heat and power services for less cost, less emissions, better reliability, and greater control than what they can get from the utility grid. Because of their compact size, modularity, and potential for relatively low cost, efficient, and clean operations, microturbines are emerging as a leading candidate for meeting these needs for electricity and thermal energy. The mission of this program is to lead a national effort to design, develop, test, and demonstrate a new generation of microturbine systems that will be cleaner, more fuel efficient, more fuel-flexible, more reliable and durable, and lower cost than the first generation products that are just entering the market today. This mission is consistent with the goals set forth in the Department’s Comprehensive National Energy Strategy to improve the efficiency of the energy system, ensure against energy supply disruptions, expand future energy choices, and promote energy production and use in ways that Tespect health and environmental values. This plan covers fiscal years 2000 through 2006. The projected funding requirement for the program is $63 million in appropriations from the U.S. Congress and at least $63 million of additional funding is expected in cost sharing. The program’s planned activities are aimed at achieving the following performance targets for the next generation of advanced microturbine sys- tems: * High Efficiency - Fuel-to-electricity conversion efficiency of at least 40 percent. * Environmental Superiority - NOx emissions lower than 7 parts per million for natural gas machines in practical operating ranges. * Durable - Designed for 11,000 hours of opera- tion between major overhauls and a service life of at least 45,000 hours. U.S. DEPARTMENT OF ENERGY Orricé OF ENERGY EFFICIENCY AND RENEWABLE ENERGY + Economical - System costs lower than $500 per kilowatt, costs of electricity that are competitive with alternatives (including grid-connected power) for market applications, and the option of using multiple fuels including natural gas, diesel, ethanol, landfill gas, and other biomass-derived liquids and gases. There is a tremendous amount of uncertainty about the market potential of microturbines. Markets could evolve in ways to make the impact signifi- cant. Microturbines could be the kind of “disrup- tive” technology that causes users to abandon business-as-usual practice. There is considerable interest in using microturbines for stationary power applications in the industrial, commercial, institutional, and residen- tial sectors of the economy. Based on current practices, the most attractive industrial opportuni- ties lie in the chemicals, wood and agricultural products, petroleum extraction and production, mining, and textiles industries. Potential commer- cial sector markets for microturbines include office buildings, restaurants and food services, and retail services. Institutional markets include hospital complexes, schools and university campuses, government buildings and facilities, and office/ industrial power parks. Residential markets include multi-family dwellings and community-based systems. The majority of the potential market involves applications that have needs for thermal and mechanical energy as well as electricity. This means that the largest opportunity for microturbines could be as the “prime mover” in cooling, heating, and power (CHP) systems and as a clean power source for distributed generation applications. Realizing the full market potential for microturbines will help keep U.S. manufacturers on the “cutting edge” of turbine technology for power generation and enhance the industrial competitiveness of the U.S. manufacturing base in international markets. This could be lead to the creation of high-paying jobs for American workers. Realizing this potential could also produce substantial public benefits in terms of lower energy consumption, lower indus- trial energy costs, and lower emissions. The program’s RD&D activities have been organized in four main program areas: 1) Concept development, 2) Components, subsystems, and integration, 3) Demonstrations and 4) Technology base (which includes materials development, combustions systems, and sensors and controls). This program’s activities in these areas will be implemented over a seven year period. The primary implementation mechanism will be com- petitive solicitations. Figure 1 depicts the expected portfolio mix and shows how the emphasis could change during the implementation of the program. Potential RD&D performers will be able to participate at any point in the program. Concept development will be emphasized during the first several years of the program. The development and testing of compo- nents, subsystems and integrated systems will be a major emphasis during the middle years of the program, but efforts will be supported in this area from the outset, depending on proposals received from potential bidders. Pre-commercial demonstration(s) of advanced systems will be emphasized during the last several years of the program but support will be provided for demon- strations of existing microturbine systems and subsystems from the outset. Potential RD&D U.S. DEPARTMENT OF ENERGY Orrice oF ENERGY EFFICIENCY AND RENEWABLE ENERGY performers will be able to opt in and out of these various activities during the course of the program depending on their capabilities, corporate interests, and the progress of the RD&D. This program will be managed by the Office of Power Technologies with assistance from the Department’s Chicago Operations Office. Imple- mentation will be accomplished by a competitive solicitation process that will result in projects by equipment manufacturers, universities, and national laboratories. Coordination will involve the Offices of Industrial Technologies; Buildings Technologies, U.S. DEPARTMENT OF ENERGY State and Community Programs; and Fossil Energy; and equipment manufacturers, electric and gas utilities, energy services providers, project developers, and other federal and state agencies. Joint planning activities are currently underway with the California Energy Commission, the New York State Energy Research and Development Administration, and the Association of State Energy Research and Technology Transfer Institutions in accordance with memoranda of understanding that the Department has signed with these organizations. Components, Subsystems and Integration 2004 Figure 1. Program diagram Orricé oF ENERGY EFFICIENCY AND RENEWABLE ENERGY Fiscal Year 1. INTRODUCTION I T his document presents the multi-year plan of the Department of Energy’s Advanced Microturbine Systems Program. The plan outlines the mission, goals, performance targets, and proposed research, development, and demonstra- tion (RD&D) activities of the program over the next seven fiscal years (2000 through 2006). This program will be managed by the Office of Power Technologies in the Office of Energy Efficiency and Renewable Energy. The program’s strategy is to conduct research, development, and demonstration (RD&D) projects in collaboration with industry, universities, and the national labora- tories to accomplish a discrete mission in a fixed period of time. This program will culminate in an 8,000 hour field test demonstration of the next generation of microturbine system(s). It is expected that this design will be ready for commercialization by manufacturers and installation by industrial power users early in the next century. Reliability, availabil- ity, maintainability, durability (RAMD) testing will probably involve field demonstrations exceeding 8,000 hours of operation. Government involvement in such efforts will be considered at that point in the program. This program strategy is similar to the one used successfully by the Advanced Turbine Systems Program in developing a new generation of industrial turbines. However, as shown in Figure 1, this plan calls for the mix of activities to evolve over the course of the program. U.S. industries such as petroleum refining, chemi- cals, pulp and paper, steel, aluminum, and light manufacturing are among the biggest electricity users in the economy and currently rely heavily on utility generation, self generation, and combined heat and power systems to meet their electric power needs. With the restructuring of electric power markets, these industries are finding a wide array of new electric power opportunities including distributed generation, innovative pricing and risk management strategies, and energy management services. Industrial interest in distributed generation technologies such as microturbines and reciprocat- ing engines is rising because these systems can cut power costs and boost reliability while lowering overall emissions. Microturbines can also be used in commercial, institutional, and residential buildings. Promising commercial building markets include offices, restaurants and food services, and retail services. Institutional markets include hospital complexes, schools and university campuses, industrial/office power parks, and government buildings and facilities. Residential markets include multi-family dwelling and community energy projects. It will take some time for customers, manufacturers, and energy services providers to identify and exploit all of the promising applications markets for microturbines. As defined for this program, the microturbine system comprises the flange-to-flange microturbine core, rated at up to 1000 kW at ISO conditions. The system definition includes all secondary components such as the fuel compressor, recuperator/regenerator, generator or alternator, CHP equipment, sound attenuation, and power conditioning equipment. Although further develop- ment of power conditioning equipment could result in easier interconnection by microturbine systems with the grid, the system definition of secondary components does not include equipment solely for that purpose. Microturbines offer a number of potential advan- tages compared to other technologies for small- scale power generation; for example, a small number of moving parts, compact size and light weight, multi-fuel capabilities, and opportunities for greater energy efficiency, lower emissions, and lower electricity costs. Realizing these advantages U.S. DEPARTMENT OF ENERGY OrFicE OF ENERGY EFFICIENCY AND RENEWABLE ENERGY would mean substantial public benefits in terms of cleaner, more affordable, and more reliable power options for the nation’s electricity users. The size range of commercial microturbines varies and depends primarily on economics and customer power needs; but technical constraints and permit- ting/policy considerations are also factors. In recognition of the diversity of potential applications, and the need for flexibility in designing the next generation of microturbine systems, this plan does not contain an exact specification for the size of the next generation of microturbine systems. That decision will be made by the system designers and manufacturers based on market needs and oppor- tunities. Existing microturbine systems range in size from 25 to 75 kW; future products up to 1000 kw are planned. It is expected that the advanced microturbine prototype developed under this program will be in the 25 to 1000 kW range. Support for larger advanced microturbine systems could be provided if those designs represent evolu- tionary changes in microturbine development. The specifics outlined in this plan are the result of numerous consultations with industry experts and market studies that have explored the future of distributed energy resource technologies and the potential role of microturbines in industrial, com- mercial, institutional, and residential power applica- tions. For example, the Microturbine Technology Summit was held in December 1998 as part of the consulta- tion process to discuss the future outlook for microturbines including public policies, market barriers and opportunities, and technology chal- lenges.’ More than 60 stakeholders with expertise in microturbines, utility systems, industrial power and markets, and government regulations attended the Summit. ‘ Summ: 1999 DOE/ORO 2081. Among the issues raised at the Summit was the need for the Department of Energy to establish RD&D partnerships with industry to develop the next generation of microturbine systems. The stimulus created by government involvement was deemed a necessary ingredient for overcoming the engineering, technical, and institutional barriers facing the development and deployment of the next generation of microturbine systems. In the absence of a focused and appropriate government role, the Summit participants generally agreed that industry would not be able to develop the next generation system on their own and a substantial opportunity for cleaner, more reliable, and more affordable power options for the indus- trial, commercial, institutional, and residential sectors might be lost. Market studies have been conducted by Arthur D. Little, Incorporated? and Resource Dynamics Corporation’ to estimate the potential for microturbines and other small-scale power systems such as fuel cells and reciprocating engines to meet power needs in the future industrial market. Based on current industry practice, both of these studies identified potential markets for microturbines in the manufacturing sector serving needs for continuous power generation, peak shaving, back-up generation, remote power, premium power, and combined heat and power. The studies found that certain scientific, engineer- ing, and institutional barriers would need to be addressed and cost, efficiency, and emissions performance targets achieved for the market potential of microturbine systems to be fully realized. Many of the same applications and barriers that the studies found for the manufactur- ing sector also apply to the commercial, institu- tional, and residential sectors. of the Microturbine Technology Summit prepared by Energetics, Incorporated for Oak Ridge National Laboratory, March 2 tunities for Micro power and Fuel Cell/Gas Turbine Hybrid Systems in Industrial Applications prepared by Arthur D. Little for O idge National Laboratory, April 1999. ? Industrial Applications for Micropower: A Market Assessment prepared by Resource Dynamics Corporation for Oak Ridge National Laboratory, April 1999. U.S. DepartMENT Or ENERGY OFFICE OF ENERGY EFFICIENCY AND RENEWABLE ENERGY 2. SITUATION ANALYSIS AND MARKET ASSESSMENT -S. consumers used approximately 3,240 billion kWh of electricity in 1998 at a cost of $218 billion. Industrial electricity consumers used 32 percent of the total, commercial consum- ers used 30 percent, and residential consumers used 35 percent.‘ Electricity sales are expected to grow by 1.4 percent annually over the next twenty years. To meet this growing demand, electric generating capability in the U.S. is expected to grow from approximately 740 gigawatts in 1998 to approximately 957 gigawatts in 2020°, representing an annual increase of 1.2 percent. Growth in the use of electricity outside of the U.S. is expected to be even greater. Annual electricity use is expected to grow 2.5 percent worldwide by 2020, including both industrialized and developing countries. For developing countries only, electricity use is expected to grow 4.4 percent annually by 2020.6 The role of non-utility generation in U.S. markets is changing. In 1998, over 23 gigawatts of electric capacity were sold by utility companies to non- utility buyers. As a result, the number of states that have a non-utility share of electric generation greater than 25 percent doubled from two in 1998 to four in 1999.’ Distributed Energy Resources The concept of distributed energy resources refers to local energy systems that generate electric, thermal, or mechanical energy on sites near the customer’s premise. Also included are energy efficiency measures that can be installed on customer buildings and equipment that affect the need for electricity and thermal energy. Many distributed energy resource systems are located on-site, others are connected to customers through the utility’s transmission and distribution grid. Various technologies are used in distributed energy resource applications including combustion tur- bines, reciprocating engines, solar power systems, wind turbines, energy storage systems, and fuel cells. One of the factors in the growing interest to use distributed energy resources is concern about the reliability of the existing electric power system, the need to minimize production losses from power outages, the importance of protecting sensitive electronic equipment from power quality disrup- tions. Industrial processes, manufacturing produc- tion systems, and commercial business operations rely on computers, information systems, and telecommunications equipment to a greater extent than ever before. Power interruptions and spikes or sags in voltage or frequency can cost companies millions in lost production and damaged equipment. Many of the companies that have concems about the reliability of the electric grid under competitive market conditions or who cannot withstand the costs of weather-related disturbances view distributed energy resources as an important supplement or alternative to grid-connected power. Private investment in the development and deploy- ment of the various distributed energy resource technologies is increasing. This includes investment in advanced technologies for combustion turbines, reciprocating engines, fuel cells, energy storage devices, and solar and renewable power. If these * Electric Power Annual 1998 Volume II U.S Department of Energy, Energy Information Admninistration December 1999 DOE/EIA- 0348(98)/2 ’ Annual Energy Outlook 2000 With Projections to 2020 U.S. Department of Energy, Energy Information Administration December 1999 DOE/EIA-0383(2000) * International March 1999 DOE/E1A-0484(99) Energy Outlook 1999 With Projections to 2020 U.S. Department of Energy, Energy Information Administration ” Electric Power Annual 1998 Volume | U.S. Department of Energy, Energy Information Administration April 1999 DOE/EIA- 0348(98)/1 U.S. DEPARTMENT OF ENERGY OFFICE OF ENERGY EFFICIENCY AND RENEWABLE ENERGY systems are adopted in large numbers, the resulting “distributed energy system,” could stimulate new interconnection requirements for the electric power grid and natural gas pipelines. Utilities have been voicing concems about the safe and effective interconnection of distributed energy technologies and the possibility of negative impacts on electric grid operations. There is a great deal of interest in developing standardized interconnection protocols that balance utility concerns for safe grid opera- tions with the concerns of distributed energy resource developers for quick and low cost interconnection procedures. For microturbines and other distributed energy resources to be competitive in power markets, electricity costs from these systems will have to be more attractive than they are today. Without cost reductions, most electricity users will prefer grid- connected power and energy-efficient distributed energy resources will be confined to a relatively small market niche. To achieve these cost reductions, the installed costs of distributed energy resources will have to be lower to reduce the up-front investment for electricity users. In addition, operation and mainte- nance requirements will have to be lower and service lives longer to reduce the “hassle factor” associated with on-site power systems, the costs of service contracts, the need for major equipment overhauls, and the costs of other day-to-day expenses. Finally, the efficiency and environmental performance of the systems will have to be better to reduce the costs of fuel and compliance with environmental regulations. Utility Restructuring The continued restructuring of the electric and natural gas utility industries in the U.S. is expected to increase the role of non-utility generation in the nation’s power mix even more. Since 1996, 22 states have enacted major electricity restructuring legislation, while two others have issued compre- hensive regulatory orders. These actions have also led to growth in the competitive energy services industry. There is now a greater array of choices for electricity consumers than ever before. Electricity and natural gas users in the states that are active in the restructuring process are fre- quently able to get electricity providers to tailor service offerings to suit their individual needs. In particular, the larger industrial and commercial users, including municipalities, school, and irrigation districts, are increasingly being offered flexible contractual terms and conditions, innovative pricing options, financial risk management strategies, energy efficiency audits and services, and distrib- uted energy resource options. Environmental Policies Implementation and enforcement of existing environmental laws and regulations affect today’s technology choices for power generation. As existing power plants get replaced, the new ones will necessarily incorporate new designs and advanced systems to achieve greater efficiency and lower emissions. Power plant emissions are currently subject to regulatory controls for sulfur dioxide, oxides of nitrogen, particulates, volatile organic compounds, carbon monoxide, and air toxics. In addition, global concerns about climate change have led to interest in tracking carbon emissions from power production. In the future, carbon dioxide and other “greenhouse” gases could be added to the list of power plant emissions subject to regulatory controls. The designs for advanced microturbines and other distributed energy resource options must include features to ensure that they comply with all foreseeable environmental siting and permitting regulations. The trend is clearly toward increas- ingly stringent environmental requirements. If the next generation of microturbine systems have lower emissions and higher efficiencies compared to today’s models, then commercialization of these advanced products could yield substantial public benefits. Use of clean and renewable fuels, highly U.S. DEPARTMENT OF ENERGY OrFice oF ENERGY EFFICIENCY AND RENEWABLE ENERGY efficient combustion equipment and turbines, advanced materials, and advanced recuperators are among the options that can be used to control environmental emissions from microturbine sys- tems. Use of microturbines in combined heat and power systems can double or triple overall thermal efficiency compared to electricity-only units, thus providing even greater opportunities for emissions reductions. One of the promising applications for microturbines involve their use in buildings for cooling, heating, electricity, humidity control, and indoor air quality. In these cases, building codes and fire and safety codes will need to be considered along with environmental siting and permitting requirements. Market Applications Microturbines can be used in a variety of electric- ity and thermal energy applications due to their small size, low unit costs, and useful thermal output. The market assessments recently com- pleted by Arthur D. Little, Inc. and Resource Dynamics Corporation identified eight potential types of applications for microturbines: 1) continu- ous generation, 2) peak shaving, 3) back-up power, 4) premium power, 5) remote power, 6) cooling, heating and power, 7) mechanical drive and 8) wastes and biofuels. The use of microturbines for continuous genera- tion will typically involve applications requiring over 6,000 hours of operation per year. To succeed in this market application, microturbines will have to be able to generate electricity at costs competi- tive with grid-connected power. In certain circum- stances, users that have deep concerns about the reliability of the grid or about power quality may be willing to pay more for on-site power generation than for grid-connected electricity. Peak shaving’ applications for microturbines would typically require much less than 1,000 hours of operation per year. For peak shaving, users would run on-site generation to avoid paying high on-peak prices or utility demand charges. In some areas, avoidance of these costs can justify invest- ment in on-site power facilities that operate only several hundred hours per year. The shift toward competitive electricity markets has also meant a shift toward real-time pricing of electricity. During peak periods, it is not unusual for the cost of power to be 3-5 times higher than it is during off-peak periods. During system emergencies, on-peak power costs can be 10 times greater or more than off-peak power costs. Short term price spikes 20- 100 times higher occurred in wholesale spot markets in the Midwest during the summer of 1998. Back-up power users require 100% reliable electricity. Some users, like hospitals and airports, are required by regulations to install and maintain back-up power units. Back-up power systems may run less than 100 hours per year but they must be ready to come on line at a moments’ notice in the event of a power outage. Diesel generators currently have a large fraction of the back-up power market. The use of microturbines in this market will be driven by a variety of factors, particularly their costs relative to diesel generator sets, but also their ability to start-up rapidly and reliably. Relatively low expected O&M costs could be an advantage for microturbines in back-up power applications. Markets for premium power exist where the industrial process requires power with a higher quality than provided from the grid. This could include AC power with a well-defined wave form, frequency, and/or power factor. Power quality concerns are found in industries that use sensitive electronic equipment that requires tightly con- trolled, sinusoidal AC wave forms, or machinery that operates on well-defined DC power. The use of microturbines for premium power could defray power conditioning costs to the user, allow for more precise and flexible manufacturing processes, * Although efficient, clean, durable gas turbines are not necessarily required for intermittent modes such as peak shaving and backup, the incremental cost of installing advanced microturbines for these purposes would extend the parameters for economical operation, thus improving the benefits. U.S. DEPARTMENT Or ENERGY OFFICE OF ENERGY EFFICIENCY AND RENEWABLE ENERGY and reduce losses in production from outages and other types of power quality disruptions. Remote power applications are for off-grid locations such as oil and gas production and certain mining operations. Locations that lack grid access often lack access to natural gas distribution systems as well. The ability to use portable fuels such as diesel or propane is a distinct advantage for remote power equipment. System reliability is a top priority. Markets for cooling, heating, and power systems include those manufacturing processes and building applications that have needs for thermal energy as well as electric power. There is potential for expanded use of industrial combined heat and power systems. The possibilities expand when economical off-site uses for the thermal energy are identified, as in district energy systems. The use of microturbines in cooling, heating, and power applications could open up new opportunities for smaller scale systems in manufacturing plants to meet specific needs for thermal or mechanical energy as well as electric power. Buildings cooling, heating, and power systems can provide electricity and thermal energy for cooling and humidity control. Mechanical drive applications would use microturbines to run shaft-driven equipment such as gas and air compressors, refrigeration units, chillers, desiccant humidity control systems, and pumps. Operation and maintenance costs are a critical driver along with the cost of electricity and the ease of access to fuels. The market for wastes and biofuels burning microturbines are found in those industries that produce solid, liquid, or gaseous fuels as a waste or by-product such as pulp and paper, food process- ing, and steel making. The amount of power produced from these applications is a function of the amount of waste material produced and the technologies available to convert the waste into usable fuel. Market Potential The U.S. Department of Energy’s Energy Infor- mation Administration’ reports that approximately 380 gigawatts of new electric capacity will be added to the nation’s power fleet by 2020, including retirements of existing facilities. The market share for distributed energy resources has been esti- mated to range from 10 to 20 percent of these capacity additions, or 38 to 76 gigawatts.'