HomeMy WebLinkAboutSeward Power Plant Integration 2011ECrlectric Power Systems
INC.
Consulting Engineers
City of Seward
Fort Raymond Substation
Diesel Generation Upgrade Project
Conceptual Design Report
October 21,2011
Draft Report
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FT.RAYMOND PowER PLANT UPGRADE CDR
Table of Contents
1 SCOPE ooo...ccccsccccessnsceecesnececsssneceseneecessescaceesnsnansesstsesesseasesesnseseesesaeecessaaaesseseessecaaeeseaeeseneseeecesssereccssssuaesessavsnsensens 1
2 Plant Overview/ASSCSSMENT ........seeeeccccessscecssseecessssneceensneeesteseessuseaeeecescaesensnesesessseeesseeasssssasescessracesstnsesessussesecs 1
3 Remediation,Upgrades and Additions ................ccccccsceseceesesseereesancecevensessnsassessassesssesseessesssesecesaeesstensenseanacss 4
3.1 Protection COMPOnents ...........ce seessecesenseecsecsseeessanecessnneecessaaeeecesanescesaeeeesaseeseseuaeecnsussaseaueeesaeesesesesesaeeues 4
3.2 Unit #3 and Unit FG ooo ccccsececssnerecesnseeeenenaeeeseneecseesneesesaeecnsaseesseeeeeecesauensesesuessneeesceseaseeseesnensensaes 4
3.3.Relocate Unit #4 and Unit #5 to New Generation Building ..............cccccccsecssccsssccesseecssseesseseseseseesasausssssees 4
3.4 Fence and Grounding System...ccessccccssnseeessseeeeesceseesesneeeenenseesesneeeesesaesessesaeeesessstecesaeenseeerscauenaeass 5
3.5 OffiCE/WArehOUSE...........cccccccescccecessescececeneecesncenecueescseceeeseeeevesesaeeeuenseesenececeseasenessasaeeesscaeescsssasensuneseesnaenens 5
4 -_-Cast Estimate...ec ccesscccssnscecsscceseeeessnseessnacenssenaeeesessuecesesuneeceeneeeseaeeseseeaeeesssasesessasessessssenseneeecseuedesessaaeess 6
5 -Project Component Prioritization/SChedule 00...ee eceeeeeeeeseceseseeeeeeeceesseeeaeeaesaeesansaeseeneaesaeeaesaeeseseeeaeteetenees 6
Appendix A -Cost Estimates ...........ccccsccssceceseceseneceneecsseessaneceaeerseneecanesensesesaeessnecseaeeseeessaeessaseeeasecnaeessateenaesesnsaeeneas 7
FT.RAYMOND POWER PLANT UPGRADE CDR
1 Scope
Electric Power Systems,Inc.of Anchorage,Alaska ("EPS”)was contracted by the City of Seward (City)to assist
in the development of a Conceptual Design Report ("CDR”)to identify issues and costs associated with the
upgrade of the diesel power plant at the City's Fort Raymond Substation.This report addresses the remaining
work with estimated costs needed to bring the entire generation plant to reliable operation after the recent (2010)
installation of two newly refurbished EMD diesel generators,associated switchgear,controls and auxiliary
equipment and new generation building.
The Fort Raymond plant is sized to serve City's electric service area in the event of a loss of power from the City's
electric power supplier Chugach Electric Association (CEA).The City's power plant is presently designed as a
standby plant for the loss of the CEA intertie.It is desired to upgrade the plant towards the eventual operation of
the plant to supplement the South Central Alaska's generation and transmission system.
The City has no building resources for the electric systems management,operation and maintenance personnel
or for the storage of vehicles,materials and equipment.An electric office/warehouse is planned to be constructed
on City land adjacent to the Fort Raymond Substation
The State of Alaska has granted four million dollars ($4,000,000),administered through Alaska Energy
Association,to the City to use for the necessary renovations and upgrades to improve the plants reliability and
operation.
The costs estimated in this report are based on historical construction costs realized during the recent power plant
expansion,as well as on EPS work in similar areas on similar projects.
2 Plant Overview/Assessment
Total existing installed capacity of the Fort Raymond diesel plant is 15.7 MW and the City's present system peak
load is less the 10 MW.The existing generation is composed six diesel driven generator units.Two of the six
diesel units are recently refurbished and installed in a newly constructed diesel generator building which was
designed to house a total of four units.Two of the other units are housed in a metal building erected in 1974.
The remaining two units are housed in individual arctic packs enclosures and were installed in 1984.
