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File: PI-93009 - Port Colborne Hospital Cogen 01.DOC 93009 - of 15

Above: Entrance of Port Colborne General Hospital, Port Colborne, Ontario.

Project Description: 2nd Hospital Cogeneration System in Ontario (1993)

In 1993 Marsh Energy Inc. was awarded a turnkey contract by the Port Colborne General Hospital to design, build, operate and maintain the 2nd hospital cogeneration system in Ontario utilizing a natural gas reciprocating engine-generator with steam heat recovery.

The system prime-mover is a Caterpillar Model 3306 natural gas fuelled reciprocating engine-generator set, producing 150 kWe of load displacement electricity (no export), approximately 240 lbs/hr of steam at 125 psig from the exhaust heat recovery steam generator, and about 165 kWth of hot water from the oil cooler and jacket water cooling circuits. Heat recovery was not incorporated for the aftercooler circuit.

Under normal operation the plant is unmanned.

The engine-generator set was located in an acoustically separated room, adjacent the boiler plant in the basement level, and next to the exhaust heat recovery steam generator (HRSG), (photos, right & below-right).

To achieve the low NOX emission levels required for the site, the system had to be equipped with a catalytic convertor and special “Altronic” air-fuel ratio controller, which tuned the engine for “rich-burn” operation.

To minimize noise transmission, the combustion and ventilation air inlet opening as well as the ventilation air outlet where fitted with specially designed silencers. Engine exhaust piped to the HRSG was exhausted through unused stack for the decommissioned boiler, (photo, below-left).

Port Colborne General Hospital Port Colborne, Ontario

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

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

Above: CAT 3306 genset, genset power & control panel, and Vaporphase HRSG.

Above: Outdoor view of cogen room, ventilation & combustion air inlet silencer,

ventilation outlet damper, and genset cooling circuit piping to remote roof-mounted heat dump radiator.

Above: Skid mounted genset (CAT 3306) with heat recovery circuit piping and

pumps (P-1 & P-6) to HX-1, and natural gas train.

CAT3306

GENSET 150 kWe

HRSG (125 psig)

Genset Exhaust

Stack

PORT COLBORNE GENERAL HOSPITAL

Genset Cooling Circuit Piping toRoof Mounted Heat Dump Radiator

Cogen Room

CAT 3306

HX-1

P-6

P-1

Ventilation Air Outlet Damper(silencer inside cogen room)

Ventilation & Combustion Air Inlet Silencer

Genset Exhaust Inlet Outlet

VentilationSilencer

Power & Control Panel

Exhaust Bypass

Ventilation &Combustion

Air Inlet Motorized Dampers




Project Description: 2nd Hospital Cogeneration System in Ontario (1993), cont…Prime Mover Location and Ventilation Air System:

Service Provider: Marsh Energy Inc., Burlington, Ontario. An area previously occupied by a decommissioned steam boiler that was removed provided a suitable location to house the cogen system. The space was large enough to accommodate the skid mounted genset, the HRSG and a storage tank for preheating laundry domestic water.

Storage Room (previously a boiler room) sited for the new cogeneration system.

Pre-Construction: Outlining limits of new cogen room and major equipment.

Engine Exhaust Heat Recovery Steam Generator (HRSG).

Cogen Room Ventilation Air Opening, and Cooling Circuit Piping to Dump Radiator.

Installation of ventilation / combustion Variable Speed Ventilation Fan air inlet silencer in existing opening.

Cogen System Installation: Placement of skid mounted genset and HRSG.

Natural Gas Line

Outline of spaceallocated for HRSG

Ventilation

Air Outlet Opening

HRSG

VentilationAir Inlet Opening

HRSG

Cogen Room Wall Outline

Cogen Room Wall Outline

Genset

Cogen Room

Cogen Room

Boiler Room

Elec. Room

Natural Gas Line

Variable Speed Ventilation Fan

HRSG

VentilationAir Inlet Opening

Cogen Room

Cogen Room

Existing window usedas opening for outlet of

cogen room ventilation air

Cogen Room

Cogen Room

SilencerElbow

Vibration Isolation Springs

Genset Exhaust

Stack

GensetExhaust

Stack

Existing boiler combustion air opening used for inlet of cogen combustion air and cogen room ventilation air. Cogen Cooling

Circuit Piping to Dump Radiator

CAT3306

GENSET 150 kWe

Cogen Cooling Circuit Piping to Dump Radiator

Ventilation & Combustion Air Inlet Silencer





Project Description: 2nd Hospital Cogeneration System in Ontario (1993), cont… Prime Mover – Skid Mounted Engine-Generator Set:

At the heart of the cogeneration system is the prime mover; a 150 kWe Caterpillar 3306 natural gas spark-ignited reciprocating engine generator set (genset).