° Because of their compact size, relatively low capital costs, and expected low operations and maintenance costs, microturbines are expected to capture a significant share of the potential distrib- uted generation market. While substantial, these estimates are based on the assumption that in the future power users will face largely similar power choices under generally similar market conditions. However, there is a widely held alternative view that holds distributed generation as a potentially revolutionary technology with “disruptive” impacts that “...reshape the fundamental value network of an industry.”"! Examples given of other revolutionary technologies that have had disruptive impacts include personal computers, the internet, cellular telephones, and mini-mills. Such possibilities for distributed genera- tion make it difficult to assess the market potential for microturbines. The technical potential for microturbines in the manufacturing industries has been estimated recently by Onsite Sycom Energy.'? There are approximately 100,000 industrial sites in the U.S. * Annual Energy Outlook 1999 Energy Information Administration, December 1998, DOE/EIA-0383(99). #0 “Small Generators Fuel Big Expectations” by John C. Zinc, Power Engineering, February 1999. “” Distributed Generation Primer: Building the Factual Foundation — An Arthur D. Little Multi-Client Study Draft October 1, 1999 ” Onsite Sycom Energy November, 1999 Inc Estimates of Technical Potential for Micropower in Manufacturing Industies Technical Memorandum U.S. DEPARTMENT OF ENERGY OFFICE OF ENERGY EFFICIENCY AND RENEWABLE ENERGY with average electrical demand between 100 kW and 3,000 kW. This represents about 70 GW of electrical demand today and 91 GW in 2010 that could be supplied by microturbines or other power technologies. For example, electrical demand in the forest products industries at facilities between 100 kW and 3,000 kW is estimated to be about 9 GW in 2010. For chemicals the 2010 estimate is 6.3 Gw. Several recent studies have attempted to estimate the potential industrial power market for microturbines. However, these studies do not take the potential for disruptive impacts into account. They also do not address the full market potential because of the difficulty of capturing the industrial market for mechanical drives or the extent to which grid reliability and power quality will be a factor. The studies also do not account for the market for microturbines in buildings for power, heat, hot water, cooling, and humidity control. Even so, the studies by Arthur D. Little, Incorpo- rated and Resource Dynamics Corporation (see footnotes 2 and 3 on page 2 in the Introduction) conclude that the market potential for existing microturbine products is significant and that the potential market could increase substantially if the cost, efficiency, durability, reliability, and environ- mental emissions of the existing designs are improved. U.S. DEPARTMENT OF ENERGY 7 OrFice OF ENERGY EFFICIENCY AND RENEWABLE ENERGY 3. OVERVIEW OF MICROTURBINE SYSTEMS M icroturbines have primarily evolved from 4 automotive and aerospace applications. Figure 2 is a schematic of a microturbine in a generic stationary commercial or industrial applica- tion.'® For the urposes of stationary energy generation combustion turbines such as microturbines have advantages over other kinds of heat engines in terms of atmospheric emissions, fuel flexibility, noise, size, and vibration levels. Combustion turbines have limitations which include relative efficiency, costs, and rotational speeds. All of these relate directly to the size of the machine. While this relationship between size and perfor- mance level generally holds for other types of heat engines, the scaling laws tend to be more restric- tive for combustion turbines than for the other types of heat engines, such as piston-driven reciprocating engines, for example. Exhaust Potential waste-heat recovery Compressor Air a. \ Heat to users Within the class of heat engines known as combus- tion turbines, certain design features as well as size distinguish the various types. Figure 3 illustrates how specific design features relate to the size and performance of turbines. This figure provides a basis for discussing the differences between microturbines and other types of combustion turbines. Large Combustion Turbines For electricity generation, large combustion turbines are generally characterized by the follow- ing major design features: * Axial flow multi-stage compressors and turbines * Internally cooled turbine vanes and blades * Cooled disks and vane support structures Turbine Figure 2. A schematic of a generic microturbine system. “ The figure is presented for illustrative purposes and is intended to describe common or possible gas turbine systems. It is not intended to constrain conceptual designs or configurations for advanced microturbine systems. U.S. DEPARTMENT OF ENERGY OrFicr OF ENERGY EFFICIENCY AND RENEWABLE ENERGY * Low NO, combustion systems based on lean premix for natural gas or water/steam injection for fuels other than natural gas * Multiple burner combustion systems * Single shaft layouts The larger size systems (150-400 megawatts) frequently are designed for use with steam bottom- ing cycles, and newer advanced turbine system designs are adopting closed-loop, steam cooling. With this in mind, pressure ratios are typically 16:1. Design features such as intercooling, staged combustion, and methods to reduce parasitic heat losses may also be incorporated. Aeroderivative Industrial Combustion Turbines Aeroderivative combustion turbines are generally characterized by the following design features: * Axial flow multi-stage compressors and turbines ¢ Higher pressure ratios (over 25:1) ¢ Higher temperatures (2400° F) * Internal cooling (as in the large gas turbines) ¢ Multi shaft arrangements * Multiple burner combustion systems * Greater use of advanced alloys, a RR RSE nS et RE SRR ca encnnean * Usually axial flow multi stage compressors, but sometimes radial flow compressors are used in smaller models * Axial flow turbines * Single or split shaft arrangements, depending on the application * Internal cooling in early stage vane rows, but less use of blade cooling and advanced alloys than in other types of turbines * Cooled disks and vane support structures * Geared output shafts for electric power In the industrial turbine size range of 2-20 MW there is a pronounced gradation in the design characteristics. In the larger size ranges, industrial turbine designs tend to be similar to those of the large combustion turbines, although geared output shafts are still usual where electric power is produced. Direct mechanical drive, with a separate power turbine shaft are also used. Gas compres- sion is one example. In the smaller size ranges, tadial flow compressors are sometimes used, pressure ratios tend to decrease as size decreases, blade cooling is seldom used, and single side- mounted combustors are often used (rather than the in-line arrangements used in larger turbines). especially single crystal alloys for 60 L | COMBINED blade castings | { CYCLE 50 t T There generally is less use of refine- REROCCRNATHE ments to reduce heat losses, but more = 40 SIMPLE CYCLE use of variable compressor geometry to z | INDUSTRIAL improve part load performance. Com- GB 30 | pressor intercooling may be used, depend- E | ing on the design of the core aircraft engine and the way in which it is adapted for stationary use. N o Heavy Frame Industrial Combustion Turbines 40 Industrial combustion turbines are generally characterized by the following design features: 0.01 ADVANCED — COOLED BLADES COOLED VANES 0.10 1,00 10.00 OUTPUT MW 100.00 re 3. Gas Turbine Design Features Related to Output Capacity U.S. DEPARTMENT OF ENERGY OFFICE OF ENERGY EFFICIENCY AND RENEWABLE ENERGY Since economies-of-scale do not apply in the smaller size ranges, design simplification and production economics assume greater importance. The materials and mechanical design issues, and the increased aerodynamic penalties associated with smaller size systems, tend to reduce thermo- dynamic efficiency. Microturbines Microturbines are the newest type of combustion turbine that are being used for stationary energy generation applications. There are certain design features that distinguish microturbines from the other types of combustion turbines discussed above. However, there is not a distinct size limit that distinguishes microturbines from smaller sized industrial turbines. In fact, small industrial turbine designs inevitably share some of the microturbine features.As a result, small industrial turbines will benefit from advances made in the design features used in microturbines. Microturbines are generally characterized by the following design features: * Radial flow compressors + Low pressure ratios defined by single-or possibly two-stage compression * Minimal use of vane or rotor cooling Recuperation of exhaust heat for air preheating Use of materials that are amenable to low cost production Very high rotational speeds on the primary output shaft (25,000 RPM, or more) With these design elements the simple cycle efficiency (without the use of a recuperator) would be substantially lower than the efficiency of competing systems such as reciprocating engines, particularly in high load factor applications with base-load or intermediate-load requirements. However, for applications such as emergency power, where the duration of operations is rela- tively low and fuel costs are of secondary concern, where other factors such as ease of installation and maintenance are considered, unrecuperated microturbines may be used. In many applications the very high rotational speeds require gear reduction equipment. In the case of electricity generation a commonly used alternative is a direct drive high frequency alterna- tor coupled with a stationary rectifier and mains frequency alternator. Microturbines have been produced in very small sizes (e.g., a few kilowatts), but commercially viable products are in the range of tens to hundreds of kilowatts. This range spans two to three orders of magnitude, and the efficiencies that can be achieved in practice will vary significantly. Existing Microturbine Systems Microturbine systems are just entering the market and the manufacturers are targeting both traditional and non-traditional applications in the industrial and buildings sectors including combined heat and power, backup power, continuous power genera- tion, and peak shaving to reduce costs during peak demand periods. So far, four U.S. manufacturers have made commitments to enter the microturbine market. Honeywell (AlliedSignal) is offering a 75 kW product, Capstone has a 30 kW product, Elliott has 45 and 80 kW products, and Northern Re- search and Engineering Company will have several products in the 30 to 250 kW size range. These manufacturers are entering into marketing and distribution alliances with other firms. Other companies such as Allison Engine Company, Williams International, and Teledyne Continental Motors have expressed interest in developing microturbine products. European (Volvo and ABB) and Japanese (Toyota) companies are also devel- oping microturbine products and are expected to enter the U.S. market within the next several years. U.S. DEPARTMENT OF ENERGY 10 — Orrice oF ENERGY EFFICIENCY AND RENEWABLE ENERGY 4. PROGRAM Mission, GOALS, AND STRATEGY hrough partnerships with industry, government, and non-government organi- zations, the Office of Power Technologies devel- ops and delivers advanced technologies and practices to assist in meeting challenging goals in the areas of renewable resource development, environmental protection, and global competitive- ness. The mission of the Office is to lead the national effort to support and develop clean, competitive, reliable power technologies for the 21* century. This mission is accomplished by: * Encouraging electricity suppliers to choose and deploy renewable energy and energy efficiency technologies on an equitable basis with other supply technologies. Addressing the technological and institutional constraints that impede the adoption of renew- able energy and energy efficiency technologies worldwide. Working with utility, industry, and other stake- holders to realize the full market potential for renewable energy and energy efficiency tech- nologies, both in the United States and in other countries. The mission, goals, and strategies of the Advanced Microturbine Systems Program support these aims. The mission of the Advanced Microturbine Systems Program is to lead a national effort to design, develop, test, and demonstrate a new generation of microturbine systems that will be cleaner, more fuel efficient, more fuel-flexible, more reliable and durable, and lower cost than the existing fleet of first generation products that are just entering the market today. The overall goals of the program are to improve energy efficiency, reduce environmental emissions, and increase the competitiveness of U.S. busi- nesses through the development and deployment of advanced microturbine systems. The program’s mission and goals are consistent with the Department’s overall goals as set forth in the Comprehensive National Energy Strategy to improve the efficiency of the energy system, ensure against energy disruptions, promote energy production and use in ways that respect health and environmental values, and expand future energy choices.'* The program’s mission and goals are consistent with the goals of several recent initiatives of the Department of Energy in the areas of energy grid reliability and distributed energy resources. The program can also contribute to the President’s Executive Orders on increasing the use of energy efficiency and renewable systems in federal facilities and on increasing the use of bioenergy and biobased products throughout the economy. The ultimate aim of the program is to produce “ultra-clean, highly efficient” microturbine product design(s) by fiscal year 2006 that are ready for commercialization and achieve the following performance targets: * High Efficiency — Fuel-to-electricity conver- sion efficiency of at least 40 percent. ¢ Environmental Superiority — NO, emissions lower than 7 parts per million for natural gas machines in practical operating ranges. * Durable — Designed for 11,000 hours of operation between major overhauls and a service life of at least 45,000 hours. + Economical — System costs lower than $500 per kilowatt, costs of electricity that are competi- tive with the alternatives (including grid-con- nected power) for market applications, and capable of using alternative/optional fuels includ- ‘ Comprehensive National Energy Strategy, U.S. Department of Energy, DOE/S-0124, April 1998. U.S. DEPARTMENT OF ENERGY OFFICE OF ENERGY EFFICIENCY AND RENEWABLE ENERGY ing natural gas, diesel, ethanol, landfill gas, and other biomass-derived liquids and gases. There are a number of scientific, engineering, and institutional barriers that need to be addressed for these mission goals and performance targets to be achieved. The strategy is to implement a multi- year RD&D program that is tightly integrated with research programs on microturbine systems in industry, universities, national laboratories, and other federal programs and agencies. The program will build on recent and existing RD&D efforts sponsored by the Office of Energy Efficiency and Renewable Energy and Fossil Energy and others in advanced materials, combustion systems, turbines and engine components, power electronics, and sensors and controls. An important aspect of the proposed RD&D activities will be complementary efforts in technol- ogy transfer, technical analysis and coordination, and communications. In part, these efforts will help to ensure that the RD&D projects stay well- aligned with market needs. Efforts will be under- taken to monitor and analyze industrial, commer- cial, institutional, and residential needs for all types of renewable and fossil-fueled distributed energy resources, particularly microturbine systems. Projects to develop information clearinghouses, workshops, program review meetings, and confer- ences will be undertaken to foster better communi- cations among the many stakeholder groups with interests in distributed generation and microturbines, including federal and state govern- ment officials, equipment manufacturers, electric and gas utilities, energy services providers, inde- pendent power producers, and potential users from the industrial and buildings sectors. U.S. DEPARTMENT OF ENERGY 12 — Orrice or ENercy EFFICIENCY AND RENEWABLE ENERGY 5. RD&D NEEDs ‘ or microturbines to reach their full market Ez potential and compete successfully with grid-connected power and other distributed energy Tesource options such as reciprocating engines, fuel cells, wind, and solar power systems improvements must be made in the technology. While there is a significant market for the existing technology microturbines, improvements in the efficiency, cost, durability, and environmental performance can expand the potential market two- to-three fold.'* For example, new system designs are needed as well as improved performance of subsystems and components to increase the efficiency and teliability of microturbines, and to lower system costs. Significant progress can be made through development and use of advanced materials to improve the reliability, durability, and useful life of various subsystems and component parts, and to enable operations at higher temperatures. Long term improvements can come from materials research and development in ceramics and metal alloys to improve recuperators and other system parts including hot section components such as rotors and combustor liners. In addition, promising designs need to be field tested for users to gain confidence in their performance. Certain problems can only be detected and resolved though monitoring of field installations to determine microturbine failure and maintenance requirements and in answering questions about the service life of the equipment. Microturbine Systems, Subsystems, and Components In order to meet the program mission and goals, research must be conducted on the performance of the entire microturbine system, including their integration into market applications and the utility gtid. The total system must be designed properly to work together efficiently and reliably. Component integration will be an important task especially as individually improved components are integrated into existing and new product designs. System modeling and simulation will be an important part of this task. System-level RD&D will be important in determining the research priorities for specific components through better understanding of trade-offs in cost, efficiency, and environmental performance. Modeling and Simulation To conduct systems studies and develop promising designs for advanced microturbines, it will be necessary to model and simulate the performance of various subsystems and components. A particu- larly important challenge is combustion modeling to develop more detailed understanding of the emis- sions characteristics and controls. Work is needed to identify innovative cycles, to optimize cycles, and to optimize heat recovery. Simulation modeling of aerodynamics and heat transfer in turbine blades in small machines will aid in the development of advanced microturbine designs. Improved models that can simulate operations of complete microturbine systems under a variety of environmental and operating conditions need to be developed to analyze trade-offs in the integration of individual subsystems and components. Also needed are simulation models that can analyze the potential impacts of microturbine systems on the stability and operations of the utility’s power grid. These simulations should cover the full range of potential applications for microturbines, including continuous generation, peak shaving, back-up power, combined heat and power, and remote operating modes. “ Opportunities for Micropower and Fuel Cell/gas Turbine Hybrid Systems in Industrial Applications prepared by Arthur D. Little for Oak Ridge National Laboratory, April 1999, and industrial Applications for Micropower: A Market Assessment prepared by Resource Dynamics Corporation for Oak Ridge National Laboratory, April 1999. U.S. DEPARTMENT OF ENERGY Orrick OF ENERGY EFFICIENCY AND RENEWABLE ENERGY Manufacturing Costs In commercializing advanced microturbine designs, manufacturing scale-up techniques will be signifi- cant in lowering system costs. In fact, existing microturbine systems have yet to be mass pro- duced. Studies are needed to identify scale-up issues for the next generation of systems since these could include greater use of advanced alloys, coatings, ceramic components and other electronic parts. As ceramic subsystems and components are developed and tested, the RD&D effort should include more detailed research and analysis on manufacturing scale-up issues and techniques. Concurrent engineering techniques should be used in the design of ceramic components. The ceramic components design team should consist of both engine and component designers. The concurrent engineering design team should aim for compo- nents that can be fabricated at high yields to reduce costs and waste of materials. Recuperators/Regenerators Conventional recuperators are sheet-metal heat exchangers that recover some of the heat from an exhaust stream and transfer it to the incoming air stream. The preheated incoming air is then used in the combustion process. If the air is preheated, less fuel is required to raise its temperature to the required level at the turbine inlet. The most effective conventional metal recuperators can produce 30-40 percent fuel savings from preheat- ing. However, conventional stainless steel recuperators can be used only with exhaust-gas inlet tempera- tures below 1200° F. At higher temperatures, the metal is susceptible to creep and oxidation, which causes fouling and structural deterioration and leaks, rapidly reducing the effectiveness and life. Advanced metal or ceramic recuperators will be necessary as engine operating gas temperatures increase to increase efficiency. Further recuperator development is needed to reduce costs, extend service life, and enable reliable operation at higher temperatures. Work needs to continue in the development of advanced metal materials and designs that have the capability of operating at higher temperatures and that have improved corrosion resistance. Many of the advanced metal and ceramic materials remain largely untested. Cost effective manufacturing with these materials will play a crucial role in decreas- ing the cost of advanced recuperators. Manufac- turing research is needed to identify cost reduction techniques such as near net-shape fabrication of ceramic recuperator elements that require minimal machining and assembly. Combustion To meet market and regulatory requirements and achieve the performance targets set forth by this plan, research on combustion characteristics and emissions is needed. Techniques for pollution prevention and control of the criteria pollutants and carbon dioxide should be researched. Trade-offs among pollution control, energy efficiency, and cost must be understood and optimized. Technologies such as catalytic combustion, hot wall liners, dry controls, lean premix, selective catalytic reduction, and others need to be investigated to determine how they can be applied to reduce NO, emissions in microturbines. Other Fuels Fuel options other than natural gas include diesel, landfill gas, industrial off-gases, ethanol, and other biobased liquids and gases. The development of biomass-derived fuels is a top priority of the Department’s Biobased Products and Bioenergy Initiative and opportunities to use these fuels for distributed generation need io be explored. Natural Gas Compression Natural gas is currently the preferred fuel for microturbines due to favorable costs and combus- tion and emissions characteristics. Fuel gas compression equipment will be needed in locations where the gas pressure is too low for direct firing in microturbines. Needed are lower cost, more reliable, and more durable gas compression U.S. DEPARTMENT OF ENERGY 14 = Orrice or EnerGy EFFiciENCy AND RENEWABLE ENERGY equipment in size and pressure ranges suitable for microturbines. Gas compression equipment have been used in larger power plants, but are not readily available for smaller, low-cost microturbines where capital and O&M costs are critical. A concern to be addressed is that when used in industrial power applications other than continuous power or combined heat and power