Following is a listing of the diesel generators with status description:
Unit #Type/Size Status
1 EMD/2850 kW Newly refurbished diesel generator was installed in 2010 with new
microprocessor based protection,switchgear,SCADA operation and
control.Unit is installed in new generation building.Diesel generator,
auxiliary support equipment,controls,relay protection and switchgear
are new and in good operating condition.
FT.RAYMOND POWER PLANT UPGRADE CDR
Type/Size
EMD/2500 kW
EMD/2500 kw
EMD/2850 kw
EMD/2500 kW
EMD/2500 kw
Status
Newly refurbished diesel generator was installed in 2010 with new
microprocessor based protection,switchgear,SCADA operation and
control.Unit is installed in new generation building.Diesel generator,
auxiliary support equipment,controls,relay protection and switchgear
are new and in good operating condition.
Diesel generator,conventional controls and switchgear were installed in
1974.Upgrades to the unit were completed in 2010 which included
reconnection of the generator for 4160 volt generation and the addition
of microprocessor based relay protection.Unit is installed in a 1974
metal building.Diesel generator is in fair to good condition.There is
possible water damage to rotating exciter which needs investigating.
Auxiliary support equipment is in fair to good condition excluding
silencer.Controls and switchgear are aged.A neutral resistor available
in City inventory needs to be installed on the neutral of the generators
winding.
{Refurbished diesel generator,microprocessor controls (no SCADA),
microprocessor based relay protection and switchgear were installed in
2001.Unit and controls are installed in a 1974 metal building.
Switchgear and protection are installed in the substation control house
which was built in 1974 (building was upgraded expanded in 1985 and
in 2001).Diesel generator,auxiliary support equipment,controls,relay
protection and switchgear are good operating condition.A neutral
resistor available in City inventory needs to be installed on the neutral of
the generators winding.
Diesel generator,conventional controls,electro-mechanical relay
protection and switchgear were installed in 1984.The diesel was
completed overhauled in 2004.Unit and controls are enclosed in a self
contained arctic enclosure.Switchgear and protection are installed in
the substation control house which was built in 1974 (building was
upgraded expanded in 1985 and in 2001).Diesel generator set is in
good condition.Existing radiator,motor control center and engine
controls are in poor condition.Switchgear and mechanical protection
are aged.A neutral resistor available in City inventory is planned to be
installed on the neutral of the generators winding.
Diesel generator,conventional controls,electro-mechanical relay
protection and switchgear were installed in 1984 Unit and controls is
enclosed in a self contained arctic enclosure.The diesel was completed
overhauled in 1994.Switchgear and protection are installed in the
substation control house which was built in 1974 (building was upgraded
,PtsPrueStenKeConsultingEngineers
FT.RAYMOND POWER PLANT UPGRADE CDR
expanded in 1985 and in 2001).Diesel generator is in fair to good
condition.Existing radiator,motor control center and engine controls
are in poor condition.Switchgear and mechanical protection are aged.
A neutral resistor available in City inventory is planned to be installed on
the neutral of the generators winding.
The new generation building installed in 2010 was designed to house four total diesel generation machines.Unit
#1 and Unit #2 were installed with the intention of installing existing units#4 and #5 when funding became
available.New radiators and silencers were purchased for #4  and are in city inventory.Foundations for
radiators,silencer and units are in place.Fuel system upgrades,480V motor control center,air system expansion,
5 kV switchgear,and engine contro!center are need to be procured and installed.
The 1974 metal building which houses Unit #3 and #6 supports the silencer for Unit #3.The silencer is in poor
condition and the mounting has caused damage to the existing roof system which has resulted in water leaks.
Relocation of the silencer from the roof to an area adjacent to the building and repair of the roof is scheduled.
Water leaks may have impacted the exciter for #3 generator.Investigation to this water damaged is also
scheduled.
During interruptions to the CEA intertie it is necessary to back feed the City's transmission line from Ft.Raymond
Substation to two other City Substations in order to maintain electric service to their customers.During these
back feed events a ground source on the 69 kV transmission system was not available due to the step down
substation transformers at Fort Raymond were connected Delta-Wye (high to low respectively).A three phase 69
kV potential transformer bank was recently installed to correct the problem and protective relaying was adjusted
accordingly.
Distribution system is served via 5 each 12.5 kV oil/vacuum reclosers which utilize SEL 351 controllers.Firmware
and software updates are needed to be installed in the controllers to allow remote monitoring/operation and allow
interrogation of the recloser operations.
Existing fencing around the Substation has been partially replaced but approximately 75%is in poor condition and
is in need of replacement.
The existing ground grid has not been tested in over 25 years and is scheduled to be tested.
FT.RAYMOND POWER PLANT UPGRADE CDR
3 Remediation,Upgrades and Additions
Improvements necessary to bring the Fort Raymond Power Plant to an up to date and reliable plant are listed
below.