The genset was equipped with hot water heat recovery for the Oil & Jacket Water cooling circuit; the High Temperature Cooling Circuit (HTCC). Heat from the HTCC is transferred to the building hot water heating (HWH) system via a plate-frame heat exchanger (HX-1).

Pump P-1 pulls hot water from the HWH system supply header and circulates it through HX-1 to capture thermal energy from the genset HTCC and returns it back to the HWH system return header. The recovered heat is utilized by the building heating system, to preheat domestic hot water for general hospital use and to preheat laundry water. Energy utilization is measured by temperature differential and flow, via a turbine flow meter.

Left/Right: Skid mounted genset, cooling circuit piping to HX-1/radiator, and gas train.

To achieve the low NOx emission levels required for the site, the system had to be equipped with a catalytic convertor and special “Altronic” air-fuel ratio controller, (photo, left), which tuned the engine for “rich-burn” operation.

Left: Skid mounted genset, HX-1, cooling circuit piping to HX-1/radiator, engine exhaust to catalytic converter, Altronic air/fuel ratio controller mounted on the side of the genset control panel.

Natural Gas Train

Ventilation Air Outlet Silencer

Genset

Catalytic Converter

Genset Exhaust

Cogen Cooling Circuit Piping to Dump Radiator:

LTCC, HTCC, & Expansion Lines

Starting Batteries

Genset Exhaust

Genset Power & Control Panel

HX-1

P-1

P-6

HX-1

P-6

P-1

Genset

Fan

HX-

1

Genset

Genset

P-1

Starting Batteries

Starting Batteries

VentilationAir Outlet Silencer

Natural Gas Train


Turbine Flow Meter & Manual Bypass

Cogen Cooling Circuit Piping to Dump Radiator

Vibration Spring

Altronic

Genset Cooling Circuit Piping to Remote Heat

Dump Radiator

HTCCto

Rad

HTC

C to

Rad

Thermostatic3-way

Mixing Valve

LTCCto

Rad

LTCC to

Rad

HTCC

HTCC

HTCC

from

Rad

LT

CC fr

om R

ad

LTCC

to R

ad

HWH-R

Expa

nsion

line





Project Description: 2nd Hospital Cogeneration System in Ontario (1993), cont… Electrical Power & Control Panel & Other Electrical Equipment

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

An “Altronic” Air/Fuel Ratio Controller installed on the side of the Control Panel (photos bottom-left & bottom-middle), along with a catalytic convertor limits cogen system NOX emission levels to levels required for the site.

The utility interface/sensing panel is located in the main electrical room and includes double (redundant) utility grade protection relays (below).

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

Above: Utility Interface/Sensing Panel (Inside Electrical Room)

Above: Altronic Air/Fuel Ratio Controller installed on Cogen Power & Control Panel

Above: Battery Charger

Battery Charger


Generator Breaker

Annunciation Lights

Genset Synchronization

Annunciation lights

Engine control switches and buttons

Utility Interface / Sensing Panel

Ventilation Air Outlet Silencer

Elbow





Project Description: 2nd Hospital Cogeneration System in Ontario (1993), cont…

Auxiliary Equipment Electrical Motor Control Centre (MCC)

The cogen system auxiliary equipment is powered through various motor control centers located inside the cogen room.

The remote heat dump radiator fans are powered through a disconnect switch and a fan motor starter/controller panel (photo, right & middle-right).

The system circulating pumps are powered through a pump motor control center (photo, middle-left & bottom-left).

The cogen room variable speed ventilation fan, (photo, right), is powered through a fan motor starter panel and controlled by a separate variable speed controller (photo, middle-left & bottom-right).

Auxiliaries: Remote Heat Dump Radiator Fan Starter / Controller.

Auxiliaries MCC: Pumps MCC, Ventilation Fan Starter & Variable Speed Controller.

Auxiliaries: Remote Heat Dump Radiator Fan Starter / Controller.

Auxiliaries MCC: Cogeneration System Pumps MCC.

Auxiliaries: Ventilation Fan Starter & Variable Speed Controller.