operations, the starting and stopping of multiple, gas-powered microturbines could place strain on the natural gas supply system, potentially leading to local gas main pressure fluctuations. Fuel flexibility is a desirable product attribute for industrial power users and is one of the perfor- mance targets of this program for microturbine systems. Many potential users of microturbines value the ability to switch fuels to control costs. The capability of a combustor to handle multiple fuels without increasing emissions would greatly increase the number of opportunities for microturbines. For example, the ability to utilize waste fuels could give microturbines an important advantage in expanding its share of the distributed generation market. Power Electronics Because most microturbines typically generate high frequency AC that must be converted to DC and then back to grid compatible AC, the systems require reliable and efficient electronic power conditioning devices. Improved power conditioning equipment such as thyristors and inverters would greatly benefit the performance and packaging of microturbines. Other distributed generation technologies as well as conventional power plants would benefit from improvements in these power electronic devices. While power electronic equipment is commercially available, the costs are high due to small production volumes. Sensors and Controls Advances in sensing and controls technology enable the optimization of the system in ways not previously imagined. These advances include the development of sensors permitting in-situ combus- tion and power quality measurement. Advanced controls technologies permit rate optimization, economic load allocation, and predictive and data- centric control. Integrated into advanced distrib- uted sensing and control architectures, these technologies allow new trade-offs to be made in the design that achieve the system requirements called for in this plan. Advanced Materials New materials will be a key enabling technology for advanced microturbine systems, subsystems, and components. Advanced materials will have to be designed and tested to endure and perform properly in microturbine-specific environments. These environments will reflect the operating conditions in terms of pressure and temperature. In fact, a big jump in microturbine efficiency can be achieved with significant increases in engine operating temperatures, and the most likely materi- als to accomplish this are ceramics. Current microturbine designs utilize metallic components without air-cooling, and the resulting high metal temperatures result in shortened lifetimes. There is a lack of proven low-cost ceramic components for turbines and recuperators for achieving such high temperature operation. In general, research is needed on cost effective, high temperature materi- als and manufacturing processes for use in microturbine systems as well as design and life prediction tools for subsystems and components. Structural ceramics such as silicon carbide or silicon nitride have long been considered primary candidates for hot section components in advanced gas turbines. Initial property limitations such as low strength, low Weibull modulus, and poor creep resistance were successfully addressed in a number of materials development programs. In spite of these advancements, recent engine tests have shown that the long-term performance of ceramic components may still be limited by envi- ronmental degradation and foreign object damage. In addition to these technology barriers, several U.S. DEPARTMENT OF ENERGY OrFice OF ENERGY EFFICIENCY AND RENEWABLE ENERGY manufacturing challenges including high component costs and unacceptable product yields remain to be solved. These challenges can be addressed by the concurrent design of the components. The materials requirement for recuperators used in near-term microturbines may be categorized by recuperator maximum operating temperatures: 1200°F (type 347 stainless steel), 1500°F (Inconel) or >1600°F (ceramics). These limits are imposed by existing materials properties such as strength and corrosion, oxidation, and creep resistance that affect recuperator failure. Metallic alloys are now usable within the two, lower temperature ranges, while ceramics would be needed for the higher temperature environments if required. Development of advanced materials for energy technologies is a top priority RD&D area for the Department of Energy and other federal agencies including the Department of Defense, the National Aeronautics and Space Administration, and the National Institute of Standards and Technologies. As a result, there are opportunities to leverage existing RD&D investments in advanced materials and apply them to microturbines through enhance- ment of existing or creation of new industry- government RD&D partnerships. Technology Evaluations and Demonstrations Microturbines are relatively new and untested in commercial applications. Users have no indepen- dent, statistically significant data on performance, reliability, and life of microturbines for comparison with reciprocating engine characteristics and grid supplied electricity. In fact, much of the existing field test information on microturbines is consid- ered proprietary and is not widely shared. Durability, reliability, and useful service life remain significant unknowns for potential users who are trying to decide among alternatives. Both technical performance and O&M costs over the life of the machines must be proven through reliable data collected from demonstrations and field tests. Computer simulations, calibrated with field data, can be a valuable tool for supporting field testing and demonstration projects. Achieving fuel flexible systems will be a major technical challenge. Testing will be needed to determine the optimal combustion conditions for different types of fuels. The market entry phase for the existing generation of microturbines provides an opportunity to gather data and answer a variety of questions about operating performance, cost, and life expectancies. Also, there are concerns to address related to interconnection with the grid. In general, demonstrations are an area for exten- sive joint industry-government collaborations, with industry providing the majority of the resources needed. Government involvement can include financial assistance as well as technical assistance in disseminating results to a wide audience of potential users. Reliability and Durability Although some testing has been done by the manufacturers, from the customer’s standpoint the reliability and durability of microturbines remains unproven. There is a great need to gather data on microturbine systems running in a variety of environments, operating modes, and utility intercon- nections. Extensive RAMD (reliability, availability, maintainability, durability) testing should be con- ducted. Government support for RAMD testing beyond the 8,000 hour field test will be considered at that point in the program. Demonstration of the reliability of the hot gas path parts will be espe- cially important. A database of microturbine operating experience is needed and to be made available to potential users of systems. The data could also be used to guide RD&D. Grid Interconnection Interconnection with the electric grid has posed a significant barrier to microturbines and other small distributed energy resources. There are disagree- U.S. DEPARTMENT OF ENERGY 16 — Orrice or ENERGY EFFICIENCY AND RENEWABLE ENERGY ments between utilities and developers of distrib- uted energy equipment about how to address this problem. One issue is that interconnection stan- dards vary from utility to utility. Many project developers say they face interconnection standards that require them to use outdated equipment, undertake costly engineering studies, and go through lengthy approval procedures. On the other hand many utilities worry about maintaining reliable grid operations for customers located on feeders where distributed power systems have been installed. The utilities also worry about worker safety issues. The efforts of the Institute of Electrical and Electronic Engineers (IEEE) to develop standard interconnection protocols for distributed generation systems are being supported by the Department. The IEEE activities should be extremely helpful in specifying equipment needs for safe grid interconnection. With more units placed in the field, a better under- standing of the safety and reliability requirements of grid interconnection can be determined. For example, modification of protective relaying schemes may be needed at both ends of the circuit to insure proper coordination between upstream and downstream protective devices and to fully protect line repairmen and equip- ment. Application Issues Packaging of microturbine systems for the full range of potential applications remains an important, market-driven need. For example, microturbines can bre Seeger on sees ot nara rater @ Cosi, ney, and durability. ° Kavenoed ceramics and mets\ alloys. * energy efficiency and reduced emissions. Simple water heating and other forms of thermal energy connections are needed so the unit becomes a “plug and play” type of installation. For cooling, heating, and power and other applica- tions the potential customer base for microturbine systems is still not well understood. At the same time, potential customers are not aware of the product and its capabilities. While this is largely a marketing issue for the manufacturers, demonstra- tions and reliable data available to the public can play a useful role in serving customer needs. This can be accomplished through field tests that are conducted over a range of applications, geographic locations, and operating conditions. Table 1 summarizes the research, development, technology evaluation, and and demonstration needs of microturbine systems. @ Cost. effic emissions trado-ofts. ° Impacts On uulty system operations. L-@ High temperature capabilities. 00 ool oe toring. eee. number of units. cost, tite. BAM test ‘on bperating experience. Lo “Pegand piey"eption, @ “Plug and play” options. be used in cooling, heating, ne and power applications and in this mode they offer large possibilities for public benefits in terms of higher —— Table 1. Summary of RD&D Needs for Microturbines — U.S. DEPARTMENT OF ENERGY OFFICE OF ENERGY EFFICIENCY AND RENEWABLE ENERGY 6. RD&D Pian — Fiscar Years 2000 tHroucH 2006 T his RD&D plan calls for activities in three main areas toward the development of advanced microturbine systems over the next seven fiscal years. The four areas are: 1. concept development, 2. components, subsystems, and integration, 3. demonstrations, and 4. technology base development. The Department is planning to co-fund activities with industry in these three areas to produce new technologies that can be developed into commer- cial products or designs that satisfy the efficiency, economics, durability, and emissions goals of this program. Table 2 summarizes the estimated annual government funding requirements to implement this program. The total government funding require- ment over the next seven fiscal years is $63 million. It is expected that the total industry cost share will be fifty percent over the life of the program. Applicants will have the flexibility to allocate the cost sharing requirements among the members of the bidding team. Industrial plants and commercial, institutional, and residential buildings are important targets for commercial application of the advanced technolo- gies developed under this program. As a result, each funded activity must be able to demonstrate that its products address the needs of one or more REQUESTED = “4 of these potential market applications for clean, affordable, and reliable electric power, steam, hot water, process heat, refrigeration, air compression, space heating and cooling, humidity control, and/or mechanical drive. The Department plans to implement the program by allowing all program areas to be developed simultaneously as depicted in Figure 1 on page iii in the Executive Summary. Potential RD&D per- formers will be able to participate at any point in the program. The first several years of the program will emphasize concept development. However, projects that design and conduct initial tests of advanced components, subsystems and integrated microturbine systems could also be undertaken. A small effort to demonstrate existing microturbine systems, subsystems, and/or compo- nents could also be initiated from the outset of the program, depending on the applications that are received. The advanced testing, fabrication and prototyping of new components, subsystems and integrated microturbine systems will be emphasized during the middle years of the program. It is expected that the concept development area of the program will be completed by fiscal year 2005. The last two fiscal years will focus on the comple- tion of an 8,000-hour field test demonstration of one or more advanced microturbine systems that meet the goals of the program. PROJECTED FY 2000 | FY 2001/ FY 2002] FY 2003 | FY 2004 [FY 2005 | FY 2006 12.0 12.0 12.0 Table 2. Requested and Projected Government Funding Requirements of the Advanced Microturbine Systems Program (§ M) “ FY 2000 and 200! includes funding from the Industrial Distributed Generation Program ” The technology base development resources including the Advanced Microturbine Systems program. U.S. DEPARTMENT OF ENERGY it efforts focus on enabling technologies that support several programs in distributed energy OrFicr OF ENERGY EFFICIENCY AND RENEWABLE ENERGY Concept Development This area consists of new and novel concepts and conceptual designs that can be developed into commercial products that satisfy the goals of the program. The starting point for activities in this area will be, at minimum, technological concept(s) that have prior experimental evidence that indicate potential for contributing to the development of more efficient and cleaner advanced microturbine systems. New and novel concepts and conceptual designs will be supported for components, subsystems, and integrated microturbine systems. Successful concept development projects will include prelimi- nary designs for advanced components, sub- systems, and integrated systems. Preliminary design studies should include sufficient testing, empirical evidence, and/or computer analysis to prove the robustness of the concept in meeting the goals of the program. Potential applicants who have an innovative concept but lack the development experience to prepare a detailed design and fabricate and test prototypes can choose to team with firms who have that kind of experience or they can end their involvement in the program after submitting their concept. Concept development will continue through fiscal year 2004 to leave the door open for new and innovative concepts to have an impact on the design, fabrication, and testing of advanced microturbine components, subsystems, and inte- grated systems. It will also be possible for appli- cants to propose new concepts and preliminary designs based on lessons learned from on-going RD&D. It is conceivable that concept development activi- ties could be supported through fiscal year 2005 as it would be ill advised to rule out the potential for support for truly merit worthy ideas. However, support for concept development beyond fiscal year 2004 is not planned at this time and would ultimately depend on the quality of the concept and the amount of funding available at that point in the program. Components, Subsystems, and Integrated Systems This area is expected to cover the majority of research and development activities of this pro- gram. The area consists of a wide variety of potential activities that can be aimed at single components, multiple components and subsystems, and/or integrated microturbine systems. Activities in this area will be supported up to the last year of this program. During the program’s final year emphasis will be on the 8,000 field test demonstra- tion project(s) of the advanced microturbine system(s). Activities in this area will begin with the develop- ment of detailed designs of the selected compo- nents, subsystems, and integrated systems. The detailed designs will include investigations of all process and economic parameters. The analysis will include all facets of operations under a variety of environmental conditions. Detailed designs for the development of components and subsystems will include plans for the subsequent integration into a microturbine system that meets the goals of the program. The detailed designs will be manufactured and assembled into components, subsystems, and integrated systems suitable for bench-scale testing. Further development studies and testing will be done to verify the design, provide operating and control parameters, and full-scale definition such as allowable operating ranges, sensitivity to fuel variability, and other factors that could affect the cost and performance of the advanced microturbine components and subsystems. This area will include fully verified and tested designs and/or bench-scale prototypes of components, subsystems, and integrated systems. U.S. DEPARTMENT OF ENERGY OFFICE OF ENERGY EFFICIENCY AND RENEWABLE ENERGY | SE ER RR ER ER SE RTE SEE SRR RE SNARES TS Design and testing of advanced microturbines will include development of control systems. Such systems will include sensors, controllers, and logic that direct the operation of the advanced microturbine components and subsystems and the integration of the entire microturbine system into the operations of users and the electric power and natural gas distribution system. Control system activities could include hardware and software development for the implementation of operating procedures for start-up, steady operations over usual power ranges, maintenance schedules, and unplanned outages. Depending on the relative maturation of the technology, detailed design and testing activities of components and subsystems could begin during fiscal year 2000 and will continue through fiscal year 2005. The design and testing of the advanced microturbine itself will be developed in parallel to the development of components and subsystems to assure compatibility, optimum fit, and functionality. It is possible, but not expected, for work to begin immediately in fiscal year 2000 on a complete microturbine system that meets all of the goals of the program. This activity will be a major aim from fiscal year 2005 through the completion of the project in fiscal year 2006. Such activities include fabrication of a complete microturbine system that incorporates the scientific and engineering prin- ciples, components, and subsystems (including controls). The entire microturbine system could be the result of concept development funded under this program, or not. Through testing, computa- tional analysis, and other means, the performance of the advanced microturbine system will be verified and validated to achieve the design parameters. Prior to proceeding to field test demonstrations, the design(s) for the advanced microturbine system(s) must be shown to achieve the goals of the program and account for potential trade-offs in the targets for efficiency, economics, durability, and emissions. Proof testing will be based on natural gas fuels but it should be ac- knowledged that multi-fuel capability is an impor- tant marketing issue that advanced microturbines may address under this program. Demonstrations One of the first activities in this area will be the development of a plan for conducting field test demonstration projects over the course of the program. Because of the small size and modularity of microturbine units, it is critical to obtain operat- ing data across a wide range of sites, sizes, environmental conditions, and applications. Be- cause of funding constraints, it will be necessary to limit demonstration projects to those that offer the greatest information and value. As mentioned, the focus of the demonstration activities in the last two years of the program will be on an 8,000 hour field test of the advanced microturbine system(s). Reliability, availability, maintainability, durability (RAMD) testing will probably involve field demonstrations exceeding 8,000 hours of operation. Government involvement in such efforts will be considered at that point in the program. Throughout the program, demonstra- tion projects will be supported to obtain information on components and subsystems (including con- trols), as long as those activities can be shown to contribute to achieving the goals of the program. At minimum, all demonstration projects will be designed for 4,000 hours of operation. Host sites will be sought from industrial, commercial, institu- tional, and residential buildings and will cover a range of geographical and weather conditions and include buildings cooling, heating, and power applications, if possible. Each demonstration project will include a coordinated plan for the demonstration that incorporates the perspectives of all parties and explains how the results will be disseminated to interested users. The plan will include a discussion of assignment for responsibil- ity of various tasks including business arrange- ments, balance of plant equipment, site construc- U.S. DEPARTMENT OF ENERGY 20 = Orrice or ENERGY EFFICIENCY AND RENEWABLE ENERGY tion, licenses and permits, site integration, periodic inspections, third party visits, data acquisition, and Teporting. Demonstration projects must be representative of significant market segments or applications of the distributed power generation industry. Successful demonstrations will be expected to exemplify resolution of critical engineering and/or institutional barriers such as interconnection with the local electric power and/or natural gas distribution system. Because of the widespread perception of utility interconnection as a barrier to the use of microturbines and other distributed power systems, it is expected that most of the demonstration projects will address this issue. In this regard, it is expected that all hours of operation accumulated under the demonstrations shall be gained while the microturbine is generating electric power. Addition- ally, all such hours of operation may be accumu- lated while the host site is interconnected with the existing electric power and natural gas distribution grid. However, information from demonstrations of mechanical drive and combined heat and power applications are also encouraged. Accelerating the use of cooling, heating, and power systems is one of the top priorities of the Department. Technology Base Development The technology base development effort is a crosscutting activity that contributes to several programs in distributed energy resources, including the Advanced Microturbine Systems program. This area consists of work in advanced combustion systems, materials, and sensors and controls that could be used in the development of advanced microturbine concepts, subsystems, components, and integrated systems. The most critical issue facing users of advanced combustion equipment are increasingly stringent environmental standards for air emissions. One of the major targets will be continued development of low NO, burner tech- nologies. Also needed are combustion processes for using biobased, wastes and off-gases, and low Btu fuels cleanly and efficiently. One of the more promising areas of advanced materials develop- ment is in engineered ceramics such as continuous fiber ceramic composites and advanced metal alloys for high temperature operations of turbine systems. Efforts are underway for demonstrating advanced materials such as engineered ceramics and alloys in advanced turbines. These efforts need to be continued for microturbine applications. Advanced sensors and control systems are needed to support microturbine development and applica- tion in buildings and manufacturing process envi- ronments. Data acquisition systems for gathering and processing measurements on performance parameters could lead to expanded use of adavnced microturbine systems in distributed energy resource applications. U.S. DEPARTMENT OF ENERGY OrFice of ENERGY EFFICIENCY AND RENEWABLE ENERGY 7. PROGRAM MANAGEMENT PLAN his program will be managed by the Office of Power Technologies in the Office of Energy Efficiency and Renewable Energy. A number of other organizations will be involved in the implementation and coordination of the planned RD&D activities. Figure 5 outlines the program structure and lists some of the major organizations that will be involved in the implementation and coordination of the program. Program management responsibilities include development and defense of the program’s annual funding request to Congress, development and dissemination of programmatic guidance and technical directions, coordination with related programs, priority setting, procurements, monitoring and tracking of projects, and achievement of the program’s mission, goals, and milestones. To assist in carrying-out these functions, the Chicago Figure 4. Program Structure Operations Office will be assigned responsibility for conducting major procurements and for manag- ing the execution of work by the industrial teams. Program implementation will be handled primarily by a variety of private industry contractors; the national laboratories and universities will also be involved. Selection of specific performers will be determined by a series of competitive solicitations and direct contracting under existing competi- tively awarded contract mechanisms. Periodic program review meetings will be held to track progress toward comple- tion of program milestones. Coordination with other offices in the Department, other federal agencies, industry groups, and state agencies is an important program management responsibility. Within the Department, the Office of Industrial Technologies (OIT) is working on the Industries of the Future process, including manaufacturing needs for industrial power and cooling, heating, and power technologies. The Office of Buildings Technologies and State and Community Programs (OBTS) is developing advanced energy systems for buildings. The Office of Transportation Technologies (OTT) conducts research and technology transfer activities in advanced combustion technologies and high temperature ceramics for vehicle engines. The Federal Energy Management Program is promot- U.S. DEPARTMENT OF ENERGY Orrick OF ENERGY EFFICIENCY AND RENEWABLE ENERGY ing the use of renewable energy, energy efficiency, and distributed energy resource technologies in federla buildings and facilities. The Office of Fossil