3.1 Protection Components
3.1.1 Installation of 3 phase 69 kV PT's along with setting development and reprogramming of the associated
relaying.This installation was completed the summer of 2011.
3.1.2 Install firmware and software updates to existing 12.5 kV reclosers.
3.1.3 Install generator neutral resistor on Units #3.
3.1.4 Install generator neutral resistor on Units #6.
3.2 Unit #3 and Unit #6
3.2.1 Relocate #3 silencer from building roof to grade adjacent to building.Relocation will require new silencer,
foundation and related exhaust piping.
3.2.2 Repair leaking roof on Unit #3 and #6 generator building
3.2.3.Inspect and determine damage to generator #3 exciter and other possible equipment.
3.2.4 SCADA control conversion for both Unit #3 and Unit #6.
3.3 Relocate Unit #4 and Unit #5 to New Generation Building
3.3.1 Ready Relocation of Unit #4 and Unit #5
e Remove arctic enclosure
Disconnect for auxiliary support equipment and electrical connections
Procure and install vibration isolators
e Relocate units
e Modify air intake air ducts on both units and integrate into existing air intake/exhaust system
e Add pyrometers to each unit
3.3.2 Retrofit Unit #4 and #5 Engine Control Components
e Procure components and install
3.3.3.Engine/Generator SCADA Cabinet
e Procure components and install
3.3.4 15 kV Metalclad Switchgear
e Procure components and install
3.3.5 480V Motor ControlCenter
e Procure components and install
FT.RAYMOND POWER PLANT UPGRADE CDR
3.3.6 Upgrade Fuel System
Upgrade existing fuel line to main distribution vault
Install fuel day tank
Install fuel lines to diesel units
Air Starting System
Convert #4  units to air start
Expand existing air system
Connect to diesel units
Silencers
Install existing silencers
Procure and install expansion joints,piping and supports
Cooling Radiators
Install existing radiators
Procure and install piping and supports,expansion tanks?
Requires new underground cable runs
Utilize approx 400 to 500 gal of existing glycol (each unit),procure remaining 300-400 gallons (each unit)
3.4 Fence and Grounding System
Replace existing substation deteriorated fence with new fencing,approximately 1400 ft
Test to insure adequacy of existing ground grid.
3.5 Office/Warehouse
Engineer,procure and install a two story office/warehouse building on city land adjacent to the Fort Raymond
Substation.The office will provide 3,500 sq.ft.of warehouse on the first floor and 3,500 sq.ft.of office space and
storage on the second floor for a total square footage of 7000.
FT.RAYMOND POWER PLANT UPGRADE CDR
4 Cost Estimate
The costs associated for installation of the above listed project components are outlined below.The details of the
cost estimate are included in Appendix A.
Protection Components ..............::eceeeeseeeeeeees $64,250
Unit#3 and Unit #6 ou...cee cee eeeeeeeteeseeee 8 440,750
Relocate Unit #4 and Unit #5 oe $1,807,000
Fence and Grounding System ......................20...8 161,250
Office Warehouse ................ccceceeceeceeeeeeeeeeeseres 91,400,000
Subtotal $3,873,750
10%Engr $387,375
10%Constr Mgt $_387,375
$4,648,500
20%Contingency $929,700
$5,578,200
15%City Costs $836,730
Total Estimated Cost $6,414,930
5 Project Component Prioritization/Schedule
To allow the best benefit of funding available,a prioritization of the improvements was completed.The
prioritization was based on safety,protection and reliability respectively.
To be determined...not completed.
FT.RAYMOND POWER PLANT UPGRADE CDR
Appendix A -Cost Estimates
10/21/2011
Project Component
-Protection
3 ph 69 kV installation w/relay settings
12.5 kV Recloser control upgrade
Frimware Update/Changeouts
Unit #3 neutral resistor w/489 monitoring
Unit #3 neutral resistor w/489 monitoring
Subtotal Protection
Unit #3 and Unit #6
Relocate Unit #3 silencer to Vertical Mount
Foundation
Silencer Installation w/Exhaust Piping
Subtotal #3 Silencer
Repair leaking roof on #3 Bldg
#3 Exciter Inspection
Scada Conversion for #3  Control
Engine Control Cabinet,wiring,programming
Govenor Changeout
Voltage Regulator
Communications
Cabling to #1&2 Bldg
Subtotal #3  SCADA Conversion
10/21/2011 NNNNDNhCITY OF SEWARD
Fort Raymond Substation
Diesel Generation Upgrade
Cost Estimates
Unit
Ea.
Ea.