Ventilation Fan Starter

Motor Control Centre Auxiliaries – Auxiliary Equipment

RemoteHeat Dump Radiator

Fan Starter / Controller Panel

PowerDisconnect

Switch

Variable Speed

Ventilation Fan

HRSG

Remote Heat Dump Radiator

Fan Starter / Controller

Auxiliaries MCC

HX-1 Circ. Pump

P-1

HX-2 Circ. Pump

P-2

Feedwater Pump P-4

Laundry Preheat Pump

P-3

Hot Water Preheat Pump

P-5

Jacket Water Preheat Pump

P-6

Ventilation Fan Variable Speed

Controller

Exhaust to Stack

125

psig

HR

SG s

team

sup

ply

to h

eade

r





Project Description: 2nd Hospital Cogeneration System in Ontario (1993), cont…

Engine Exhaust Heat Recovery via Heat Recovery Steam Generator:

Thermal energy is recovered from the engine exhaust as high pressure steam. The Heat Recovery Steam Generator (HRSG), located directly adjacent to the engine-generator set inside the cogen room, generates approximately 240 lbs/hr of steam at 125 psig which is supplied to the main steam header. A backpressure steam valve only releases enough steam to maintain the supply pressure at approximately 125 psig.

During periods of low steam usage, below the output of the HRSG, steam pressure rises and excess steam blows off through an excess steam blowoff valve, to maintain steam pressure at 135 psig.

Above: CAT 3306 genset, genset power & control panel, and Vaporphase HRSG.

Above: HRSG, Genset Exhaust Piping, Feedwater Supply and Steam Outlet.

Above: HRSG Steam Supply, Backpressure Valve, Excess Steam Blowoff Valve.

Above: HRSG Steam Supply, Backpressure Valve, Excess Steam Blowoff Valve.

Above: HRSG Steam Backpressure Valve.

HRSG (125 psig)

CAT 3306

Genset Exhaust Inlet Outlet

VentilationSilencer

Power & Control Panel

Exhaust Bypass

HRSG PneumaticFeedwater Valve

HRSG

Boiler Blowdown Line

Water Level Controller

Feedwater Connection

Backpressure Steam Valve(Set at 125 psig) Excess Steam Blowoff Valve

(Set at 135 psig) Exhaust Bypass

125

psig

HR

SG s

team

sup

ply

to h

eade

r

Exhaust to Stack

HRSG Pneumatic Feedwater Valve & manual bypass

Clorius Boiler FeedwaterMagnetic Flow Meter

& Manual Bypass

125

psig

HR

SG S

team

Sup

ply

Steam Header

Backpressure Steam Valve(Set at 125 psig) Excess Steam Blowoff Valve

(Set at 135 psig)

HR

SG S

team

Sup

ply

Steam Header

HRSG Steam Supply

Backpressure Steam Valve

(Set at 125 psig)

HWH-R(Return)

HWH-S(Supply)

Steam Header

Cogen HWH Flow Meter &

Manual Bypass

HWH-S

HWH-R

HWH-R




Project Description:


2nd Hospital Cogeneration System in Ontario (1993), cont… Laundry Water Preheat / Storage and Domestic Hot Water:

Cogen Room: Laundry Water Preheat Station.

Thermal energy from the cogen system’s Jacket Water & Oil Cooler circuits is recovered and transferred to the building’s hot water heating (HWH) system, via heat exchanger HX-1. This cogen HWH is then utilized to heat both domestic hot water (DHW) and laundry water. Hot water for the hospital laundry system is preheated by the cogen HWH system, via a double-wall plate-frame heat exchanger (HX-2). Makeup domestic cold water (DCW) enters the tank, where Pump (P-3) circulates water from the storage tank to the heat exchanger (HX-2) and back the tank to preheat the water which supplies the main laundry hot water storage tank. Left: View of Laundry Water Preheat

Station inside Cogen Room. Right: Laundry Water Preheat Station,

including 100 gallon preheat storage tank, heat exchanger (HX-2) and circulation pumps (P-2 & P-3).

Laundry Water Preheat Tank, HX-2, P-2 & P-3.

Hospital DHW was previously heated by steam via shell & tube heat exchangers (HX) in primary and secondary storage tanks. The primary DHW storage tank was converted to preheat domestic water.The heat exchanger in Tank No. 1 was converted to utilize cogen HWH. Pump (P-5) circulates cogen HWH supply water to the existing heat exchanger (HX) and temperature in the tank is controlled via a 3-way thermostatic mixing valve. Left: Existing primary DHW Storage

Tank No. 1, heat exchanger (converted to utilize HWH), circulation pump (P-5), and thermostatic 3-way mixing valve.