Energy (FE) conducts research for large-scale gas turbines for central station utility applications. Coordination with these offices will include identifi- cation of opportunities for cost sharing of joint activities. There are other federal agencies that have RD&D programs related to the development of advanced microturbine systems. These agencies include the Department of Defense (DOD), National Aero- nautics and Space Administration (NASA), Environmental Protection Agency (EPA), and the National Institutes of Standards and Technologies (NIST). Opportunities for joint sponsorship and other forms of collaboration will be explored with these agencies. There are a number industry groups that have interest in or conduct RD&D activities related to microturbines. The end user industries that have the greatest estimated market potential for microturbines include food processing, large and small chemicals, mining, oil and gas production and exploration, pulp and paper, wood product, and textiles. This group includes several of the Indus- tries of the Future (IOF). The utility industry (electricity and natural gas) have significant interest in microturbine development including a number of individual utility companies, energy services companies, and independent power producers. Several industry groups have formed that have specific interest in distributed power technologies including microturbines. These groups include the U.S. Combined Heat and Power Association (U.S.CHPA), the Distributed Power Coalition of America (DPCA), and the California Alliance for Distributed Energy Re- sources (CADER). Research organizations such as the Electric Power Research Institute (EPRI), the National Rural Electric Cooperative Associa- tion (NRECA), and the Gas Research Institute (GRI) have identified distributed generation in general and microturbines specifically as strategic technology opportunities for their members. Several states have energy research offices that have interest in microturbine development. For example, the California Energy Commission (CEC) and the New York State Energy Research and Development Administration (NYSERDA) have programs underway, funding available for demon- stration projects of microturbine systems, and interest in working with the U.S. Department of Energy. The Association of State Energy Research and Technology Transfer Institutes (ASERTTD), an organization representing agencies in over a dozen states (including the CEC and NYSERDA) also has interest in working with the Department on microturbines. The CEC, NYSERDA, and ASERTTI have already signed memoranda of understanding with the Department of Energy to conduct collaborative activities in a number of areas, including microturbines. U.S. DEPARTMENT OF ENERGY OrFice oF ENERGY EFFICIENCY AND RENEWABLE ENERGY FUEL CELLS Department of Energy . Office of Fossil Energy Federal Energy Technology Center Iateaaehepecaaea ca FUEL CELLS Opening New Frontiers in Power Generation uel cells initially found application in space exploration, opening new frontiers by virtue of their inherently clean, efficient, and reliable service. Now efforts by the Department of Energy’s Federal Energy Technology Center, in partnership with industry, are bringing fuel cell costs down and opening new frontiers in the power generation industry. Fuel cells have the potential to truly revolutionize power generation. Fuel cell systems have few moving parts, making them reliable and quiet as well. No solid wastes are produced: and pollutant emissions are negligible. The potential electrical efficiencies can reduce carbon dioxide emissions by 50 percent relative to existing power plants. Moreover, their modular construction and electrochemical processing allow suppliers to match demand over a range of several kilowatts to a hundred megawatts and to maintain efficiency independent of size. FUEL CELLS—a Revolutionary Technology How Fuel Cell Systems Work uel cells produce power electro- chemically by passing a hydro- gen-rich gas over an anode and air over a cathode, and introducing an electrolyte in between to enable exchange of electrical charges called ions. The natural propensity of hydrogen in the fuel gas to react with oxygen in the air causes one or the other stream to become charged, or ionized. The flow of ions through the electrolyte induces an electric current in an external circuit or load. The effectiveness of this process is strongly dependent upon the electrolyte to create the chemical reactivity needed for ion transport. As a result, fuel cells are categorized co, by the type of electrolyte. The anode and cathode typically use catalytic materials to enhance reactivity. The products of the electrochemical conversion are heat, carbon dioxide (CO.), and water. No solid waste is produced. Very low levels of nitrogen oxides are emitted, but usually in the undetectable range. The process heat can be applied to useful purposes to further enhance efficiency. are relatively low because of high in concentrated form, facilitating capture. The CO, emissions => processor efficiency, and are vale Water Fuel cells have tremendous feedstock flexibility. Any hydrocarbon material can be used, whether gas, liquid, or solid. These materials must, however, undergo “reforming” to free the hydrogen from the carbon bonds. ; Natural gas, the most a common fuel used with fuel cells, is reformed by subjecting it to steam and Heat high temperatures. In order to use coal, biomass, or a range of hydrocarbon wastes, a similar pro- cess is applied, called gasification. But these more complex fuels require a clean- up step to remove pollutants that could otherwise poison the fuel cell elements. Fuel cell systems also require a power conditioner to convert direct current from the fuel cell to the more commonly used alternating current. A single cell typically produces 0.5 to 0.9 volts. These cells are stacked together and electrically connected in series to build up voltage and power delivery capability. Plants can be built to a customer's specific requirements from one to hundreds of kilowatts now, and eventually hundreds of megawatts. Fuel cells convert a remarkably high propor- tion of the chemical energy in fuel to electricity, making them very efficient. The electrochemical conversion also makes fuel cell efficiency largely insensi- tive to the size of the unit or the amount of load applied. FUEL CELLS—the Right Technology . . . he emergence of fuel cells comes at an opportune time. An unprecedented expansion in electricity need is forecasted, retail electricity deregulation (utility restruc- turing) is underway, and public environmental policy is placing a premium on efficiency and environmen- tal performance. StandAlone Remote Central Station Meeting Electricity Needs Domestically, there is a projected need for as much as 1.7 trillion kilowatt-hours of additional electric power over the next two decades, almost twice that of the past 20 years. The magnitude of this growth will severely strain many existing transmission and distribution (T&D) systems, precipitating capacity con- straints. Upgrading T&D systems is extremely costly and time consuming. Fuel cells are ideally suited to relieve T&D pressures by placing power at or near customer sites, which is called distributed generation. Power can be located near a substation to relieve transmission, or at user sites to relieve distribution. Fuel Cell Applications Efficiency can be significantly enhanced in on-site applications by using fuel cell process heat to: (1) heat facilities (com- bined heat and power), (2) generate steam for industrial processes (cogenera- tion), or (3) generate steam for electricity generation. On-site applications include: (1) relying solely on on-site power with no grid connection—stand-alone; or (2) using on-site power during periods of peak grid load and providing power back to the grid during off-peak periods—peak i shaving. Siting fuel cells is relatively easy with their small footprint, low noise levels, and lack of emissions. Computer Chip Manufacturer ... at the Right Time Alleviating Risk Utility restructuring shifts the burden of financing energy ventures from consum- ers to power suppliers, favoring less capital-intensive projects and projects requiring less time for permitting and construction. The modular nature of fuel cells enables energy suppliers to match capacity with specific load requirements, avoiding the high costs of large new plants and the potential for underutilized capacity. The absence of emissions significantly re- duces permitting time, usually a major time requirement in scheduling electric- ity generating operations. In addition, shop fabrication on a mass-assembly basis shortens installation time. Providing Reliable Quality Power Uncertainties associated with utility restructuring have exacerbated concerns over the reliability and quality of electric power delivery. Reserve margins are shrinking as energy suppliers increase capacity factors on existing plants rather than install new capacity to meet growing demand. This increases the probability of forced outages and reduced power quality. On-site fuel cell installation ensures reliable service, eliminates the voltage spikes and harmonic distortion typical of grid power, and tailors the power delivery for the most sensitive elec- tronic equipment. Addressing Environmental Concerns U.S. source emission standards are tightening for sulfur dioxide (SO,), oxides of nitrogen (NO,), and particulate emis- sions. More importantly, ambient air quality standards impose requirements that translate to near-zero tolerance for additional emissions as most regions of the country strive to come into compli- ance with existing capacity. Public policy, reflecting concern over global climate change, is providing incentives for capacity additions that offer high efficiency and use of renewable re- sources. Fuel cell emissions are negligible, and as a result, systems have been installed in some of the most environmentally sensitive areas without ramifications. Blanket environmental permitting exemptions have been issued in Califor- nia and Massachusetts. In addition, their high efficiency has resulted in fuel cells being adopted by a presidential Climate Change Action Plan. As part of the plan, the resultant U.S. Climate Change Fuel Cell Program provides rebates to acceler- ate fuel cell commercialization. Leveraging the Global Market Worldwide forecasts show electricity consumption nearly doubling over the next two decades, largely due to growth in developing countries without nation- wide power grids. Public dissatisfaction in urban population centers of these developing countries is beginning to precipitate environmental standards, but this will only become an economic driving force in the long-term. There are, however, an estimated 2-billion people in rural areas without access to a power grid who are demanding electricity. Industrialized countries like the United States face the same pressures to lower pollutant emissions and stabilize carbon emissions as energy requirements increase to support economic growth. Fuel Cells— The Technology of Choice Negligible emissions High efficiency Cogeneration options Modularity Distributed and centralized configurations Uninterruptible power Fuel flexibility Public acceptance Incremental power additions Low noise/small footprint Useful heat Siting flexibility Premium power quality In the urban sector of developing coun- tries, fuel cells have near-term sales potential in the rapidly growing indus- trial sector and critical public service applications where a premium is placed on reliable, quality power delivery. The fuel flexibility afforded by fuel cells opens up the possibility of lowering project costs through use of fuels derived from municipal, agricultural, forestry, or refinery wastes (opportunity fuels). For rural regions currently without access to commercial power, fuel cells are an attractive option, particularly where opportunity fuels exist, such as landfill gas, anaerobic digestor gas, and other waste gas. Fuel cells have tremendous potential in industrialized countries outside of the United States for the same reasons outlined for domestic use. DomeEsTIC OPPORTUNITIES omestically, an estimated 363 gigawatts of capacity will be required by 2020 to meet new demand and to replace lost capacity from plant retirements. Under utility restructuring, distributed generation is expected to capture a considerable portion of the market. This projected market capture is the result of energy suppliers shouldering the financial risk of capacity additions, customers con- cerned about reliability and power quality, and increased T&D traffic. One assessment indicates a requirement of 5-6 gigawatts per year over the next decade. Fuel cells are ideal for distrib- uted generation given their ability to match demand, operate efficiently, produce near-zero pollutant emissions, and facilitate permitting and installation. On-site markets are targeted for early entry as a proving ground for natural gas-fueled plants of 200 kW to 20 MW. Fuel cell attributes can be leveraged in these markets to support higher prices. Commercial building applications can support the highest fuel cell price and represent important long-term potential for fuel cells, particularly with the emergence of energy management service companies. As fuel cell costs decrease, industrial applications will represent a major market. With the increased use of sensitive electronic components, the need for reliable, high-quality power supplies is paramount for most indus- tries. The cost of power outages, or poor quality power, can be ruinous to indus- tries with continuous processing and pinpoint-quality specifications. Studies indicate that power fluctuations cause annual losses of $12-26 billion nation- wide. Fuel cells can provide reliable, high quality electric power and high energy heat for industrial processes. Lastly, as a fuel cell industry emerges and manufacturing capacity and tech- niques bring down costs, a broader spectrum of applications will emerge, including central power generation. The chart below summarizes fuel cell market opportunities along with competing options. Fuel Cell Markets and Competition Market segment ‘commercial building 0.2-2 Broader commercial 0.2-2 self-generation and cogeneration Distributed power Public power, self-generation “ Industrial cogeneration Central station * competed retail grid price Typical capacity (MW) Vosges ge 10-1 125-250 Market size (MW/yr.) vo ReTEE Competing options ag . Reciprocating engine Power marketer* Reciprocating engine Gas turbine combined cycle Reciprocating engine Gas turbine Power marketer” Pulverized coal Circulating fluidized-bed combustion Gas turbine combined cycle GLOBAL OPPORTUNITIES n future years, electricity will continue to be the most rapidly growing form of energy consumption. Forecasts show total worldwide electric- ity consumption rising from 12 trillion kilowatt-hours in 1996 to almost 22 trillion kilowatt-hours in 2020. The strongest growth is expected in develop- ing Asia at an average annual rate of nearly five percent, followed by Central and South America at an average annual rate of over four percent. And by 2020, developing nations are expected to account for 43 percent of the world's total energy consumption, compared with only 28 percent in 1996. In meeting worldwide power needs, fuel cells are applicable to both central powerplant generation and distributed generation scenarios. Their greatest potential, at least in the near term, lies in distributed generation. World Electricity Consumption by Region, 1996 and 2020 Triffton kilowatt-hours: Central and Sauth Amence Source: Energy Information Administration, International Energy Outlook 1999 The first commercial fuel cell on the market, the phosphoric acid fuel cell (PAFC), proved that early entry markets exist to sustain their relatively high initial costs of $3,000-4,000/kW. These niche PAFC being installed at New York City’s Times Square markets include premium power applica- tions, such as use in hospitals and computer centers, and opportunity fuel applications where gas from waste materials can be generated in quantity. Regions exceeding ambient air quality standards for pollutants (non-attainment areas) also represent prime market areas. The premium power market in the United States alone is conservatively estimated at $1 billion per year. The U.S. Environmental Protection Agency estimates that the current global market for opportunity fuels is 40-50 gigawatts. Ultimately, for fuel cells to realize their full potential, costs must be competitive with other distributed generation tech- nologies such as gas turbines and reciprocating engines. The incentive to bring costs down is reflected in the size of the global market. The U.S. and European growth and replacement market for distributed generation is expected to approach 10 gigawatts per year for the next decade. Globally, it is expected to be 20 gigawatts per year. THE PROGRAM Goals ETC, in partnership with the power industry, is carrying out a fuel cell research and develop- ment program targeting the stationary power generation sector. Industry participation in the program is extensive, with over 40 percent cost-sharing. Intended applications include distributed generation in the near- to mid-term and central power in the longer-term. The goals are: @ To enable the power industry to take advantage of the superior efficiency, reliability, and environmental perfor- mance characteristic of fuel cells by reducing cost and further enhancing performance; and ® To strengthen the economy by developing U.S. leadership in the manufacture of fuel cells. ao oO N oO Efficiency (% LHV) oa o Oo oO » o 1976 Objectives ® By 2003, commercially introduce high-temperature natural gas-fueled molten carbonate fuel cells (MCFC) and solid oxide fuel cells (SOFC) at $1,000-1,500/kW capable of 60 percent efficiency, ultra-low emis- sions, and 40,000 hour stack life. @ By 2010, commercially introduce early fuel cell/gas turbine hybrids capable of 70 percent efficiency. @ By 2015, achieve market entry for a 21* Century Fuel Cell using solid state composition and advanced fabrication techniques to achieve 80 percent efficiency, near-zero emis- sions, 40,000 hour stack life, and capital costs of $400/kW (<$90/kW stack). @ By 2015, increase market penetration and efficiency of fuel cell/gas turbine hybrids by introducing Vision 21 hy- brids with advanced materials and manufacturing, and combustion tech- niques and expanded fuel flexibility. Strategy FETC relies on its long history of working with industry to forge partnerships that allow the public interests to be protected, innovation to be encouraged, and technical progress to proceed rapidly. The effectiveness of these partnerships is reflected in the commercial success of the first generation PAFC technology. This success resulted from a close working relationship between Interna- tional Fuel Cells (IFC) Corporation and FETC. ONSI Corporation of South Windsor, Connecticut, the marketing subsidiary of IFC, is now manufacturing commercial 200-kW units using ad- vanced robotics and automated assembly techniques. Turnkey 200-kW PAFC plants have been installed at more than 165 sites around the world. Similar partnerships are in place to introduce the next generations of fuel cells. Fuel Cells for the Future 1980 2010 2015 EMERGING FUEL CELLS A Fuel Cell Energy (formerly Energy Research Corp) molten carbonate fuel cell Siemens Westinghouse Solid Oxide Fuel Cell Tube Interconnection Fuel Electrode irst generation PAFC systems currently being commercialized operate at about 200 °C (400 °F), which is sufficient for providing hot water and space heating. Electrical efficiencies for PAFCs range from 40-45 percent on a lower heating value (LHV) basis, and overall thermal efficiency can reach 80 percent LHV in applications that use the process heat. Emerging second generation fuel cells are designed to operate at higher tempera- tures to enhance both fuel-to-electricity i and thermal efficiencies. The higher temperatures contribute to improved fuel-to-electricity efficiencies and enable increased thermal efficiency through generation of steam for cogeneration, combined-cycle applications, and reform- ing of fuels. Moreover, these units either tolerate or use reformed fuel constituents such as carbon monoxide, which repre- sents a poison to PAFCs. One of two high temperature fuel cells currently under development is the molten carbonate fuel cell (MCFC). MCEFC technology has the potential to reach fuel-to-electricity efficiencies of 60 percent LHV. Operating temperatures for MCFCs are around 650 °C (1,200 °F), which allows total system thermal efficiencies up to 85 percent LHV in combined-cycle applications. The other high temperature fuel cell under development is the solid oxide fuel cell (SOFC). SOFCs operate at tempera- tures up to 1,000 °C (1,800 °F), which further enhances combined-cycle perfor- mance. The solid-state ceramic construction permits the high tempera- tures, allows more flexibility in fuel choice, and contributes to stability and reliability. As with MCFCs, SOFCs are capable of fuel-to-electricity efficiencies of 60 percent LHV and total system thermal efficiencies up to 85 percent LHV in combined-cycle applications. ACHIEVING MARKET ENTRY econd generation fuel cell devel opment is proceeding efficiently. FETC is working with Fuel Cell Energy (FCE) and M-C Power to bring two versions of the MCFC to commercial fruition, and is working with Siemens Westinghouse Power Corporation (SWPC) to commercialize the SOFC. These second generation systems are currently being demonstrated, with market entry for natural gas-based systems planned for 2003. Objectives include achieving 40,000 hours of stack life and reducing capital costs to $1,000- 1,500/kW. Subsequent to market entry, capital costs are expected to decline as manufacturing capacity and capability increase. By 2003, natural gas-fueled MCFCs and SOFCs will be commercially available in sizes ranging from 500 kW to 3 MW. As market acceptance and manufacturing capacity increases, natural gas-fueled plants in the 20-100-MW range will become available. Follow-on testing will address expanding the fuel options by testing other reformed fuels and associ- ated cleanup systems. By 2010,a transition to coal-gas-powered fuel cells will occur as gasification and gas cleanup costs are reduced through commercial plant replications. M.-C Power's 250-kW MCFC demonstration unit at the Miramar Marine Corps Air Station, San Diego, California 100-kW SOFC cogeneration system operating in The Netherlands, built by Siemens Westinghouse (photo courtesy of Siemens Westinghouse) FUTURE SYSTEMS — Foe: Ce/Tureme Hyerms System Integration Yields Synergy fforts also are underway to develop a system that inte- grates a fuel cell with a gas turbine. Hybrid fuel cell/gas turbine technology for stationary power genera- tion offers the potential to achieve efficiencies in excess of 80 percent, nitrogen oxides and carbon monoxide emissions less than 2 parts per million (ppm), and costs 25 percent below a comparably sized fuel cell. The synergy realized by fuel cell/turbine hybrids derives primarily from using the rejected thermal energy and residual fuel from a fuel cell to drive the gas turbine. This leveraging of thermal energy makes the high-temperature MCFCs and SOFCs ideal candidates for hybrid systems. Use of a recuperator contrib- utes to thermal efficiency by transferring heat from the gas turbine exhaust to the fuel and air used in the system. FETC is engaged in exploratory research on fuel cell/turbine hybrids in partner- ship with the National Fuel Cell Research Center at the University of California at Irvine. The experimental work involves evaluation of a 75-kW turbine at FETC operating in combina- tion with a simulated fuel cell. The particular focus is on dynamic operating conditions (start-up, shutdown, load following, and upsets) and the associated controls. The objective is to establish: key operating parameters and their interrelationships, a range of safe operating conditions, and a database and dynamic modeling tools to support further development. FETC also supports hybrid system development in its Low-Btu Combustion Studies Facility. Fuel cell anode gases can be simulated for combustor design studies. The fully instrumented facility is made available for cooperative research between FETC and industry under Cooperative Research and Development Agreements (CRADAs), which are designed to protect industrial partici- pants’ intellectual property. In an attempt to develop an early entry hybrid system, FETC engaged five teams of fuel cell and turbine manufacturers, who conducted conceptual feasibility studies on fuel cell/turbine systems. The teams were predominately com- posed of the high-temperature MCFC and SOFC fuel cell manufacturers and the turbine manufacturers participating in the Department of Energy's industrial scale Advanced Turbine Systems Program. The goal is to develop hybrid systems with efficiencies greater than 70 percent for market entry by 2010. More advanced hybrid configurations with 21* Century Fuel Cells could offer 80 percent efficiency by 2015. Example of Fuel Cell/Turbine Hybrid System Air courtesy of Siemens Westinghouse = 9 215 CenTurRY FuEL CELLS esearch and development into new ceramic materials and manufacturing techniques is ongoing. In the near-term, R&D sup- ports cost and performance improvements in MCFCs, SOFCs, and hybrid systems. The long-term goal is to develop a new solid state fuel cell that provides quantum leaps in cost and performance—a 21" Century Fuel Cell. Integration of design, high-speed manu- facturing, and materials selection from the start is deemed critical to meeting the goal. Long-term materials develop- ment is anticipated to realize the full potential of the 21* Century Fuel Cell. A set of cost and performance targets has been established that will provide wider and deeper penetration into a full range of market applications. These targets include achieving stack fabrica- tion and assembly costs of $100/kW, system costs of $400/kW, efficiencies of 80 percent or more, near-zero emissions, and compatibility with carbon sequestra- tion. These targets represent order-of-magnitude improvements in power density and cost, and a factor of two improvement in efficiency. Fuel Cell Program Future Cost Reduction 90 4,000 PAFC se 80 So oS > 3,000 < 70 2 2 o S 2 2,000 ti wi = : MCFC & SOFC 2 Oo = : x Hybrids & # 1,000 BL 1998 2003 2010 2015 Calendar Year 10 @ 1998 Efficiency Improvement 21st Century Hybrids MCFC & SOFC 2003 2010 