Air Force Center for Engineering and the

EnvironmentMassachusetts Military

Reservation

MA Wind Working Group

06 Oct 2011

Rose H. Forbes, P.E.AFCEE/MMR

2

The Installation Restoration

Program at the Massachusetts

Military Reservation

(MMR)

Ai r For ce Cen ter for En vi r on men ta l Excel l en ce ( AFCEE)

Primarily PCE, TCE, and EDB

Concentrations generally < 1 mg/L

Plumes are typically deep (>100 ft) and thick (>100 ft)

9 treatment plants treating 10.3 MGD (down from 17.8 MGD)

> 27 miles of pipeline

> 100 EWs and RWs

> 3,000 MWs

5

Optimization & SustainabilityBetter, Cheaper, Faster Cleanup

• Carbon• Well Maintenance• Labor • Energy/Fuel • Sampling • Drilling• Regulations• Reporting• Alternative Technologies

Energy Optimization • Wellfield optimization • Use of passive diffusion bag sampling• Use of direct push rig vs larger sonic/auger rig• On site O&M/well maintenance• Installation of VFDs and premium efficiency motors• Elimination of booster pumps and pump motor

downsizing• Replaced sodium vapor overhead lighting• Use of bio-diesel, soy based hydraulic fluid • Reduction in propane use• Installation of low-wattage heaters• Misc energy (motion sensors, lighting replacement,

programmable thermostats, LED exit lighting, new windows, etc.)

• Signed up with the load reduction program (demand response program)

• Evaluated utility rate structures

Sustainability Evaluation

8

Wind Turbine - Energy Optimization • Expected to produce ~ 3,810 MWh annually based on 29% capacity factor (P50); ~ 3377 MWh annually based on 25.7% (P50)

• Annual load from treatment systems in 2007 ~ 12,300 MWh; in 2011 ~10,862 MWh

• Expected to generate 25-30% of AFCEE’s total electrical requirement (>$2M in 2009; $1.7 M in 2011)

• Expected to reduce ~25-30% air emissions

• Payback originally anticipated in 6-8 years (RECs/O&M); working on a better ROI/SROI

Distance from turbine to base

housing ~ 1140 ft

10

Wind Turbine Costs•Constructability Assessment/Environmental Assessment (CH2M Hill) - ~ $400,000

•Construction contract awarded in Sep 2007 (ECC), $4.87M (includes O&M contract for two years)

•$5000 for Safety Training•$29,900 per year for two years (FLAG O&M sub - 2 maintenance events per years + warranty + availability guarantee)•$20,000 for website development•$2700 for blade inspection (year 1); $2800 for blade inspection (year 2)

•Title II Services/Oversight (CH2M Hill) - $150,000

•NSTAR Interconnection/Witness Test Costs - $53,858

25 Jan – 23 Feb 2011

$573,871: 02 Dec 2009-25 Jul 2011(+ $60,000 availability guarantee for first year)

Wind Turbine II• 2 new GE 1.5-77 wind

turbines in northern part of MMR

• Constructability Assessment/EA (CH2M Hill) - $462,284

• Construction Contract (ECC) + one year O&M = $9.4M

• Title II Oversight/Environmental Surveys - $340,994.82

• Nstar Costs $272,000

13

Progress To-Date • Completed Constructability Assessment [Basis of Design, Economic

Analyses, Environmental Assessment (EA)]• EA FONSI signed in Nov 2010• Submitted Interconnection application to NSTAR• FAA studies approved• PAVE PAWS evaluation approved• Coordination with other agencies and community completed

– EMC/SAC/CAC, USFWS , MA NHESP, MHC/BHC, THPO, MA FWS, MMRCT/SMB, newsreleases

• Awarded construction project in Sep 2010 to ECC ($9.4M)• Initial clearing of two turbine sites in Oct/Nov 2010, included turtle surveys

and baseline invasive species survey• Grubbing, cut/fill and substation clearing in March/April 2011 , included

Eastern Box turtle surveys• Pre- and post-construction bird/bat surveys started/continuing

Foundations~470 yds 5000 psi concrete47’ diameterSpread form designCompleted in May 2011

Blades - Texas

• Insert photoLength = 121.4 ftWeight = 13,900 lbsFiberglass constructionArrived 7 Jun 2011

Tower Sections - Iowa

Mid: 80,700 lbs; 85 ft long; 14 ft diameter at base

Top: 62,700 lbs; 97 ft long; 11 ft diameter at base

Base: 111,400 lbs; 72 ft long; 15 ft diameter at baseSteel constructionArrived June/July 2011

Tower Sections (cont)Mid section hit an overpass in Indiana on 22 Jun 2011

Driver varied from permitted route

Damage was cosmetic; tests/repairs conducted on site

Machine Head - Florida

126,000 lbs12.5 ft high29 ft long

Progress To-Date (cont.) • Both wind turbines installed late June through mid July 2011

View from Scenic Highway (across the canal)

View from Canal

View from Sagamore Bridge

Remaining Schedule • Substation construction to be completed in October 2011• Wind turbine commissioning starting 11 Oct 2011• Interconnection anticipated 15-16 Oct 2011 • Ribbon cutting event on 27 Oct 2011 as part of October Energy Awareness

Month

Visits to Date• Congressman Keating – 28 Jun 2011• Environmental Business Council – 7 July 2011• Fox News video – 21 Jul 2011• EOEEA Secretary Sullivan – 28 Jul 2011

QUESTIONS/COMMENTS?

rose.forbes@us.af.mil

25

Notable Issues/Lessons Learned• Communicate early and often with stakeholders• Understand net-metering, RECs, and state rules• Utility Interconnection – build in time and plan for costs • Logistics - room to haul and build (bridges, road width,

corners, permits, bad drivers, Military Cargo Preference Act of 1904, etc)

• Explore additional grants• Inspect the manufacturing facilities if possible• Make sure the turbine components suppliers and

transportation companies are insured.• Evaluate modes of transportation (roadway, rail, barge)

Notable Issues/Lessons Learned• Construct foundation in cool weather and allow time to achieve

strength• Long lead time on turbines - explore interest from manufacturers • Plan on a schedule and hold contractors to it – include liquidated

damages in contracts• Plan submittals (deliverables) and have a submittal register• Use existing wind resource data and other studies if available

and applicable • Evaluate warranties and O&M/service contracts in advance;

build in availability guarantee• Consult experts (i.e. DOE) on funding mechanisms (EULs, ESPCs,

tax credits)• Don’t plan a ribbon cutting ceremony until the turbine is up and

operational• Long Haul Project – need a dedicated champion• Take photos and video

• Do spare parts come with the wind turbine purchase?• Just because spare parts are new doesn’t necessarily mean they will

work • Plan for technical and safety training – involve local emergency

response personnel• An FAA ruling of presumed hazard is not the end of a project, it’s the

beginning of negotiations• Ensure manufacturers are reputable and there are working wind

turbine models in the US for several years• Select contractors who have experience with wind turbine planning

and construction projects • Are anchor bolts sized correctly? Metric vs english conversions can

cause problems• Provide site signage/directions to transportation companies and

police details