Right: View of existing Primary DHW

Storage Tank No.1 & Secondary Storage Tank No.2, circulation pump (P-5), and mixing valve.

HRSG

Excess Steam Blowoff

New 100 Gallon

Laundry Water

Preheat Storage

Tank

Existing Primary DHW Storage

Tank No.1 converted to

preheat DHW

HX

P-2

HX-2

P-6

Genset

P-5

Exhaust to Stack

P-3

P-3

P-2 Laundry Water

Preheat Storage

Tank

P-5

HX

Thermostatic 3-way

Mixing Valve

Thermostatic 3-way

Mixing Valve

DCW Makeup

Preheated DHW Supply To Laundry

Storage Tank

HR

SG B

oile

r Fee

dwat

er L

ine

Cogen HWH

Return

Cogen HWH

Supply

CogenHWH

Supply

Cogen HWH

Return

Existing Primary DHW

Storage Tank No.1 converted to preheat

DHW

ExistingSecondary

DHW Storage

Tank No.2

HX

DHW Tank No.2





Project Description: 2nd Hospital Cogeneration System in Ontario (1993), cont… Remote Heat Dump Radiator:

The engine-generator set requires adequate cooling of the low and high temperature cooling circuits in order to maintain proper operation. This is accomplished via a remote roof mounted split coil heat dump radiator.

Heat recovery was not incorporated for the genset aftercooler circuit; the Low Temperature Cooling Circuit (LTCC). All thermal energy from the LTCC is rejected to the LTCC coil (outer coil) of the heat dump radiator.

Heat recovery was incorporated for the genset oil cooler and jacket water circuits; the High Temperature Cooling Circuit (HTCC). Thermal energy not utilized within the building hot water heating system is diverted to the HTCC coil (inner coil) of the heat dump radiator where it is rejected.

Above: View of the remote heat dump radiator, and connecting piping / conduits.

Above: Roof mounted remote Heat Dump Radiator & piping to cogen room.

Above: Heat dump radiator - coils, expansion tanks, variable speed fan & silencers.

Above: Heat dump radiator - coils, expansion tanks, variable speed fan & silencers.

Above: Piping & conduits to radiator. Above: Expansion Tank & Low Level Alarm.

Remote Heat Dump

Radiator

2 ½” Cogen HTCC Piping (Glycol/Water) 1” Expansion Lines (Glycol/Water) 1 ½” Cogen LTCC Piping (Glycol/Water) Electrical Conduits (Power & Controls) Cogen Room Ventilation Outlet Damper

Radiator Cooling Coils:Outer - LTCCInner - HTCC

Remote Heat Dump

Radiator Remote

Heat DumpRadiator

1” Expansion Lines

ExpansionTank

ExpansionTanks

DischargeSilencer

Inlet Silencer FAN

Inner Coil HTCC

Outer Coil LTCC

1 ½” Cogen LTCC Piping (Glycol/Water) 2 ½” Cogen HTCC Piping (Glycol/Water)

Expansion Tank

Low Level Alarm Switch

Power disconnect box

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




Project Description: 2nd Hospital Cogeneration System in Ontario (1993), cont… Drawing M-1: Mechanical Schematic: Mechanical Schematic of Cogeneration System interconnection to existing Heating Plant.





Project Description: 2nd Hospital Cogeneration System in Ontario (1993), cont… Drawing M-3: Mechanical Demolition and Ventilation Layout: Mechanical Demolition Work and Layout of new Cogen Room Ventilation System.





Project Description: 2nd Hospital Cogeneration System in Ontario (1993), cont… Drawing M-6: Mechanical North Elevation: Mechanical - North Wall Elevation.





Project Description: 2nd Hospital Cogeneration System in Ontario (1993), cont… Drawing M-7: Mechanical Sections: Mechanical Sections – Inside New Cogen Room.





Project Description: 2nd Hospital Cogeneration System in Ontario (1993), cont… Drawing M-8: Roof Mounted Heat Dump Radiator – Layout and Details: Mechanical Layout of Roof Mounted Remote Heat Dump Radiator.





Project Description: 2nd Hospital Cogeneration System in Ontario (1993), cont… Drawing P&I-1: Remote Monitoring P&I: Process and Instrumentation Drawing for Remote Monitoring / Datalogging System.





Project Description: 2nd Hospital Cogeneration System in Ontario (1993), cont… Drawing E-3: Electrical Layout – Plan: Electrical Layout Drawing.