2015 Calendar Year DEVELOPING THE POTENTIAL Building the Foundation In fiscal year 1995, fuel cells became an integral part of the federal government's Strategy to address global climate change concerns. Through a Defense Depart- ment appropriations bill, Congress authorized the Climate Change Fuel Cell Program to accelerate commercialization of fuel cells—a joint effort of the U.S. Departments of Defense and Energy. FETC is responsible for implementing the program, which is managed by the Department of Defense Construction Engineering Research Laboratory. The program is a key element of the Federal Administration's Climate Change Action Plan, designed to curb green- house gas emissions through expedited deployment of highly efficient, clean technologies. Defense Department goals were addressed as well by helping to create a fuel cell manufacturing capabil- ity critical to the Department's energy security and readiness needs. The Climate Change Fuel Cell Program has resulted in over 165 ONSI 200-kW PC25TM fuel cells being sold worldwide. Many of these installations are at military bases. FETC fuel cell test and evaluation facility To explore expanded applications for fuel cells, FETC has established a test and evaluation facility to simulate operating cycles typical of military and other specialty applications for fuel cells in the 20-5,000 watt range. The objective is to explore, through joint government- industry-academia partnerships, new ways to leverage the unique performance characteristics of fuel cells. The facility provides the fuel, thermal management, humidification, load simulation, and performance measurement instrumenta- tion necessary to fully evaluate fuel cell systems. i The impetus exists to fully develop the potential of fuel cells. They offer the hope of satisfying energy needs without adverse impact on the environment, and providing a means of ushering in a hydrogen-based energy infrastructure. Establishing a strong U.S. fuel cell technology position and manufacturing capability strengthens the economy, creates quality jobs, enhances the environment, and provides energy SUMMARY OF BENEFITS Customer Benefits = Ensures reliability of energy supply, increasingly critical to business and industry in general, and essential to some where interruption of service is unacceptable economically or where health and safety is impacted; Provides the right energy solution at the right location; ® Provides the power quality needed in many industrial applications depen- dent upon sensitive electronic instrumentation and controls; = Offers efficiency gains for on-site applications by avoiding line losses, and using both electricity and the heat produced in power generation for processes or heating and air conditioning; = Enables savings on electricity rates by self-generating during high-cost peak power periods and adopting relatively low-cost interruptible power Tates; ™ Provides a stand-alone power option for areas where transmission and distribution infrastructure does not exist or is too expensive to build; = = Allows power to be delivered in environmentally sensitive and pristine areas by having characteristically high efficiency and near-zero pollutant emissions; = =Affords customers a choice in satisfying their Supplier Benefits particular energy needs; and = Limits capital exposure and risk because of the size, siting = Provides siting flexibility by virtue of the flexibility, and rapid installation time afforded by the small, small size, superior environmental perfor- modularly constructed, environmentally friendly, and fuel mance, and fuel flexibility. flexible systems; = Avoids unnecessary capital expenditure by closely matching capacity increases to growth in demand; & Avoids major investments in transmission and distribution system upgrades by siting new generation near the customer; ® Offers a relatively low-cost entry point into a competitive market; and National Benefits = Opens markets in remote areas without transmission and = Reduces greenhouse gas emissions distribution systems, and areas that have no power because of through efficiency gains and environmental concerns. potential renewable resource use; = Responds to increasing energy demands and pollutant emission concerns while providing low-cost, reliable energy essential to maintaining competi- tiveness in the world market; & Positions the United States to export distributed generation in a rapidly growing world energy market, the largest portion of which is devoid of a transmission and distribution grid; ® Establishes a new industry worth billions of dollars in sales and hundreds of thousands of jobs; and = Enhances productivity through improved reliability and quality of power delivered, valued at billions of dollars per year. 12 = Py Fuel Cells « eee Lf .doe.gov 3 es bey me 7: = . Department of Energy %, (Fed Energy Technology Center ¥ 361 Ferry Road “see POMBGRBB0 ke ‘Sg .Morgantown;"WY.26507-0880 Vee. a we, ne Visit cursaigite al Swine: fetc.doe.goy in the Ete Web Network a "Office of Fossil Energy + * S of > . ae : a ae i gee in tonetinersy tal 5 enmaia Typical Properties of Propane Formula C3Hs BTU/gal 91,500 BTU/cu. ft. of gas at 60F, atmospheric pressure BTU/Ib. of gas 21,560 Range of inflammability: percent of gas in gas-air mixture 2,520 2.15% to 9.60% Vapor pressure, psig at 60F 92 Vapor pressure, psig at 100F 172 Lbs. per gal. of liquid at 60F, storage tank pressure an Specific gravity of liquid at 60F _ 0.51 (water = 1) Boiling point of liquid at _44F atmospheric pressure Cu. ft. of gas per pound of liquid 8.59 (at 60F, atmospheric pressure) . Cu. ft. of gas per gallon of liquid (at 60F, atmospheric pressure) So Specific gravity of gas(air=1) 1.53 egenerative RPM's Near-Zero-Loss Flywheel Battery RPM (Regenerative Power & Motion) is developing a flywheel battery, expressly for stationary on-site electric power storage, that will afford important advantages over other power storage options. With virtually no losses, no maintenance, and unlimited service life, we expect it can quickly grow a $2 billion yearly market for urban UPS (Uninterruptible Power Supplies) to $20 billion. There is currently a poorly met need for reliable no- maintenance UPS, for critical manufacturing, hospitals, computing centers, datacom, telecom, and intranet/internet servers and routers. The Electric Power Research Institute estimates that central utility grid power outages cause losses amounting to $50 billion yearly, which are rising with increased dependence on quality power. Despite low customer satisfaction with existing options, this market is growing very fast. It can be RPM's main and most profitable near-term market. Ultimately, RPM's flywheel batteries can enable a global $200 billion new building- integral solar/wind power industry, and can even enable dual-mode high- performance electric highway vehicles. These clean, sustainable technologies afford profound environmental benefits. Conventional UPS is mainly a combination of high-maintenance diesel-generators and lead-acid batteries. Other flywheel batteries offer only short-term (most "tens of seconds") ride-through power, during utility line outages; and while the utility or on-site generator supplies power, they constantly consume typically kilowatts while idling. That's over 1000x more losses than RPM's Flywheel Battery; which runs far cooler, will have far longer service life, negligible self-discharge, far higher reliability, far lower life-cycle cost, no wear-out, and no maintenance! For on-site generated solar or wind power, that is available on demand, or distributed power storage for load-leveling, other available on-site options require tons of lead-acid batteries, that have troublesome limits on numbers of charge/discharge cycles, plus service, replacement, reliability, safety, pollution, siting, and disposal problems. In such applications, requiring daily or even more frequent charge/discharge cycles, annualized life-cycle cost is higher than RPM's flywheel battery. Other flywheel batteries have been developed for different purposes, and don't meet needs for practical carefree UPS -- and certainly not for on-site solar/wind power systems (which we view as our ultimate market) -- mainly because their idling losses and resulting failure modes are intolerable. RPM's flywheel battery can provide on-site (underground flywheel for most urban installations) long-term (days) uninterruptible power. It can store energy for years, without significant self-discharge. It will afford safe, care-free, clean, quiet, no- maintenance, environment-friendly UPS and on-site power storage with virtually no cycling limits, at lower life-cycle cost, than all other options (including fuel-burning generators). Weight of our total flywheel battery system is now about 20% that of lead- acid batteries; future fiber-composite materials may reduce its weight to 10%. What gives RPM's flywheel battery such remarkable competitive advantages, and performance not available from any other: ¢ Ultra-efficient motor/generator (m/g) with essentially no idling loss. Its permanent-magnet rotor is integral with a magnetic bearing rotor and flywheel rim, that all spin in a vacuum enclosure without mechanical contact. Its patented configuration incurs no hysteresis losses; its windings block and buck eddy current. e Magnetic bearings with practically zero-power axial and radial servos; with a rotor having axial and radial stability and stiffness, spin with no physical contact to backup bearings, and no hysteresis or eddy loss, for practically no idling loss. e Rolling contact touchdown bearings, used only for transit, startup, powerdown and backup, don't depend on lubrication (which is not practical to maintain in vacuum). ¢ Concentric cylinder carbon fiber composite flywheel rim, for low weight, safe, and lower cost bearings. ¢ Power controller that interfaces m/g to dc power conduit, has PWM (Pulse-Width- Modulated) sinusoidal current control, responsive to dc conduit voltage, rotor feedback, rotor vibration (prevents over-speed, full-energy explosion; monitors reserve energy, etc.). Controller includes integrated safety, bearing servo electronics and m/g control; has LCD (minimal power Liquid-Crystal-Display) for monitoring; runs on under 2-watts power (including bearing, m/g, and windage losses). Parallel systems can accommodate more diverse applications and greatly enhance reliability. ¢ Light-weight thin-wall vacuum enclosure for flywheel and other parts it contains. Unlimited life with no maintenance facilitate housing it in an underground site that can absorb a possible nearly FE ea IE LPN - adiabatic . explosive burst. Left: Illustration of RPM's flywheel battery; showing "see-through" underground vacuum Pahkirere beees enclosure, containing integral flywheel, magnetic and backup : bearings, and Storage motor/generator; plus System wall-hung controller Piste electronics with LCD diagnostic read-out. ee hase oe Power This is a zero- maintenance design, that makes safe underground installation practical. Due mainly to its exclusive zero idling losses, the system uses under 2-watts to maintain full energy, and all its on-line monitoring, safety, and display functions. Unique safety features include: Electronics, that initiate power-down on sensing abnormal magnetic bearing servo activity; concentric rims, that prevent total flywheel disintegration; and underground siting, that can absorb rapid energy discharge, which prevents damage outside the flywheel site, from possible flywheel disintegration. It uses a standard reinforced concrete slab floor, and flush bolt-down steel cover enclosing the flywheel site, that protect building occupants from possible blast and explosion JSragments. All of these proprietary features are obtained at lower life-cycle cost than any other power storage device, mainly due to thorough integrated system design expressly dedicated to stationary on-site applications. Right: Block diagram of electrical system of a building, with RPM flywheel battery and multiple power sources. RPM created the only flywheel UPS that will accommodate on-site solar and wind power, utility-line- powered UPS (switchgear at U.P. for utility power, P.F. during utility power failure outage), and any combination of power inputs. It can have adequate power generation and storage capability, plus discretionary loads, so that it does not require utilities to buy excess power generated on-site. Also, it does not subject utility lines to hazardous "live" loads, which have killed workers performing otherwise routine line repairs. The PWM regulator interface, to solar tiles and windmill generators, maximizes their energy yields and prevents dc line over-voltage when the flywheel reaches maximum energy capacity. At first glance, except for reducing 60-Hz inverter cost, it may seem that including dc power outlets does not make sense, because it requires additional wiring and another type of socket, to prevent users from plugging in electric appliances that could be damaged by dc. But that rationale neglects these facts: Most consumer electronics could be produced 10-60% smaller and lighter, 10-40% lower cost, and even more reliable, if designed for dc. It would eliminate need for rectified 60-Hz hold-up capacitors in all, 60- Hz power transformers and rectifiers in many. That's ample incentive for their producers to make the straightforward changes needed within a year, for their products to work from dc power outlets. Electric ovens, cook-tops, toasters, and incandescent lights can use ac and dc interchangeably. Power tools like drills, saws, etc. have universal motors. They are more efficient with dc, because ac causes more core loss. Most induction motors: for fans, blowers, refrigerators, washers, and dryers, run at less than 50% efficiency on single-phase 60-Hz power. Brushless de motors that run at more than 90% efficiency, and are smaller and lighter, could replace them. Conventional 60-Hz inductive ballast, for fluorescent lights, could be replaced with smaller instant-starting electronic ballast. SCR light dimmers and speed control can be replaced with numerous types of PWM controls that run on de power. Clearly, there are enough advantages for most dc appliances, to replace ac within a 1-year transition period. | installation, made practical by our zero- maintenance design. It can absorb a maximum fast-release energy discharge (exploding flywheel) with minimal pressure and temperature rise. H It uses a standard reinforced concrete slab floor (except for f the flywheel siting installation) of a garage or storage area for a safety barrier between the flywheel and other parts of the building. The backfill is permeable, and preferably filled with energy-absorbing material, to absorb energy over a volume far larger than the flywheel enclosure. Besides its safety advantages, this underground flywheel siting design does not take up valuable space. This feature further reduces overall cost of the building UPS. Existing UPS batteries, housed on multiple-level shelves, and fuel-powered generators, need a ventilated off-limits area protected from weather, that is a major additional site expense. Examples of clean, cost-competitive, convenient, care-free, renewable on-site power that RPM's Flywheel Battery can ultimately enable, to meet vast global power needs Right: Proposed remote UPS application, integrated with photovoltaic solar tiles and windmill power generator. By enabling clean renewable energy use, it can help meet vast global power needs, besides current need in remote homesites, military posts, scientific field stations, etc. These remote applications are expected to be a substantial part of RPM's early markets. PV (photo-voltaic) solar panels and windmills are increasingly used to provide power for remote buildings. Lead-acid batteries are currently the only real available option for power storage. They are not widely acceptable in millions of US buildings that need UPS (e.g., medical, dental, critical manufacturing, banks, etc.) due to high maintenance, replacement, and life-cycle cost, plus housing and toxic waste disposal problems. Right: Proposed urban building design, suitable for mini-malls, offices, manufacturing and commercial facilities; with solar tiles generating power, providing translucent skylight and window areas, and funneling wind to increase windmill power. Building-integral PV panels are the basis for a very high growth industry. But windmills are rarely integrated with them. Combining solar and wind power can provide higher energy yields, with lower peak-to- average power ratio; and thus lower power electronics cost. It will encourage innovative new architecture, of cost-effective and attractive buildings, with stand-alone power capability. UPS and load leveling (with lower off-peak utility rates) are afforded to buildings connected to utility power lines. Benefits from UPS depend upon criticality of on-site power. Off-peak rate savings alone could result in typical payback periods of 10 to 20 years for RPM's flywheel battery. Most importantly, buildings like this could enable profound environmental and energy conservation benefits. Left: Proposed urban or remote building design, with solar tiles providing roofing, skylights, windows, and exterior walls. This is a cost-competitive, functional, attractive, integrated- power building, with important energy and environmental benefits. The building provides high elevation mounting, without incurring the cost of towers, for the integrated windmills, and funnels wind through them, to increase power generated by 10x or more. Through-flow (possibly hemispheric shape) small-mesh (.5"x.5") grills on each side of the windmills provide a shield around them, to protect people and other parts of the building from harm of possible blade disintegration; eliminate bird kill; and shield blades from sun damage (particularly ultra-violet on fiber-composite blades). A vertical-axis rotatable "ring mount" can support the turbine and its bearings. It should result in far less cyclic blade and stem stress, and "swooshing sound" compared to typical towers. Contemporary "wind farms" (with numerous turbines, mounted on towers, exposed to weather damage) must depend on terrain for channeling wind. And their high-speed blades strike birds that may fly too close to them. Birds also are killed, that fly into building walls and windows, perceiving them as open space, if they reflect light like a mirror or are clear. PV panels are far better in that regard, because birds perceive them as solid obstacles. Examples of attractive homes by pioneering architects, with handsome solar tile roofing and lead-acid battery power storage. RPM's Flywheel Battery would be ideal for, and encourage future projects like these, and enable far greater use of clean, renewable, cost- competitive, ubiquitous, environmentally compatible energy sources ... Residential construction projects, with on-site electric power and heating from PV and solarthermal panels. Since PV panels can be substituted for conventional roofing and windows, total building cost can be quite competitive. Examples of solar-powered industrial & public structures. RPM's flywheel battery would enable clean, safe. lower life-cycle cost UPS and power storage; to facilitate more environmental and energy conservation benefits, from handsome and durable buildings like these (now using lead-acid batteries to store power) = . PPR : s e _ Beautiful PV exteriors for company headquarters, factories, power & shade (that can charge EVs). Great looking PV skylights and translucent PV-glass windows as an extra bonus (creating a new art- form). Power-generating PV panels instead of conventional roofing, skylights, windows, and walls. A website is available with links to descriptions and pictures of building-integral PV projects in various countries. Global markets for PV panels is now over $1 billion yearly, and growing about 50% yearly. It would grow much faster with RPM's on-site flywheel battery, providing carefree, lower total life-cycle cost power storage. More web pages about RPM... RPM Flywheel Battery Comparison with Others (we don't run with the pack) RPM Business Plan Abstract (who we are, what we've done, what we plan) Flywheel energy storage tutorial (review of basic flywheel physics & applications) RPM's Resources (people, capabilities. development labs, offices, machine shops) On-site Solar and Wind Power Tutorial Electric Vehicles with In-transit Power from Highways: Graphic Analysis Links to flywheel batteries, solar and wind power, dual-mode EVs, and a plan to achieve them Urban EV with Onboard Batteries, Charger, PV, Regenerative Motor, Pedals We hope you share our vision. For more examples of projects by pioneering architects and builders, and renewable power research programs, visit these links: Featured Solar Building Construction Projects (RPM hopes to play a pivotal future role) C.R.E.S.T. (Center for Renewable Energy & Sustainable Technologies) Solar Design Associates (architectural firm designing building-integral solar power buildings) Renewable Energy Projects at NREL (has links to NASA and contractor sites) Last update: February 8, 2001 If you have questions, comments, or suggestions, email me: fradella@earthlink.net TITLE: MICRO GAS TURBINE MARKET SUBJECT COUNTRY : JAPAN POST OF ORIGIN: TOKYO SERIES: INTERNATIONAL MARKET INSIGHT (IMI) ITA INDUSTRY CODE: ELP DATE OF REPORT (YYMMDD): 000710 DELETION DATE (YYMMDD): 010110 AUTHOR: KENJI KOBAYASHI APPROVING OFFICER: KENNETH B. REIDBORD OFFICER'S TITLE: COMMERCIAL ATTACHE NUMBER OF PAGES: 2 INTERNATIONAL COPYRIGHT, U.S. & FOREIGN COMMERCIAL SERVICE AND U.S. DEPARTMENT OF STATE, 2000. ALL RIGHTS RESERVED OUTSIDE OF THE UNITED STATES. 1. Summary: Japanese micro gas turbine market is rapidly expanding led by U.S. manufactures and followed by European and Japanese manufacturers. With deregulation in Japanese power industry being at an initial stage and environmental concerns increasing among public, micro gas turbines (MGT) are drawing hot and keen attention from power industry and users as an economical and environmentally friendly on-site power source. A market survey for MGT in Japan recently made by Mitsubishi Research Institute (MRI), partly reported in an industry magazine, indicates that the potential demand for MGT, even under the current performances, would be 100,000 units of 50kW unit size to be used at small and medium factories, apartments, hotels and restaurants, etc. The report estimates the total potential demand to be one trillion yen ($9400 million at yen 107/$) and market size to be approximately 200 billion yen ($1,900 million). The report also indicates that, with further increase in power generation efficiency, further progress in waste heat use technology and development of smaller units in the future, it is possible that the market would expand to be one trillion yen. Although the MGT market seems to be bright in the future, there are several regulatory barriers to be cleared before the market sufficiently grows. End summary. 2. Japanese power industry and users are showing strong interest in MGT for the following reasons: - Japanese power industry is experiencing deregulation and competition, and the demand for economical and environmentally friendly small scale on-site power generation system has been increasing - Electric power utility business had been strictly regulated by the Electricity Utilities Industry Law (EUIL). With the revision of EUIL, the electric power market has been opened for approximately 30 percent since March 21, 2000. Auto-generation market is less regulated and on-site power generation by MGT just fits into this market. - Low NOx emission (approximately 10-30 ppm) - High power generation efficiency (approximately 25 percent), and high thermal efficiency (approximately 80 percent) in the case of co- generation - Reasonable initial cost (approximately $1,200 per kW, including construction cost) - Low maintenance cost 3. Currently, the following manufacturers are trying to develop and expand sales of MGT of different capacity: Capstone (U.S.): 28 kW Honeywell (U.S.): 75 kW Elliot (U.S.): 45 kW Ingersoll-Rand Energy Systems (U.S.): 70 kW International Power & Light (U.S.): 50 kW and 250 kW Toyota Turbine System (Japan): 50 kW Mitsubishi Heavy Industries (Japan): under development ABB (Europe): under development 4. Japanese electric power industry are also showing strong interest in MGT and started the following actions: - Many electric power utilities, including Tokyo Electric (TEPCO), Kansai Electric, Chubu Electric, Tohoku Electric, Hokkaido Electric, and Kyushu Electric have purchased micro gas turbines from different manufacturers for testing. - Ebara Corporation has purchased Elliot Energy Systems and has made it as a subsidiary. - TEPCO, in cooperation with Mitsubishi Corporation, Nippon Mitsubishi Oil Corporation and others, newly established a subsidiary called “MY Energy? to provide users of electricity with services for procurement of equipment, construction, lease of equipment, fuel procurement and maintenance for auto-generation using MGT. - Meidensha, in cooperation with Sumitomo Corporation, working as one of Capstone’s distributors in Japan, is selling micro co-generation system using Capstone’s MGT. - Mitsubishi Heavy Industries (MHI) and Kawasaki Heavy Industries (KHT) are developing MGT by themselves. - Hitachi Ltd., is studying to import MGT for resale in Japan. 