Material
$7,500
$4,000
$1,000
$1,000
$2,000
$25,000
$2,000
Manhour
120
50
60
60
40
240
40
10
320
20
20
140
100
Labor
$21,000
$8,750
$10,500
$10,500
$7,000
$42,000
$7,000
$1,750
$56,000
$3,500
$3,500
$24,500
$17,500
labor rate=$175
Mat&Lab Extended Total
$28,500 $28,500
$12,750 $12,750
$11,500 $11,500
$11,500 $11,500
$64,250
$9,000 $9,000
$67,000 67,000
$76,000
$9,000 $9,000
$1,750 $1,750
$106,000 $212,000
$8,500 $17,000
$8,500 $17,000
$34,500 $69,000
$19,500 $39,000
$354,000
estimates.xls
Project Component Qty Unit Material Manhour Labor Mat&Lab Extended Total
Bidg #1  Equip Addition
480 Volt MCC-6 Breaker Positions 1 Ea.$20,000 60 $10,500 $30,500 $30,500
Fuel System Upgrade
Double Wall Day Tank 500 gallon 1 Ea.$15,000 40 $7,000 $22,000 $22,000
Fuel Pump w/Wiring 2 Ea.$5,000 40 $7,000 $12,000 $24,000
Control 2 Ea.$5,000 40 $7,000 $12,000 $24,000
Piping from Bulk to Day Tank 1.Ea.$2,500 -40 $7,000 $9,500 $9,500
Piping from Day to Engine 2 Ea.$2,500 40 $7,000 $9,500 $19,000
200 $35,000 $98,500
Starting Air Upgrade
Air Compressor w/Wiring 1 Ea.$20,000 40 $7,000 $27,000 $27,000
Air Tank 1 Ea.$3,500 40 $7,000 $10,500 $10,500
Air Piping 2 Ea.$2,000 160 $28,000 $30,000 $60,000
240 $97,500
Cooling System
Set Existing Radiators and Install Piping 2 Ea.$30,000 520 $91,000 $121,000 $242,000
Glycol (500 gallon)Filtering and reuse of existing 2 Ea.$3,000 60 $10,500 $13,500 $27,000
Wiring 2 Ea.$1,500 40 $7,000 $8,500 $17,000
620 $286,000
Exhaust System
Elbow,Piping,Flex Joint,Insulation 2 Ea.$40,000 320 $56,000 $96,000 $192,000
15 kV Switchgear,2 breakers 2 Ea.$90,000 60 $10,500 $100,500 $201,000
15 kV Power Cable Feeds 2 Ea.$30,000 160 $28,000 $58,000 $116,000
Neutral Resistor 2 Ea.$1,000 60 $10,500 $11,500 $23,000
Cat Walk 2 Ea.$2,500 60 $10,500 $13,000 $26,000
Remote Operating Station 1 Ea.$10,000 120 $21,000 $31,000 $31,000
10/21/2014 2 estimates.xls
Project Component
Unit #4 and Unit #5 Relocation/Make Ready
Arctic Pack Removal,Skid Work,Misc retire
Relocate Units to #1  Bldg
Vibration Isolators
Air Start Conversion
Gen Air Intake Rebuild
Pyrometer Installation
Engine Control Cabinet,wiring,programming
Govenor Changeout
Voltage Regulator
Communications
Cabling
Ground Grid Testing
Substation Fence Replacement
Fencing
Gates
Office/Warehouse
10/21/2011 RLotNNDNONMNNMNNYNDNDNY Unit Material Manhour
Ea.$2,000 120
Ea.$2,000 120
Ea.$30,000 40
Ea.$45,000 40
Ea.$5,000 20
Ea.$4,000 20
Ea.$75,000 320
Ea.$5,000 20
Ea.$5,000 20
Ea.$10,000 140
Ea.$2,000 100
Ft --
Ea.--
sqft
Labor
$21,000
$21,000
$7,000
$7,000
$3,500
$3,500
$56,000
$3,500
$3,500
$24,500
$17,500
Mat&Lab Extended Total
$23,000 $46,000
$23,000 $46,000
$37,000 $74,000
$52,000 $104,000
$8,500 $17,000
$7,500 $15,000
$131,000 $262,000
$8,500 $17,000
$8,500 $17,000
$34,500 $69,000
$19,500 $39,000
$706,000
$2,500 $2,500
$125 $118,750
$20,000 $40,000
$158,750
$200 $1,400,000
Subtotal $3,873,750
10%Engineering $387,375
10%ConstrMgt $387,375
$4,648,500
20%Contingency $929,700
$5,578,200
15%City Cost $836,730
$6,414,930
estimates.xis