5. Although the Japanese market for MGT seems bright in the future, the following regulatory barriers have to be corrected in order to have the market steadily grow: - A certified boiler turbine engineered is required to be employed by a company or an entity which uses MGT. - A certified electrical engineer must be hired by a company or an entity which uses MGT. Services of such an engineer can be contracted with other qualified associations. - A monitor is required to be on duty during all hours of MTG operation. - EUIL requires installation of a protection relay for connection of a MTG to a grid. U.S. TRADE CENTER TOKYO ONLINE The U.S. Trade Center, Tokyo - Online is a Japanese-language, Internet-based tool for promoting American exports in the world's second largest economy. Through industry-specific "online exhibitions," U.S. companies can introduce a new product, refer Japanese inquiries, test the market, search for a representative or distributor, and supplement ongoing marketing efforts in Japan. Each company receives an attractive, individual webpage that includes a description of its products and services in Japanese, up to five captioned photographs, and a link to its own homepage. Viewers can send E-mail directly to the U.S. company or its Japanese agent. For more information please fax 81/3/3987-2447 or send an E-mail to ustc@csjapan.doc.gov for application materials. To view a sample company webpage go to http://www.csjapan.doc.gov/online/ or find more information on the Japanese market from other menus at www.csjapan.doc.gov. GOLD KEY/SILVER KEY PROGRAMS Access to the Japanese market means building relationships through proper introductions and careful research. The Commercial Service Japan's "Gold Key Service"(GKS) and "Silver Key Service"(SKS) programs help savvy U.S. businesses do this effectively through targeted research of potential Japanese partners for new-to-market U.S. companies. Companies visiting Japan can have appointments arranged through the GKS and SKS Services. Our industry specialists select potential Japanese representatives, distributors, and importers for your product and arrange business appointments for your visit. GKS and SKS programs include consultation with the industry specialists who will brief you on the market for your product in Japan. In addition, the specialist will provide you with background information, alert you to developments in your industry sector and accompany you to GKS meetings (SKS does not include a CS escort). Le you require services, such as interpreters for your meetings, these are made available at an additional cost. For more information on these programs, please contact via Email: Tokyo.Office.Box@mail.doc.gov or Fax: 81/3/3589-4235. INTERNATIONAL COPYRIGHT, U.S. & FOREIGN COMMERCIAL SERVICE AND U.S. DEPARTMENT OF STATE, 2000. ALL RIGHTS RESERVED OUTSIDE OF THE UNITED STATES. atte) Continuous Power System bib Atoll dada cho ch Quality Power VTC Tel Ecls Switch Renin) MF: {1 YY LU ts) EM ETEY tii sti ST Redundant 24 VDC Starting Power NY 02 MA OF “AUMNGeHes so seulU.4By pus s2. 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DER rerere to tocel energy systeme that Generate electric, thermal, or mechanical energy on or near customer sites. In addition to generation systems, DER inctudes energy storage, grid interconnection, and demand management systems, which are important components in power quaity and avaiiapiity. Advanced microturbines will be cleanen more fuel efficient and fuel-flexibie, more reliable and durable, and lower in cost than the first generation products entering the market today. Piannea activities for this program focus on the following performance targets for " . the next generation of uttra-clean, highly efficient microturbine product designs: High Ertictency - The target tuet-to- electricity conversion efficiency Is at teast 40 percent. Environment - Tne NOx target ror emissions Is less than seven parts per million for natural gas machines in practical operating ranges. Durebiity = Tne goalis 11,000 hours of operation between major overhauls and @ service life of at teast 45,000 hours. Coce of Power - Tne target is achieving Installed cost lower than $500 per kilowatt, cost of electricity com petitive with aternatives (inctuaing grid-connectea power) ror market applications. Fue! Fiexipinty - Snoutd be capable of using atternative/optional fuecis Including natural gas, diesel, ethanol, landfill gas, and other biomass-derived liquids and gases. For More Information: DOE Advanced Microturbine Program http:/Awww.eren.doe.gov/der Debbie Haught Program Manager (202) 586-2211 debbie.haught@ee.doe.gov Steve Waslo Senior Project Manager Chicago Operations Office (630) 252-2143 stephen.waslo@ch.doe.gov Dave Stinton Materials and Manufacturing Program Manager Oak Ridge National Laboratory (865) 574-4556 stintondp@oml.gov Produced for: U.S. Department of Energy 1000 Independence Avenue, SW Washington, DC 20585 February 2001 M3A Overview The M3A Flywheel Power System manages power for all types of stationary applications. The system functions like a battery sourcing or sinking power to a DC bus on demand. The M3A can serve as an ultra compact UPS or perform more complicated power processing. Typically, the M3A regulates bus voltage within a user specified tolerance. When voltage dips, the M3A provides power to the bus. When voltage surges, it absorbs power decreasing bus voltage. Applications Any stationary application with intermittent high power loads. * Power quality: 300 kW for 3 seconds + Ridethrough: 100 kW for 15 seconds * Power management: high rate charge and discharge * Power amplification: high power pulses from low power supply Description The Trinity M3A uses a composite flywheel rotor to store kinetic energy. During charging, built-in electronics absorb electrical power accelerating the rotor. During discharge, the built-in electronics deliver power decelerating the rotors. The M3A can replace batteries in a UPS or provide ridethrough on the DC input to an Adjustable Speed Drive. Modules can be paralleled for high power applications. Its very small footprint permits flexible siting. A keypad interface or optional MODbus connection let the user select many different modes of operation: bus voltage can be regulated, power pulse length and shape can be commanded externally. The M3A is far smaller and lighter than other energy storage systems with the same power rating. phone (415) 362-0643 + fax (415) 362-0196 » www.trinityflywheel.com ©Trinity Flywheel Power Features Connects to DC bus High power charge High power discharge User specified voltage regulation Built in diagnostics Accurate state-of-charge signal Custom control available MODbus compatible Shock and vibration tested No loss of capacity from cycling Dimensions Height 67” Width 22” Depth 25” Weight 300 Ib Performance Top speed 40,800 RPM Voltage range 550-800 VDC Max power 300 kW for 3 seconds 100 kW for 15 second at least 100,000 cycles 50,000 br 5,000 hr Cycle life Overhaul Maintenance Environmental Temperature 0°F to 120°F Humidity non-condensing Seismic 1g, 3 axes simlutaneot release M3A 012098 00 160/240/820/480 kw & hetve Power Reliable Backup Pawer for Your UPS When electrical outages are unacceptable and premium power protection system reliabil- ity is expected, Active Power's CleanSource energy storage delivers a higher level of perfor- mance and value for immediately available stand-by power. Your Uninterruptible Power Supply (UPS) system can be improved substantially with this alternative and/or supplement to traditional chemical energy storage. Storing energy efficiently in the quiet spinning mass of a steel wheel, CleanSource offers a reliable and predictable source of power. Unlike lead-acid batteries, the CleanSource flywheel requires minimal maintenance, is temperature-tolerant, and easily withstands outage cycling of 100s of thousands of events without degradation. CleanSource offers a number of benefits for improving your power quality over conven- tional energy storage: © Only two terminal connections. ° Flexible siting. ¢ Easily maintained. : © Long-life. e Extremely compact and power dense. ¢ Non-toxic and non-corrosive. CleanSource™ Flywheel Energy Storage System © Sophisticated real-time monitoring of over 30 system parameters. © High power density — small footprint Parallel capability for up to 14 systems © Efficient © Tested compatibility with multiple UPS brands © No special facilities requirements © Self diagnostics © Low maintenance © Long useful life Remote monitoring (RS232 or modem) © LCD monitor/control pane! © Low ripple current © Simple installation © N+ 1 Configurable © Microprocessor-based monitoring system Alarm status contacts © Quiet operation © Log file stores up to 5000 events © Adjustable voltage settings CleanSource Flywheel Energy Storage Ride-through Time in Seconds The CleanSource delivers the following power for these ride-through times: Max. power assumes 480v nominal DC bus Higher power and longer power delivery time available by paralleling systems CleanSource System One-Line Diagram GBT Inverter To UPS DC Bus Independent Contro! Electronics (Pull out for service) Monitoring, Display & Control Integrated Motor/Generator/ Flywheel See ee ee = =< = ee SPSS S= etd = oe CSView™ Real-time display and event logging for remote monitoring and control. 2 terminal DC energy storage System Dimessiegs: 40.5"w x 36"d x 78.5°h (CS 200/300) 40.5"w x 39.8"d x 82.2"h (CS 400/600) Fostpriat: Frame: 10 fe No rear or side access required Welgit. 2800 Ibs (CS 200/300) 4800 Ibs (CS 400/600) foat Float voltage range: 400 to 600 volts DC Minimum under-voltage threshold: 300 volts DC Maximum charging current required: 12 ADC (CS 200/300) 20 ADC (CS 400/600) Average standby current: 2-3 ADC (CS 200/300) 4-6 ADC (CS 400/600) Ontpat Adjustable output voltage range: 360 to 550 volts DC Nominal DC voltage regulation: +1% DC ripple: <2% From complete discharge: ~20 minutes Upon initial start-up: ~60 minutes Operating temperature range: -20°C to 40°C Non-operating temperature range: 0°C to 70°C Humidity: 0-95% without condensation Operating altitude: Up to 6,000 ft with no derating Operating noise level: 68 dBA at | meter (CS 200/300) 71 dBA at 1 meter (CS 400/600) Typical heat dissipation: 1.75 kW or 6000 BTU (CS 200/300) 3.5 kW or 12000 BTU (CS 400/600) LCD monitor/control panel RS-232 communications interface Self diagnostics Alarm status contacts Parallel capabilities Push-button shutdown UL 1778 and 1004 listed Optiees: Modem CSView — real-time monitoring software & Active Power 11525 Stonehollow Drive, Austin, TX 78758 © Tel: 512-836-6464 © Fax: 512-836-9245 © www.activepower.com @we Every effort has been made to ensure the accuracy of this information, however Active Power assumes no responsibility, and disclaims all liability for damages resulting from use of this information or for any errors or omissions. CleanSource and CSView are trademarks of Active Power. ©1998 Active Power, Inc. All rights reserved. Specifications subject to change without notice WIND GENERATION Wind Energy Resource Atlas of the United States das 50 100 150 Gambell | 700 ae | 69, Savoongs Kilometers 63°: 7A PS tawnence Ridge Crest Estimates ISLAND > ST MATTHEW aa 4 IstAno 162° 69> 45g . uy ae Se] Unalakicet ROMANzOF! | (/ 62° $5 BERING At | SEA 71 \ Ria 2 le, NUNIVAK ISLAND 62° 156° 154° ' 3-59 South-Central Alaska annual average wind power Product of Pacific Northwest Laborato Operated for the U.S. Department of Energy by Battelle Memorial Institute http://rredc.nrel.gov s 050100 _160 oo ‘e Fairbanks 7 i : 1 { ar 6a 7 6 .! > foi — 3 ay Delta Junction & (47> ° 1 = $$ - ' 1? a OD = & x 2 ; 5 S's 4 3 oF 2 3 o PR 3 i. . ° So 2 = - =- eo © + od 2 < ° = a 8 = S & = = 3-58 Northern Alaska annual average wind power Product of Pacific Northwest Laboratory Operated for the U.S. Department of Energy by Battelle Memorial Institute hitp://rredc.nrel.gov WIND - AVERAGE SPEED (MPH) DATA THROUGH 1993 JUN JUL AUG BIRMINGHAM AP,AL 6.1 5.7 5.4 HUNTSVILLE, AL 7.0 6.3 6.0 MOBILE, AL 77 7.0 6.8 MONTGOMERY, AL 5.8 5.7 5.2 ANCHORAGE, AK 8.3 7.3 6.9 ANNETTE, AK 9.0 8.0 8.3 BARROW, AK 11.5 11.7 12.4 BARTER IS.,AK 11.6 10.9 11.8 BETARE,. “AKy IT.3 10.9 11.0 BETTLES, AK 7.1 6.7 6.3 BIG DELTA, AK 6.5 6.0 6.6 COLD BAY, AK 15.9 15.7 16.5 FAIRBANKS, AK Tel 6.6 6.2 GULKANA, AK 8.8 8.1 8.0 HOMER, AK 7.9 7.4 6.6 JUNEAU, AK 7.7 7.5 7.5 KING SALMON, AK 10.9 10.0 10.2 KODIAK, AK 9.3 7.6 8.2 KOTZEBUE, AK 12.2 12.8 13.2 MCGRATH, AK 6.3 6.0 5.8 NOME, AK 9.8 9.8 10.4 ST. PAUL ISLAND, AK 13.8 12.3 14.1 TALKEETNA, AK 5.2 4.2 3.7 VALDEZ, AK 5.8 4.9 4.2 YAKUTAT, AK 7.2 6.7 6.5 FLAGSTAFF, AZ 6.9 5.5 5.1 SEP 6.3 13.2 13.2 11.7 1.3) 16.4 6.2 7.6 Wee 8.0 10.7 9.7 13.3 5.9 tie 15\.7 3.7 4.5 7.0 5.7 OcT 6.2 7.5 12.0 13.3 14.8 12.6 6.6 8.5 16.8 6.3 955 10.5 dd 13.7 10.8 18.2 YRS NOV 45 10.3 10.6 10.8 9.3) 10.0 9.0 49 Teh 8.2 8.3 6.5 7.1 6.6 40 6.4 6.8 6.9 6x0 6.2 7.0 Si. 12.0 12.3 11.0 12.4 12.6 10.6 60 11.6 ado, 12.4 11.5 33 15.1 14.4 14.9 13.9 35 14.6 15.1 I3.5 14.2 18 6.0 6.5 752 6.1 5.9 6.7 20 10.8 9.9 8.2 9.5 91.5 8.2 38 Th 17.8 17.4 as 5 17.5 16.9 42 3.1 4.0 5.2 329 3.2 5.4 8 5.1 5.6 4.8 3.6 6.8 19 8.4 8.2 8.0 8.1 8.1 7.8 48 8.3 8.5 8.5 8.5 9.0 8.3 38 10.7 11.2 10.7 10.5 40 12.8 12.4 12.4 12.4 10.9 47 14.4 12.9 12.1, 14.6 13.2 13.0 43 3.2 4.3 3-3 3.8 3.1 5.2 46 11.3 10.9 10.2 11.8 10.4 10.6 19 20 33: 20.7 20.6 21.0 17.4 dd 6.2 5.5 Crs 5.2 Die 1: 4.8 13 Too P| 6.0 ale pe ) 13.7 1352 13.9 12.8 6.5 11.4 10.8 1233) 19.0 APR 8.3 9.3 10.2 7123 Wwe 122 11.5 12.0 13.0 135 11.1 11.6 23 6.4 10.3 17.8 6.8 8.1 9.3 11.8 12.7 11.7 75 11.2 10.6 131 10.0 15.6 Table 1-1 Classes of wind power density at 10 m and 50 m”, Wind |___—s__—'10 m (33 ft) | Om (164 ft) Power Wind Power Speed” m/s Wind Power Speed” m/s _Class | Density W/m’) | (mph) | Density (W/m?) | (mph) f 1 Ls 100 4.4 (9.8) 200 5.6 (12.5) 2 |__| _ —| 150 5.1 (115) 300 6.4 (14.3) | 3 = — ee —=| 200 5.6 (12.5) 400 7.0 (15.7) | 4 - wa _ t———| 250 6.0 (13.4) 500 7.5 (16.8) 5 —— a Fo | 300 6.4 (14.3) 600 8.0 (17.9) | 6 eae aa Lees 400 7.0 (15.7) | 800 8.8 (19.7) | L_ 100 [ 9a@ty [2000 | 11.9066) (a) Vertical extrapolation of wind speed based on the 1/7 power law. (b) Mean wind speed is based on Rayleigh speed distribution of equivalent mean wind power density. Wind speed is for standard sea-level conditions. To maintain the same power density, speed increases 3%/1000 m (5%/5000 ft) elevation. “WEB NOTE: Each wind power class should span two power densities. For example, Wind Power Class = 3 represents the Wind Power Density range between 150 W/m’ and 200 W/m?. The offset cells in the first column attempt to illustrate this concept. Renewable Resource Data Center (RReDC) Home Page Page 1 of 2 General Information e News ¢ Links Special Features KidE inks ENF EGY. = Gnit: Conversions Security & Privacy Disclaimer http://rredc.nrel.gov/ Introduction Welcome to the Renewable Resource Data Center (RReDC). The RReDC is supported by the National Center for Photovoltaics (NCPV) and managed by the Department of Energy's Office of Energy Efficiency and Renewable Energy. The RReDC is maintained by the Distributed Energy Resources Center of the National Renewable Energy Laboratory. The RReDC provides information on several types of renewable energy resources in the United States, in the form of publications, data, and maps. An extensive dictionary of renewable energy related terms is also provided. The News section announces new products on the RReDC. NOTICE: Information from this server resides on a computer system funded by the U.S. Department of Energy. Anyone using this system consents to monitoring of this use by system or security personnel. [More...] Please send questions and comments to rredc@nrel.gov Information by Resource @ Biomass Resource Information =. Geothermal Resource Information (Geothermal Resource Information Clearinghouse) “©: Solar Radiation Resource Information ‘x wind Energy Resource Information &3 Dynamic Maps and GIS Data 02/01/2002 Alaska Alaska covers an area of 1,518,776 km? (586,400 mi’). Because of the state's large size, in the Alaska wind energy resource assessment (Wise et al. 1981) the state was divided into four subregions: northern,southeastern, south-central, and southwestern. The state population in 1980was 402,000. More than 40% of Alaska's population lives in the metropolitanarea of Anchorage, in the south-central subregion. The major cities, towns, villages, rivers, mountain ranges, and national parks are shown in Map 3-57. The topography of Alaska varies from subregion to subregion. A large portion of the land is mountainous; the Brooks Range is in the northern subregion, the Alaska Range is in the south-central and southwestern subregions, and the Coast and St. Elias mountains are in the southeastern subregion. Flat coastal plains, such as those along the Arctic coast and Yukon-Kuskokwim Delta (in the northern and southcentral subregions, respectively) are also prominent features. Flat alluvial plains are found in the river valleys, such as the Yukon River valley in the southeast portion of the northern subregion. Up-land plains are found throughout the state. In Alaska, high wind resource occurs over the Aleutian Islands and the Alaska Peninsula, most coastal areas of northern and western Alaska, offshore islands of the Bering Sea and Gulf of Alaska, and over mountainous areas in northern, southern, and southeastern Alaska. The largest areas of class 7 wind power in the United States are located in Alaska—data from some of the Aleutian Islands indicate an annual average wind power over 1000 W/m’ at 10 m, which corresponds to about 2000 W/m’ at 50 m. Major areas of wind resource in Alaska are described below. Maps of annual average wind power are presented for the four subregions in Maps 3-58 through 3-61. Beaufort and Chukehi Sea Coast The annual average wind power for exposed coastal and offshore areas is estimated to be at least class 5. Coastal areas near Barter Island, Point Lay, and Cape Lisburne show class 7. Even though much of the area north of the Brooks Range is of low relief, wind power drops off rapidly with distance from the coast as shown by data from Sagwon and Umiat. On the eastern Beaufort coast, an area with wind power of class 4 or higher appears to extend from the coast southward to the crests of the Brooks Range. Along the Chukchi Sea coast, wind power of class 5 to 7 is probably confined to near the coast, although there are no data available inland to corroborate this assumption. Bering Sea Islands and Coast Islands in the Bering Sea, such as the Pribilofs, St. Lawrence, St. Matthew, and Nunivak, all show annual wind powers of class 7 except in the vicinity of Savoonga on St. Lawrence Island, which has class 6. Along the coast from the Alaska Peninsula northward, wind power of class 5 or higher (with class 7 in exposed areas like the west end of the Seward Peninsula and the Cape Romanzof area) is shown. Wind power of class 5 or more extends eastward for 150 km (100 mi) in the Yukon-Kuskokwim Delta area, as shown by Bethel data. Alaska Peninsula and the Aleutian Islands The Alaska Peninsula west of 162°W shows annual wind power class 7 at all locations except those shielded somewhat by local terrain. The whole peninsula has class 5 or higher power. This area is along a major storm track from eastern Asia to North America. Storms generally move from west to east. Some storms also move northward through the Bering Sea, especially during the summer months. Amchitka and Asi Tanaga in the western Aleutians show mean annual wind power of over class 7 (1,000 Wim’). Winter is the season of maximum wind power throughout the area. Lower Cook Inlet The area from Iliamna Lake to Kamishak Bay across Cook Inlet to the Barren Islands is a corridor for strong winds. This is reflected at Bruin Bay, which shows an average annual wind power of over 1,300 W/m’. Subjective comments from mariners indicate that this lower Cook Inlet area can be very windy. Bruin Bay data and an examination of weather records from two drilling rigs operating in the area confirm this impression. There are no other permanent stations besides Bruin Bay that show this wind resource. Gulf of Alaska Coast Exposed areas of the entire Gulf of Alaska coast should experience mean annual wind power of class 3 or higher. Offshore data from Middleton Island indicate class 7 wind power. Shore data such as Cape Spencer, Cape Decision, Cape Hinchinbrook, and North Dutch Island reflect class 5 or higher power. Data from more sheltered locations, such as Cordova, Sitka, and Yakutat do not reflect these wind power classes. Most of this coastline is rugged and heavily wooded, so wind power estimates are very site-specific. Exposed Mountain Ridges and Summits At least class 3 or higher wind power is estimated for mountain summits and ridge crests in the Alaska Range, the Coast Mountains in southeastern Alaska, and portions of the Brooks Range. The map analyses represent the lower limits of the wind power resource for exposed areas. Wind speeds can vary significantly from one ridge crest to another as a result of the orientation to the prevailing slope of the ridge and its closeness to other ridgelines. Winter is the season for highest wind speed and power at mountain summits and ridge crests. September 2001 + NREL/CP-500-30668 Characterizing the Effects of High Wind Penetration on a Small Isolated Grid in Arctic Alaska Gordon Randall, and Rana Vilhauer Global Energy Concepts, LLC Craig Thompson Thompson Engineering Company Presented at AWEA's WINDPOWER 2001 Conference Washington, D.C. June 4 — June 7, 2001 fe é ans r DNR=! CuY Ean National Renewable Energy Laboratory 1617 Cole Boulevard Golden, Colorado 80401-3393 NREL is a U.S. Department of Energy Laboratory Operated by Midwest Research Institute e Battelle e Bechtel Contract No. DE-AC36-99-GO10337 NOTICE The submitted manuscript has been offered by an employee of the Midwest Research Institute (MRI), a contractor of the US Government under Contract No. DE-AC36-99GO010337. Accordingly, the US Government and MRI retain a nonexclusive royalty-free license to publish or reproduce the published form of this contribution, or allow others to do so, for US Government purposes. This report was prepared as an account of work sponsored by an agency of the United States government. Neither the United States government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States government or any agency thereof. Available electronically at http:/www.doe.gov/bridge Available for a processing fee to U.S. Department of Energy and its contractors, in paper, from: U.S. Department of Energy Office of Scientific and Technical Information P.O. Box 62 Oak Ridge, TN 37831-0062 phone: 865.576.8401 fax: 865.576.5728 email: reports@adonis.osti.gov Available for sale to the public, in paper, from: U.S. Department of Commerce National Technical Information Service 5285 Port Royal Road Springfield, VA 22161 Phone: 800.553.6847 fax: 703.605.6900 email: orders@ntis.fedworld.gov online ordering: http:/Avww.ntis.gov/ordering.htm rv G2 Printed on paper containing at least 50% wastepaper, including 20% postconsumer waste CHARACTERIZING THE EFFECTS OF HIGH WIND PENETRATION ON A SMALL ISOLATED GRID IN ARCTIC ALASKA Gordon Randall and Rana Vilhauer Global Energy Concepts, LLC 5729 Lakeview Dr. NE, Suite 100 Kirkland, WA 98033 USA grandall@globalenergyconcepts.com rvilhauer@globalenergyconcepts.com Craig Thompson Thompson Engineering Company 721 Sesame Street, Suite 2B Anchorage, AK 99503 teco@gci.net Abstract Utilities have historically assumed that wind penetration levels of more than 25-30% would result in system instability. Higher levels of wind penetration were expected to cause serious stability and reliability problems in both the generation and distribution systems. Because wind penetration levels in the United States have generally been much lower, little data have been available to determine if such problems actually occur. This paper examines the operating characteristics of the wind-diesel system in Kotzebue, Alaska, operated by Kotzebue Electric Association (KEA). KEA began incorporating wind power into its 100% diesel generating system in 1997 with three 66 kW wind turbines. In 1999, KEA added another seven 66 kW turbines, resulting in the current wind capacity of 660 kW. KEA is in the process of expanding its wind project again and ultimately expects to operate 2-3 MW of wind capacity. With a peak load of approximately 4 MW and a minimum load of approximately 1.6 MW, the wind penetration is significant. KEA is currently experiencing greater than 35% wind penetration, sometimes for several consecutive hours. This paper discusses the observed wind penetration at KEA and evaluates the effects of wind penetration on power quality on the KEA grid. Introduction The KEA wind power plant is a 0.66 MW facility of small commercial-scale wind turbines. The project consists of 10 AOC 15/50 66 kW fixed-speed, stall-controlled wind turbines manufactured by Atlantic Orient Corporation (AOC) of Norwich, Vermont. The AOC 15/50 is a three-bladed, downwind turbine with a 15-m (49-ft) rotor diameter installed on 24.4-m (80-ft) lattice towers on piling foundations, resulting in a hub height of approximately 26.5 m (87 ft). The KEA wind power project joined the U.S. Department of Energy/Electric Power Research Institute (DOE-EPRI) Wind Turbine Verification Program (TVP) as an associate project in 1997. Additional information about the KEA wind project performance and operating experience is reported by EPRI[1]. KEA’s project site is located on the tip of the Baldwin Peninsula approximately 42 km (26 mi) north of the Arctic Circle on the northwest coast of Alaska near the town of Kotzebue. With a population of approximately 3,000 residents, Kotzebue is the largest community in northwestern Alaska and serves as the economic, governmental, medical, communication, and transportation hub for the 11 communities in the Northwest Arctic Borough, an area roughly the size of Indiana. Figure 1 shows the location of Kotzebue on the Alaska state map. FIGURE 1: KOTZEBUE LOCATION MAP The only source of generation for the KEA power grid is an 11 MW diesel generating plant consisting of six diesel generators. Normally the diesel plant has only one or two generators operating, with the remaining generators providing redundancy. Typical loads on the grid range between 2 and 3 MW, with a peak load of approximately 4 MW and a minimum load of approximately 1.6 MW. The load varies with the time of day and with climatic conditions. Methodology and Data Used For the purpose of this paper, data from August 21 through September 20, 2000 were evaluated. This period was selected because total system load can be somewhat lower during the warmer summer months. The TVP reporting period for the KEA project ends on the 20" of the month, so the period evaluated corresponds to one monthly period. Data for the wind project were generated using the Second Wind Advanced Distributed Monitoring System (ADMS), a commercial supervisory control and data acquisition system (SCADA) that KEA uses to manage and operate the wind project. Parameters measured by the SCADA include turbine production and performance, meteorological data, and a variety of power quality measurements collected by the Second Wind Phaser* power transducers located in each turbine. The Phaser has also been used by TVP to make power quality measurements at other distributed wind projects, as reported by Green [2]. KEA meter readings indicating total system load and production by the diesel generating facility were also available. Wind penetration estimates were calculated by dividing the measured power output from the wind facility by the total KEA system load. KEA Grid Load and Observed Penetration Levels Figure 2 presents the diurnal pattern of grid loads during the period evaluated. The solid line indicates the average load for each hour over the month. Minimum and maximum values within the month are indicated with bars off of this line. The approximate capacity of the wind farm (i.e., approximately 660 kW) is also indicated. Total System Load, August 21 - September 20, 2000 3500 3000 + 2500 | 2000 Ff = = 1 = 1500 Approximate Capacity of Wind Farm 1000 | 500 o+ 12AM 1AM 2AM 3AM 4AM 5AM 6AM 7AM 8AM 9AM 10AM11AM12PM 1PM 2PM 3PM 4PM SPM 6PM 7PM 8PM 9PM 10PM11PM Time of Day FIGURE 2: DIURNAL DISTRIBUTION OF KEA LOAD As shown on this figure, grid loads are lowest during early morning hours, usually falling below 2 MW from approximately 1:00 a.m. to 6:00 a.m. The minimum load observed during the month was approximately 1.67 MW. Loads are higher throughout the day, although loads did not exceed 3 MW during the month. The minimum system load occurred at approximately 4:00 a.m. on August 29, 2000. The highest overall wind penetration of approximately 35% was also measured at this time. Figure 3 presents the wind speed and temperature measured over the time around this event, as well as the calculated wind penetration values. August 29 was an unusually warm morning in Kotzebue, with temperatures exceeding 13 degrees Celsius during the overnight hours. These temperatures were over 3 degrees warmer than measured values for the same time period on other days during the month. In addition, the winds were moderate to strong throughout the early morning hours, exceeding 15 m/s at 4:00 a.m. This combination of high winds and low demand on the KEA grid resulted in the unusually high penetration values. 18 45% —— Air Temperature ——Wind Speed 16 Wind Penetration + 40% 14 35% 12 § 10 6 a 15% oo 8 g & Wind Penetration Air Temperature (degrees C)/Wind Speed (m/s) 4 10% 2 5% 0 0% 12:00 AM 1:00 AM 2:00 AM 3:00 AM 4:00 AM 5:00 AM 6:00 AM 7:00 AM 8:00 AM Time of Day, August 29, 2000 FIGURE 3: AIR TEMPERAURE, WIND SPEED, AND WIND PENETRATION, AUGUST 239, 2000 In addition to the morning of August 29, penetration values in excess of 25% were observed during the early morning hours for several days following the 29". A summary of the observed penetration values is presented in Table 1. Despite a few periods of high penetration, the overall average penetration for the month was approximately 5.6%. This average is highly influenced by the few significantly higher values. The median penetration for the month was 2.0%. Penetration values of less than 1% were calculated for approximately 46% of the month; penetration values of less than 10% were calculated for approximately 77% of the month. Overall, penetration varied only slightly with the time of day. During the early morning hours (from midnight to 8:00 a.m.), the median penetration was 0.71%, which is somewhat below the overall median value. This reflects the generally lower wind speeds during this period, with the exception of August 29 and the days immediately thereafter. However, the early moming average penetration was 6.0%, reflecting the lower energy demand during this period. The opposite trend was seen during evening hours, with a higher 3.1 % median penetration due to higher winds but a lower 5.3 % average penetration because of higher energy demand. Overall wind penetration values are presented graphically in Figure 4. TABLE 1: SUMMARY OF WIND PENETRATION VALUES Evening Early Morning Day (5 p.m. - fasameter Overall _K12 a.m. - 8 a.m.) (8 a.m. - 5 p.m. 12 a.m.) laximum penetration 35.3% 35.3% 24.5% 24.2% Average penetration 5.6% 6.0% 5.4% 5.3% [Median penetration 2.0% 0.7% 2.0% [Time with less than 1% penetration 46.2% 50.5% 46.8% [Time with less than 10% penetration 77.1% 74.6% 76.9% Time with less than 20% | penetration 92.9% 91.0% 93.4% 40% [—Night (12AM-8AM) | 35% |—Day (8 AM- 5 PM) — Evening (5 PM - 12 AM) —— Overall 30% 25% c S 20% E s 5 15% a 10% 5% 0% 5% Percentile FIGURE 4: WIND PENETRATION PERCENTILES Power Quality at High Penetration A variety of power quality parameters are measured by the Phasers and recorded in the SCADA system or can be calculated from the measured values. These parameters include (among others) line voltage, voltage imbalance, total demand distortion, and frequency deviation. The following section presents an overview of how each of these parameters varied as the wind penetration increased. Power quality measurements described in this section were recorded by the Phaser at Turbine 8. This turbine was used in power performance testing conducted at the site, and the Phaser recorded a wider range of parameters than those at the other turbines. The measurements at this turbine are believed to be representative of the rest of the wind farm. For the purpose of this analysis, data were used only when the wind facility was on-line and producing at least 200 kW of power. Below this output level, it was assumed that any irregularities in power quality measurements would be caused by sources other than the wind farm. Voltage Figure 5 presents a scatter plot of 10-minute average voltages compared to the wind penetration values. The nominal voltage for the grid is 480 V. As shown, the measured voltage exceeded the nominal value by up to approximately 20 V during the time period evaluated. However, no relationship can be seen between voltage and wind penetration. At the highest penetration levels, voltage was closer to nominal than at some lower penetration values. Consequently, it appears that any effect on line voltage caused by high penetration is dwarfed by effects external to the wind farm, and possibly by effects caused by the wind farm independent of the penetration level. 92 + & Average Voltage (V) 8 0% 5% 10% 15% 20% 25% W% 35% 40% FIGURE 5: AVERAGE VOLTAGE VS. WIND PENETRATION Voltage Imbalance Figure 6 presents a scatter plot of 10-minute average voltage imbalance compared to the wind penetration values. There is relatively little scatter in the measured values, with a range between about 18.2 V and 19.6 V. No relationship can be seen between wind penetration and voltage imbalance. Total Demand Distortion Figure 7 presents a scatter plot of 10-minute average total demand distortion compared to the wind penetration values. There appears to be a slight inverse relationship between wind penetration and total demand distortion; however, the relationship is not strong and may be more related to other factors. Regardless, no adverse effect on total demand distortion is observed as wind penetration increases. Frequency Deviation Figure 8 presents a scatter plot of 10-minute average frequency deviation compared to the wind penetration values. As shown, the frequency deviation appears to remain relatively constant as wind penetration levels increase. 19.6 19.4 19.2 3 18.8 4 Voltage Imbalance (V) 18.6 4 18.4 18.2 0% 5% 10% 15% 20% 25% W% 35% 40% FIGURE 6: VOLTAGE IMBALANCE VS. WIND PENETRATION Total Demand Distortion (%) 0% 5% 10% 15% 20% 25% W% 35% 40% Wind Penetration FIGURE 7: TOTAL DEMAND DISTORTION VS. WIND PENETRATION 140 120 2 100 e 80 ee on ee @ . 60 7 = e oo th Frequency Deviation (mHz) > $ 60 0% 5% 10% 15% 20% 25% 30% 35% 40% Wind Penetration FIGURE 8: FREQUENCY DEVIATION VS. WIND PENETRATION Conclusions Based on measurements collected between August 21 and September 20, 2000, there is no apparent adverse effect on power quality on the KEA grid as wind penetration increases. During this period, wind penetration reached a maximum level of approximately 35%. It is unlikely that wind penetration will significantly exceed 35% at KEA with the current wind turbine capacity, as the highest observed penetration levels occurred during time periods with a combination of high winds and low system load. KEA plans on expanding the wind farm in the near future. Current plans for expansion include addition of two AOC 15/50 turbines during the summer of 2001. With these additional turbines, wind penetration could reach maximum levels of approximately 45%. Eventually, KEA plans to increase wind generation capacity to a total of 2 to 3 MW. References 1. Kotzebue Electric Association Wind Power Project First-Year Operating Experience: 1999-2000, U.S. Department of Energy - EPRI Wind Turbine Verification Program, EPRI 1000957, December 2000. 2. Green, J., VandenBosche, J., Lettenmaier, T., Randall, G., Wind, T. Power Quality of Distributed Wind Projects in the Turbine Verification Program. WindPower 2001 Proceedings, AWEA, Washington, DC, June 2001. REPORT DOCUMENTATION PAGE Public reporting burden for this collection of information is estimated to average gathering and maintaining the data needed, and completing and reviewing the collection of information. Send comments regardi Collection of information, including suggestions for reducing this burden, to Washington Headquarters Services, Directorate for I Davis Highway, Suite 1204, Arlington, VA 22202-4302, and to the Office of Management and t, Paperwork Reduction Pt 1. AGENCY USE ONLY (Leave blank) | 2. REPORT DATE September 2001 Conference paper 4, TITLE AND SUBTITLE Characterizing the Effects of High Wind Penetration on a Small Isolated Grid in Arctic Alaska 6. AUTHOR(S) Gordan Randall, Rana Vilhauer, Craig Thompson 7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES) Global Energy Concepts, LLC, 5729 Lakeview Dr. NE, Suite 100, Kirkland, WA Thompson Engineering Company 721 Sesame Street, Suite 2B, Anchorage, AK 9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES) National Renewable Energy Laboratory 1617 Cole Blvd. Golden, CO 80401-3393 11. SUPPLEMENTARY NOTES NREL Technical Monitor: 1 hour per response, including the time for reviewi 3. REPORT TYPE AND DATES COVERED $$ SSS $$ Form Approved OMB NO. 0704-0188 instructions, searching existing data sources, is burden estimate or any other as) of this mation Operations and Reports, 1215 Jefferson (0704-0188), Washington, DC 20503. 5. FUNDING NUMBERS WER12430 8. PERFORMING ORGANIZATION REPORT NUMBER 10. SPONSORING/MONITORING AGENCY REPORT NUMBER CP-500-30668 12a. DISTRIBUTION/AVAILABILITY STATEMENT National Technical Information Service U.S. Department of Commerce 5285 Port Royal Road Springfield, VA 22161 12b. DISTRIBUTION CODE 13. ABSTRACT (Maximum 200 words) and evaluates the effects of wind penetration on power quality on the KEA grid. 14. SUBJECT TERMS wind energy; wind-diesel hybrid systems; Kotzebue Alaska This paper examines the operating characteristics of the wind-diesel system in Kotzebue, Alaska, operated by Kotzebue Electric Association (KEA). KEA began incorporating wind power into its 100% diesel generating system in 1997 with three 66 kW wind turbines. In 1999, KEA added another seven 66 kW turbines, resulting in the current wind capacity of 660 kW. KEA is in the process of expanding its wind project again and ultimately expects to operate 2-3 MW of wind capacity. With a peak load of approximately 4 MW and a minimum load of approximately 1.6 MW, the wind penetration is significant. KEA is currently experiencing greater than 35% wind penetration, sometimes for several consecutive hours. This paper discusses the observed wind penetration at KEA . NUMBER OF PAGES . PRICE CODE 17. SECURITY CLASSIFICATION OF REPORT Unclassified 19. SECURITY CLASSIFICATION OF ABSTRACT Unclassified 18. SECURITY CLASSIFICATION OF THIS PAGE Unclassified NSN 7540-01-280-5500 LIMITATION OF ABSTRACT UL 20. Standard Form 298 (Rev. 2-89) Prescribed by ANSI Std. Z39-18 298-102 July 1999 * NREL/CP-500-26827 Power Flow Management in a High Penetration Wind-Diesel Hybrid Power System with Short-Term Energy Storage S.M. Drouilhet National Wind Technology Center Windpower ’'99 June 20-23, 1999 Burlington, Vermont aS -_ « D> NREL Y National Renewable Energy Laboratory 1617 Cole Boulevard Golden, Colorado 80401-3393 NREL is a U.S. Department of Energy Laboratory Operated by Midwest Research Institute e Battelle e Bechtel Contract No. DE-AC36-98-GO10337 NOTICE This report was prepared as an account of work sponsored by an agency of the United States government. Neither the United States government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States government or any agency thereof. Available to DOE and DOE contractors from: Office of Scientific and Technical Information (OSTI) P.O. Box 62 Oak Ridge, TN 37831 Prices available by calling 423-576-8401 Available to the public from: National Technical Information Service (NTIS) U.S. Department of Commerce 5285 Port Royal Road Springfield, VA 22161 703-605-6000 or 800-553-6847 or DOE Information Bridge http://www.doe.gov/bridge/home.htm! a % Printed on paper containing at least 50% wastepaper, including 20% postconsumer waste POWER FLOW MANAGEMENT IN A HIGH PENETRATION WIND-DIESEL HYBRID POWER SYSTEM WITH SHORT-TERM ENERGY STORAGE Steve Drouilhet, PE National Wind Technology Center National Renewable Energy Laboratory 1617 Cole Blvd. Golden, Colorado 80401 USA INTRODUCTION In the last several years, interest in medium to large scale (100 kW to multi-MW) wind-diesel hybrid power systems for rural electrification has grown enormously among energy officials and utility planners in the developing countries, multilateral lending institutions, and utilities serving the far northern areas of the developed countries. There are many indications that there is a large potential market for such systems, and though there are an increasing number of demonstration projects, a true market for such systems has yet to emerge. Consequently, an industry capable of serving this market is still only in its infancy. Only a small fraction of researchers and engineers working in the wind power industry, which is relatively small itself, are involved in hybrid systems for off-grid applications. There is therefore relatively little information available on the technical issues involved in implementing a wind-diesel power system. It is tempting to view the addition of wind turbines to a diesel mini-grid as a straightforward task, only slightly more complicated than a conventional grid-connected installation, requiring only a few ancillary components at a relatively modest cost. While this is true for low penetration wind-diesel systems, where the wind turbine output averages no more than about 15% of the load, high penetration systems, in which the average wind power generated can approach or even exceed the average load, require much more sophisticated controllers and more extensive components in addition to the wind turbines. This additional cost and complexity can often be justified by the much greater fuel savings (and associated environmental benefits) and reduced diesel operating time made possible by high wind penetration. This paper is intended as an introduction to some of the control challenges faced by developers of high penetration wind-diesel systems, with a focus on the management of power flows in order to achieve precise regulation of frequency and voltage in the face of rapidly varying wind power input and load conditions. The control algorithms presented herein are being implemented in the National Renewable Energy Laboratory (NREL) high penetration wind-diesel system controller that will be installed in the village of Wales, Alaska, in early 2000. BACKGROUND Since 1995, the National Wind Technology Center (NWTC) at NREL has been researching wind-diesel hybrid power systems. Areas of study have included optimal diesel dispatch strategies, the value of energy storage, village mini-grid optimization, power converter efficiency, system stability, and long-term performance and economic modeling. In 1997, the Hybrid Power Test Bed was constructed at the NWTC to facilitate the development and testing of both experimental and commercial hybrid power systems. One of the ways NREL supports the development and growth of the renewables-based hybrid power systems industry is to provide technical assistance to pilot and demonstration projects, both domestically and internationally. Since 1995, NREL has been engaged in a collaborative project with the Alaska state energy office and Kotzebue Electric Association, a rural Alaskan electric cooperative, to design, test, install, and monitor a high penetration wind-diesel hybrid power system in Wales, Alaska, a small village on the northwest coast on the Bering Strait. NREL’s role in this project has been the following: Identify a hybrid system architecture well suited to implementation in small northern villages e Design and build the non-wind turbine hardware components of the system (system controller, secondary load controllers, energy storage subsystem) ¢ Develop the control software necessary to operate the system stably and reliably e Fully test and debug the control system at its test facility in Boulder, Colorado e Provide training in system operation and maintenance. The control system, the secondary load controllers, and the energy storage subsystem have all been built and installed at the Hybrid Power Test Bed, where the control software is currently undergoing test and refinement. Installation of the system in the village of Wales is scheduled to begin in July 1999. SYSTEM DESIGN OBJECTIVES Because of NREL’s substantial technical involvement in the project and the availability of its hybrid power test facility, this project represented an opportunity to develop and test a system to meet design and performance objectives beyond what could be met by then-available commercial hybrid power systems. Some of the specific objectives that guided the development of the system are the following: 1. One requirement of the system architecture was that it be designed to “wrap around” an existing village power plant. Unlike many remote regions of developing countries, nearly 100% of Alaska’s rural villages are already electrified. These village power systems represent a considerable investment in diesel generation equipment. It is important in these cases to use as much of the existing diesel genset and controls equipment as possible. 2. Second, the system should have sufficient penetration to achieve at least a 50% reduction in the diesel fuel consumed for electric power generation. 3. To maximize the potential fuel savings and to reduce diesel maintenance expenses, the system should allow the diesel generators to be shut off as much of the time as possible. Prior analysis at NREL had suggested that this objective required that the system include a small amount of high power density energy storage. 4. To further maximize the return on investment, the system needs to ensure that 100% of the wind turbines’ energy output serves a productive load. In other words, wind power in excess of what was needed to meet the primary village electric demand must be diverted to another application having economic value. In Wales, the only other significant energy demand is for space heating. Because the major heat loads exist at several distributed points in the village, a distributed secondary load arrangement was required. The architecture chosen to meet these objectives is shown, in simplified form, in Figure 1. The existing diesel power station consists of three 480 VAC, three phase generator sets with ratings of 75, 142, and 148 kW. The retrofit package consists of two AOC 65 kW wind turbines, an AC-DC rotary converter, a 240 VDC 130 Ah nickel-cadmium (Ni-Cd) battery, and several secondary load controllers to control power to electric boilers located at several points in the village. These secondary loads will be used to displace heating fuel that would otherwise be burned in existing boilers. Figure 1 shows only the power components, not the variety of control hardware required to make the system operate. Figure 2 depicts the control architecture of the system. Control signals pass among the various control components either via hardwired analog and discrete control lines, or via high speed serial networks, as shown. Wind Turbines (Induction, 2X65 KW=130 KW a cen my Bank OC MACHINE = AC MACHINE 240 VOC, 130A Rotary Converter 156 KVA Heati ing System 3 xe 142 KW Diesel #2 75 kW peace, [I}- Re "heen Contes aut ae Village Load FIGURE 1. WIND-DIESEL SYSTEM ARCHITECTURE FOR WALES, ALASKA OIESEL PLANT HYDRONCLOOP (DUMP LOAD CONTROLLER ROTARY CONVERTER CONTROL CABINET FIGURE 2. WIND-DIESEL SYSTEM COMMUNICATION AND CONTROL DIAGRAM THE PRIMARY TASKS OF A POWER GENERATION SYSTEM An automated wind-diesel hybrid power system controller is called upon to do a wide variety of tasks. These include such things as (1) automatic dispatch of the diesel generators to ensure proper loading and good operating efficiency, (2) operator notification of any warning or alarm conditions, (3) performance data logging to facilitate troubleshooting and maintenance, and (4) management of the secondary loads to ensure that excess power is directed where it is most needed. Fundamentally, however, the most critical tasks of the system are to provide good frequency and voltage regulation. Unless the system can provide good power quality, as measured primarily by frequency and voltage stability, it is not viable. WND POWER [ POWER 9 ELECTRIC POWER TO RESISTIVE LOADS SYSTEM DIESEL POWER [CO (STORED ee SHAFT POWER TO MECHANICAL LOADS KINETIC ENERGY) BATTERY POWER SS a MSCELLANEOUS LOSSES FIGURE 3 POWER FLOWS INTO AND OUT OF THE HYBRID POWER SYSTEM Frequency Regulation The entire power system, including all its generators, distribution wiring, and even motors present in the village load, can be thought of as one big electromechanical entity, as shown in Figure 3. Power flows into this system as power from the wind transferred to the wind turbine rotor, mechanical power developed in the diesel engines as a result of combustion, and electric power drawn from the battery. Power flows out of the system to consumer resistive loads, to consumer mechanical loads, to secondary loads, and as various mechanical and electrical losses. At any given moment, if more power is flowing into the system than out of it, the difference will be stored as an increase in kinetic energy of the rotating machines within the system, both generators and motors, that happen to be on-line at that time. The effect of any power imbalance in the system is expressed in Equation 1. d(K.E.)_d A gon ghte 0 > Psources — ¥ Psinxs = where P = active power (kW) KE. = kinetic energy of system J = moment of inertia of rotating machine @ = angular velocity of rotating machine This increase in kinetic energy is manifested as an increase in rotational speed of the synchronous machines in the system and thus an increase in electrical frequency. The task of frequency regulation is essentially a problem of maintaining an instantaneous balance of the real power flowing into and out of the system.’ ' This relationship of power imbalance to frequency change only applies to power systems in which the frequency is determined by the rotational speed of one or more synchronous machines in the system. In systems governed by a Voltage Regulation Analogously, regulating the AC voltage of the power system is a problem of maintaining an equilibrium between the source and sinks of reactive power (VARs) in the system. The induction generators of the wind turbines, transformers in the distribution system, and induction motors in the consumer load are all reactive power sinks. Power factor correction capacitors on the wind turbines or the distribution system are sources of reactive power. Synchronous generators, both on the diesel gensets and on the rotary converter, can either be sources or sinks, but generally they are supplying the reactive power demanded by the sinks. Unlike the case of real power, where an imbalance can be absorbed by the system as a change in stored kinetic energy, there is no storage mechanism for “reactive energy”, which only actually exists as a mathematical construct. The reactive power supplied by the sources is inherently equal to the reactive power absorbed by the sinks. This is expressed in Equation 2, in which the reactive power flows for each component are expressed as functions of voltage. Y Osources(V40) = ¥Y Osmes Vac) =0 (2) where Q = reactive power (kVAR) Vac = AC bus voltage If the reactive power sources are unable to deliver the reactive power demanded by the sinks, the bus voltage will fall such that the equilibrium is maintained. With reactive power, the issue is not so much ensuring that equilibrium is maintained (which is automatic), but that the equilibrium occurs at the desired voltage level. On a synchronous machine, the function of the voltage regulator is actually to control the generator excitation such that the generator delivers the reactive power demanded by the load at the desired voltage. THE OPERATING STATES OF THE WIND DIESEL SYSTEM There are three devices subject to the direct control of the wind-diesel controller: the rotary converter AC machine, the rotary converter DC machine, and the secondary load controller (which actually consists of multiple distributed load controllers). Each of these devices has several different control modes associated with it. For example, the AC machine can be controlled to achieve any of the following: Match voltage with the AC bus (prior to synchronization) Share reactive power with the diesel generators Deliver a specified amount of reactive power to the grid Regulate AC bus voltage. The power flow management algorithm determines the appropriate control mode for each of these three devices depending on the operating state of the power system. The Wales wind-diesel hybrid power system involves multiple diesels and multiple wind turbines. In addition there is a power converter consisting of two separate rotating machines and a secondary load that is divided into “local dump load” and “remote dump load”. Because each of these components may or voltage source inverter, the frequency is typically set by a crystal oscillator and does not vary. However, a similar situation exists in that any power imbalance then typically shows up as an increase or decrease in voltage on the AC and/or DC side of the inverter. The problem then becomes one of voltage control rather than frequency control. may not be operating at any given time, there are a great number of possible system operating states. To develop a power flow management algorithm flexible enough to handle all possible operating states, one must identify a minimum set of key state variables that provide sufficient information to determine the appropriate control mode for each device. Our top level state variable is the diesel status, because it has the biggest impact on how voltage and frequency is regulated. “Diesel ON” refers to the state where one or more diesel generators is connected to the bus and loaded (i.e. not in load or unload ramp). Conversely, “Diesel OFF” refers to the state in which all diesel generators are either disconnected from the bus or connected but not fully loaded. Diesel ON State The stand-alone diesel generator is designed to regulate the voltage and frequency on an isolated power bus. In a multiple diesel configuration equipped with automatic load sharing controls, the diesels collectively regulate frequency and share both the real and reactive power load in proportion to their respective ratings. Diesel gensets do an excellent job of frequency and voltage control provided that the real and reactive power load on them remains within their rated capacity and they are not subject to large reverse power transients. In the Diesel ON state, we allow the diesel generator(s) to perform their intended function of frequency and voltage control, and we control the rotary converter and/or secondary loads to maintain the diesel loading in a comfortable range. In summary, in Diesel ON state, e The diesel generator(s) assume both frequency and voltage control e Power flow to the secondary loads and/or energy storage is controlled to maintain diesel loading within a comfortable range e The rotary converter ac machine is used to assist the diesel generators in meeting the var load, as necessary. Diesel OFF State In the Diesel OFF state, the only synchronous machine left on the system is the AC machine of the rotary converter. The rotational speed of the rotary converter will establish the grid frequency. As with the diesel generator, the voltage regulator on the rotary converter AC machine controls the field current so as to maintain the desired AC bus voltage. Frequency is controlled by modulating power flow to the secondary load or battery, depending on factors to be discussed below. System Sub-States Diesel status is only the first of the system state variables that are used in determining the appropriate control mode for the various system components. The others reflect the state of readiness of the other system components and the nature of the instantaneous real power imbalance on the system. They are embodied in the following questions: 1. Is the (rotary converter) AC machine on line and ready? Just as with the diesel generator, for the AC machine to be available to perform its control function, not only must its contactor be closed, but it must also not be in an unload ramp, preparing to go off- line. 2. Is the DC machine on line and ready? Similarly, the DC machine is only available for control when its contactor is closed and it is not in a transitional state. 3. Is there instantaneous excess wind power? In the case where there is excess wind power, secondary (or “dump”) load may be used to provide frequency control. As long as there is excess wind power, this works fine, but suppose the wind suddenly drops, resulting in a power deficit. As wind power drops, secondary load will be rapidly removed in an attempt to maintain grid frequency. Once it has all been removed, the ability to control frequency is lost. The system must switch immediately to frequency control by the DC machine. 4. Is the battery “full”? This question refers to whether the present level of current into the battery can be sustained. It is actually several questions rolled into one. With a “yes” answer to any one of them, the battery is considered “full”. e Is the battery at a high state of charge (i.e., actually full)? e Is the DC charging current limit of the rotary converter reached? e Is the charging voltage limit of the rotary converter reached? Note that the state variables presented above are concerned only with whether the various system components are on line and ready at a particular moment in time, not when and why they are brought on line. The criteria by which individual diesels, wind turbines, and the rotary converter AC and DC machines are turned on and off are the subject of a whole suite of dispatch algorithms not covered in this paper. THE POWER FLOW MANAGEMENT ALGORITHM The power flow management algorithm is presented in flow chart format in Figure 4. Each decision block represents one of the state variables described above. Each branch in the decision tree specifies the control mode of the devices actively participating in voltage and frequency control in the corresponding state. Note that each branch loops back to the beginning of the algorithm, since any of the key state variables can change at any moment. START POWER } = ais DL = SECONDARY LOAD CONTROLLER oop | ‘AC = ROTARY CONVERTER AC MACHINE VOLTAGE REGULATOR | DC = ROTARY CONVERTER DC MACHINE FIELD CONTROL <> 0») DL: DIESEL LOAD CONTROL enero RESTART Y Yes Excess [ou oFF RETURN TO] +f RETURN TO WIND — al. OC: DIESEL LOAD CONTROL START ‘START R N OL: OFF RETURN TO EF OL: CHARGE RATE LIMITING RETURN TO DC: DIESEL LOAD CONTROL START ° DC: FREQUENCY CONTROL ‘START oe ieerrenanranienacasd eY’ | | SEEN EEyECTEOT EEE | Yes. | DL: DIESEL LOAD CONTROL RETURN TO Yes. DL: FREQUENCY CONTROL RETURN TO | OC: HOLD ZERO CHARGING CURRENT START DC: HOLD ZERO CHARGING CURRENT ‘START FIGIIRFE 4 POWFR FIT OW MANAGEMENT AT GORITHM PERFORMANCE REQUIREMENTS OF THE CONTROL SYSTEM In the Wales wind-diesel control system, the loop shown in Figure 4 is executed approximately once every 20 milliseconds (ms). A short loop interval is necessary in order to detect and immediately respond to changes in component status. For example, when the last diesel goes off line, the rotary converter must step in immediately to control the grid frequency and voltage. If the transition is too slow, unacceptable deviations of either voltage or frequency could result. When a change in state occurs that calls for a change in the control modes of one or more devices, it is important that the mode changes occur seamlessly, without causing discontinuities in power flow, which would be manifested as frequency or voltage transients on the line. This requirement is not expressed in the flow chart, but it is an important part of the design of the various control modes and requires careful application of bumpless transfer techniques. CONTROL CHALLENGES OF A HIGH-PENETRATION WIND-DIESEL SYSTEM WITH ENERGY STORAGE Compared to conventional power generation systems, where short-term load variations are typically small and the principal power source is dispatchable on demand, high penetration wind-diesel power systems are challenging to implement. The wind power input to the system is stochastic in nature and highly variable, particularly at gusty sites. At the Wales project, there will be times when the wind power exceeds 200% of the village load, with short-term variations as large as the load itself. There is also the fact that on small isolated power grids, single loads tend to represent a larger percentage of the total load. Starting even a small industrial motor, for example, could have a perceptible impact on the system. The variability in the wind and the variability in the load combine to yield rapid and high amplitude fluctuations in the net load, which is the difference between the primary load and the instantaneous wind power. The net load represents the power that must be supplied by the diesel generator(s) and/or energy storage, or if it is negative, must be absorbed by secondary loads to maintain the real power balance discussed above. Low system inertia is another factor that contributes to the challenge of providing tight frequency regulation in wind-diesel hybrids. The rotating mass contained in a typical isolated wind-diesel hybrid system is disproportionately smaller than that of large utility-scale power systems. Whereas the time constant in a utility system for the frequency to respond to a change in load is measured in seconds or even minutes, it is measured in tenths of a second for the hybrid system. The actual PID control loops used to control power flow in the secondary loads and in the rotary converter must provide very fast response. Because of the requirements for speed and automatic control mode switching, AC-based” wind- diesel hybrid systems require active computer control systems to provide stable operation and good power quality. CONCLUSIONS The Wales, Alaska, project will demonstrate the feasibility of retrofitting an existing village diesel plant to create a high-penetration wind-diesel system that achieves a large reduction in diesel fuel consumption and run time and that uses all available wind energy in a productive manner. The Wales system consists of nine active power system components (three diesel gensets, two wind turbines, two secondary load controllers, an AC synchronous generator, and a DC motor). The variable status of each of these power components gives rise to many possible system operating states. The control system must respond rapidly to changes in system operating state and smoothly transition among a variety of control modes. The controller must regulate both real power to provide stable frequency and reactive power to provide stable voltage. Implementing such systems requires not only controls expertise but also a detailed knowledge of the individual system components and how they interact. For example, some wind turbines have a large inrush current on synchronization. Some turbines have no inrush and can control their own power factor. The power converter interface to the energy storage must be designed to operate in a way that is compatible with the wind turbine requirements. As another example, some secondary loads have a very fast response (e.g., electric resistance heaters) and some a slow response (e.g., water pumps, ice makers). ? In AC-based systems, the wind turbine generators are typically of the induction type and connected to the local AC distribution system. These are in contrast to small DC-based hybrid systems where wind turbines, and often photovoltaic panels, are connected to a DC bus, in parallel with a battery. A hybrid system controller algorithm would need to take these differing characteristics into account in order to achieve acceptable frequency control. Because of the considerable impact of individual component characteristics on overall system operation, it appears that in the near term, the design of hybrid power control systems will be fairly specific to a particular power system architecture. Only after considerably more high penetration wind hybrid systems operating experience has been obtained, and the many control issues posed by various generation, load, and storage devices are better understood, will it be possible to design generic hybrid system controllers capable of adapting to a wide variety of components and system architectures. Regarding the cost of wind hybrid power systems, it is misleading to think of the nongeneration hybrid system components (system controller, power converters, energy storage, secondary loads) as mere accessories to either the wind turbines or the diesel power plant. These components typically represent 25%-50% of the equipment cost of the system, not including the cost of the diesel plant and distribution system, which is pre-existing in many cases. Wind hybrid project promoters, developers, and potential customers often underestimate these costs when considering a project. 10 GENERAL PERMITTING REQUIREMENTS 1. Power Plant Permits To obtain preliminary information on what permits would be required to construct a power plant, the State of Alaska, Department of Environmental Conservation , interactive online Permitting and Plan Questionnaire was completed and submitted. A listing needed permits, based on the answers submitted was provided. The list is attached. Bethel, Railroad City and the Donlin Creek Mine site are all located in a Class II Attainment area. Therefore, it should be possible to construct a power plant at any of these three locations that will comply with applicable air quality standards. A thorough investigation of the permits required will be conducted of the preferred alternatives in Phase II of the study. hank you for using our interactive online questionnaire! Below is a list of needed authorizations based on your answers and the current requirements of the Alaska Department of Environmental Conservation (DEC). Where available, online links are provided to relevant regulations, statutes, and guidance documents. This list is provided to streamline the permitting process and assist you with general questions. It is not meant to substitute for a detailed discussion or a technical review by DEC program staff. Additional questions may be directed to program staff noted below. Air Facility Program: You indicated your facility will generate air emissions from the processing of greater than five tons per hour of material. Because of this action you should know if you extract raw material or change the chemical or physical condition of the raw material at a rate greater than five tons per hour and generate air emissions from this process, your facility may need to obtain a Construction Plan Approval and an Operating Permit. (18 AAC 50.300(b)(1)(A)) (See AQM for more information at http://www.state.ak_us/dec/dawq/aqm/newpermit.htm). You indicated you will have one or more units of fuel burning equipment, including flares, with a rated capacity of 50 million Btu per hour or more. Be advised that your facility may need to obtain a Construction Plan Approval and an Operating Permit. (18 AAC 50.300(b)(1)(B)) (See AQM for more information at http://www.state.ak_us/dec/dawq/aqm/newpermit.htm). You indicated your facility will contain fuel burning equipment with a rated capacity of 100 million Btu per hour or more. Be advised that if a single piece of fuel burning equipment has a rated capacity of 100 million Btu per hour or greater, then an Operating Permit will be required. (18 AAC 50.300(b)(2)) (See AQM for more information at http://www.state.ak.us/dec/dawq/aqm/newpermit.htm). Since you indicated that you will be operating a Coal preparation facility, Portland cement plant, or a Petroleum refinery be advised that an Operating Permit will be required which may stipulate special operations limits and conditions. (18 AAC 50.300(b)(4)) (See AQM for more information at http://www.state.ak.us/dec/dawq/aqm/newpermit.htm). You indicated your facility will burn wastes that contain sludge from a municipal sewage treatment plant (STP). Be advised that if the waste that will be burned contains more than 10% sludge from a municipal STP that serves 10,000 or more persons an Operating Permit is required. (18 AAC 50.300(b)(5)) (See AQM for more information at http://www.state.ak.us/dec/dawq/aqm/newpermit.htm). Your facility annually will use more than 330,000 gallons of diesel fuel in all fuel-burning equipment. If also the combined total of all diesel fuel used for fuel-burning equipment is greater than 330,000 gallons per year, an Operating Permit is required. An Operating Permit may be required because your facility will have special equipment specifically designed to reduce air emissions. Since your facility will emit or have the potential to emit a regulated contaminant, a permit with special conditions may be required due to regional air quality designations. (18 AAC 50.015) Since your facility is considered a listed facility, an Operating Permit may be required. You indicated that your activity will cause dust to become airborne and leave your site. Be advised that dust control options may require department approval. The air quality program is governed by Chapter 50, Title 18 of the Alaska Administrative Code, please refer http://www.dec.state.ak.us/sps/script/SECTION2.ASP 10/2/00 to its website at the URL: http://www.state.ak.us/dec/title18/aac5Ondx.htm. For more information on the Air Quality Program please refer to their website at the URL: http://www.state.ak.us/dec/dawq/dec_dawgq. htm. Wastewater Program: Since you indicated that your development will disturb 5 acres or more of the natural vegetation you will need to apply to the US Environmental Protection Agency to operate under the Federal Storm Water General Permit. The state also requires that site specific plans be submitted to the Department for approval before the project is started. (EPA Hot Line 1-800-369-1996 or the Water Quality Engineer with DEC at the number (907) 269-7692). Since you indicated that your construction activities affect lakes, rivers or streams through run-off, which may contain pollutants such as sediments you may need to obtain a Short Term Variance from Water Quality Standards or it maybe possible for you to operate under a stormwater permit. Short Term Variances apply to non-point source discharges to waters only, not to point source discharges. If the runoff is a point source, then you may need to be covered by a stormwater permit. Short Term Variances are aimed mostly at in-water work such as fills or trenching that will create turbidity. A non-point source is "a source of pollution other than a point source." A point-source is "a discernible, confined, and discrete conveyance, including a pipe, ditch, channel, tunnel, conduit, well, container, rolling stock, or vessel or other floating craft, from which pollutants are or could be discharged." Contact the Water Quality Engineer with DEC at the number (907) 269-7692) in reference to which you may need. You indicated that you will be installing a non-conventional on-site wastewater disposal system, such as package plant, above ground mound, etc. Non-conventional systems that have not previously undergone engineered plan approval must do so before the construction or installation. In some instances an individual wastewater disposal permit, or coverage under an appropriate general permit(if one is available), may be required. For additional information contact your closest SPS office. SPS office locations could be found at the bottom of this document. You indicated that your facility will have wastewater discharges onto the land, surface water, or groundwater. Because of this an individual wastewater disposal permit, or coverage under an appropriate wastewater general permit (if one is available), must be obtained. If a treatment plant discharges to surface water, the required permit may be a state-certified federal NPDES permit. In these permits mixing zones and zones of deposit would be defined. You indicated that your facility will be installing or operating a chemical/physical or biological sewage treatment plant. Your facility may qualify to operate under statewide general permit number 9940-DB001. See Appendix E or contact DEC's Environmental Specialist at (907)451-2116 for permit information. Since you indicated that you will produce and need to dispose of sludge from a wastewater treatment plant you should be advised that depending on the moisture content, you may need to obtain either an individual wastewater disposal permit or solid waste disposal permit. Contact DEC's Environmental Specialist at (907) 451-2116 for wastewater permit information or the Solid Waste Management Program Coordinator at (907) 451-2135 for Solid Waste permit information. Engineered plan approval, before construction is required for one who wishes to construct and operate a domestic wastewater treatment lagoon which may discharge treated domestic wastewater to lands or waters of the State. Routine seasonal discharges from a sewage lagoon may be done under statewide general permit number 9940-DB004. (See Appendix E ) Other discharges from a lagoon would require an individual permit. You indicated your project or activity will be in the coastal zone. Some Department permits are required to go through a coastal zone consistency review, coordinated by the Division of Governmental Coordination. For answers to questions about the Coastal Zone Process contact one of the following Division of Governmental Coordination Offices: http://www.dec.state.ak.us/sps/script/SECTION2.ASP 10/2/00 Southcentral Regional Office Pipeline Coordinator's Office Central Office 3601 "C" Street, Suite 370 Atwood Building 240 Main, Suite 500 Anchorage, AK 99503-5930 550 W. 7 Avenue, Suite 1660 P.O. Box 110030 (907) 269-7470 Anchorage, AK 99501 Juneau, AK 99811-0030 (907)271-4317 (907)465-3562 You could also reach the Alaska Coastal Management Program at the web address http://www.alaskacoast.state.ak.us. The wastewater water program is governed by Chapter 72, Title 18 of the Alaska Administrative Code, please tefer to its website at the URL: http://www.state.ak.us/dec/title18/aac72ndx.htm. For more information on the Wastewater Program please refer to their website at the URL: http://www.state.ak.us/dec/deh/water/home.htm. Solid Waste Program: You indicated that you will produce construction/demolition waste from this project. Be advised that disposal of less than 1000 cubic yards of inert wastes such as building debris, non-regulated asbestos containing material, and non-salvageable scrap metal may be disposed of on-site under statewide general permit number 9740-BA003. (See Appendix E) If disposing of greater than 1000 cubic yards of inert waste an individual permit will be required. A permit from the Department is not required to allow you to transport solid waste to an approved landfill. You may need to obtain an individual solid waste permit, since you will produce and need to dispose of sludge from a wastewater treatment plant, unless the sludge is being taken to an already permitted landfill. If you require a Solid Waste Permit at your facility or for your activity you may also need to prepare a Solid Waste Management Plan depending on whether or not public funds were used. Statewide general permit number 9640-BA001 may be used to dispose of coal ash from utility boilers and power plants. (See Appendix E) The solid waste program is governed by Chapter 60, Title 18 of the Alaska Administrative Code, please refer to its website at the URL: http://www.state.ak.us/dec/title18/aac60ndx.htm. For more information on the Solid Waste Program please refer to their website at the URL: http://www.state.ak.us/dec/deh/solidwaste/home.htm. Spill Prevention and Response Program: You must apply for approval of an oil discharge prevention and contingency plan and proof of financial responsibility because you will be operating an oil terminal facility where oil products will be stored or transferred. If you are using the services of an oil spill response contractor, that contractor must be registered with the Department. See Appendix J for applications for an Oil Spill Contingency Plan Approval, Proof of Financial Responsibility, Primary Response Action Contractor Form. You must apply for approval of an oil discharge prevention and contingency plan and proof of financial responsibility because you will be operating a tank vessel, oil barge, or any other type of vessel to transport liquid bulk oil cargo. If you are using the services of an oil spill response contractor, that contractor must be http://www.dec.state.ak.us/sps/script/SECTION2.ASP 10/2/00 registered with the Department. See Appendix J for applications for an Oil Spill Contingency Plan Approval, Proof of Financial Responsibility, Primary Response Action Contractor Form. The Spill Prevention and Response program is governed by Chapter 75, Title 18 of the Alaska Administrative Code, please refer to its website at the URL: http://www.state.ak_us/dec/title18/aac75ndx.htm. For more information on the Spill Prevention and Response please refer to their website at the URL: http://www.state.ak.us/dec/dspar/perp/home.htm. eed more information? Contact your nearest Statewide Public Service Office. Statewide Public Service Offices: ADEC - SPS/Anchorage, 555 Cordova Anchorage, AK 99501-2617 (907)269-3093 - Sally Smith ADEC - SPS/Southeast, 410 Willoughby Ave., Suite 105, Juneau, AK 99801-1795 (907)465-5355 - Mary Siroky ADEC - SPS/Northern, 610 University Ave., Fairbanks, AK 99709 (907)465-2177 - Bill Smyth ADEC - SPS/Mat-Su, P.O. Box 871064, Wasilla, AK 99687 (907)376-5038 - Alan Wien ADEC - SPS/Kenai, 43335 K-Beach Rd., Suite 11, Soldotna, AK 99669 (907)262-5210 ext. 249 - Deric Marcorelle ADEC - SPS Statewide Toll Free Number: (800) 510-2332 lease help us improve our service! Now that you’re done, we could really use your help. Please take a minute and fill out the short, multiple choice "Feedback" feedback form. This feedback form can be accessed at http://www.dec.state.ak.us/sps/script/feedback.asp This information Provided by the Alaska Department of Environmental Conservation Division of Statewide Public Service FAQ's| Publications | Links | Site Map | Hot Topics | Who We Are | Feedback Wwwastate.ak.us/dec! conc enero Seas WWW.state.ak.us/dec/dsps/ Contact: spsfeedback@envircon.state.ak.us http://www.dec.state.ak.us/sps/script/SECTION2.ASP 10/2/00 2. Transmission Line Permits As discussed in the text of the report, Route A passes through a portion of Lake Clark Wilderness Area and, from a practical standpoint, would be impossible to permit. Routes B and C, with careful routing can be built entirely on state owned lands and conveyed native lands. To build on state owned lands a rights-of-way permit is necessary. These permits are issued or denied by the State of Alaska Department of Natural Resources (DNR), after full public review and input. While DNR does not require an “Environmental Impact Statement” (EIS) it does require best interest findings. The information generally required by DNR, before it will issue a permit, is however, for all practical purposes equivalent to that normally contained in an Environmental Impact Statement or, at a minimum, an Environmental Assessment. Route D can be built entirely on conveyed or interim conveyed lands while within the confines of the Yukon-Delta Wildlife Refuge. Once outside the boundary of the Refuge, the remainder of the transmission line can be built on private lands, within the confines of the Refuge, and the Fish and Wildlife Service has no jurisdiction on private lands. In theory no EIS would be required, only a rights-of-way permit from the State of Alaska and, of course, permission of private land owners. However, it is possible that an EIS or, at a minimum, an Environmental Assessment (EA) would be required to address any adverse impact the transmission line may pose to wildlife within the Refuge area. Route E traverses federal, State of Alaska and conveyed native lands. Therefore, it is highly probable that an EJS or, at a minimum, an Environmental Assessment (EA) would be required to address any adverse impact the transmission line may pose to birds and wildlife. The 859 miles of SWGR transmission line, for the most part, will be located within the confines of the Yukon-Delta Wildlife refuge. It is most probable that an EIS will be required to address any adverse impacts these transmission lines may pose to wildlife. A more thorough investigation of the permits required will be conducted of the preferred alternative in Phase II of the study.