Analyze and Implement: Modernizing an Airport Central Utility Plant
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1 Analyze and Implement: Modernizing an Airport Central Utility Plant Sustaining Our Success June 26-29, 2017 Haven Cassidy, PE Jeff Easton, PE
2 Introduction Owner Considerations Growth / Challenges Modernization Analysis Heating Upgrades Cooling Upgrades Construction Phasing Next Steps
3 INTRODUCTION DENVER INTERNATIONAL AIRPORT Opened February 28, million travelers in 2016 (Record!) 53 sq. miles (Largest Land Area Airport in US) 76,000 Feet of Length on Six Runways 19 consecutive months of record-setting traffic >6M Square Feet of Space Under Roof Terminal, 3 Concourses & Airport Office Building Served by Single Central Utility Plant Secret Underground Bunkers Photo Courtesy of Denver International Airport
4 INTRODUCTION CENTRAL PLANT EXISTING ASSETS Heating Water Medium Temp Hot Water Boilers (230F Delivery) 70 deg design dt Original: 3 x 60 MMBTU, 1 x 17 MMBTU 60 s derated to 42 MMBTU Supplemental: 1 x 47 MMBTU Chilled Water 3 x 4,150 ton R-22 Chillers 2 x 2,500 ton R-123 Chillers (2015, VFD) 2 x 1,200 ton Free Cooling HX 1 x 4,150 ton Free Cooling HX 8 x 2,708 ton Cooling Towers (VFD) Photo Courtesy of Denver International Airport
5 INTRODUCTION CENTRAL PLANT ASSETS (2015)
6 OWNER CONSIDERATIONS INTERNAL PROCESS Stakeholder Engagement Operations & Maintenance Finance Energy Management DEN In-house QA/QC Staff On-Call Contracting Design Professionals Commissioning Photo Courtesy of Denver International Airport
7 GROWTH! CHILLED WATER
8 GROWTH! HEATING WATER
9 CHALLENGES EXISTING CUP STRUGGLES Completely land-locked Subsurface CUP Cooling tower above Legacy water treatment issues Operating inefficiencies Optimization opposition Photo Courtesy of Google Maps
10 CHALLENGES EXISTING CUP STRUGGLES Heating Firm capacity Redundancy profile Dedicated pumping Flue stack design, orientation and deterioration Cooling R-22 Phase-out CW pumping issues Redundancy profile Load Transition/Sequencing low dt
11 ANALYSIS Goals CUP MODERNIZATION Define future utility system requirements Identify technology options Analyze ancillary modifications Economic Analysis of options Provide a utility Roadmap $0.97 $0.17 $0.77 Energy Charges Demand Charges Other Charges
12 ANALYSIS CUP MODERNIZATION Technology Options Considered Alternative Boiler Size* Combined Heat and Power Alternative Chiller Size* Satellite Central Plant Thermal Energy Storage Additional Electrical Service
13 HEATING UPGRADES ALTERNATE BOILER SIZING Phase 1 Boiler #2 Replacement Phase 2 Boiler #1, 3, 4 Replacement Full Build = 8 x 20 MMBTU Challenges Maintain airport heating service Interim solution/control for mix of boiler/pumps Flue configuration / aesthetic System Improvements Variable-primary pumping Common pumping header Flue stack improvements Integrate/update controls
14 COOLING UPGRADES ALTERNATE CHILLER SIZING 8 x 2,500 ton VFD Chillers 2 per chiller bay Single set of CW pumps Challenges Maintain airport cooling capacity Phased, seasonal construction Electrical service realignment Space for variable frequency drives Refrigerant phase-out solution (R-22) System Improvements CW Pumping VS for Free cooling + Optimization Staging / Control
15 CONSTRUCTION PHASING OWNER CONSIDERATIONS Contracting method/timing Early Equipment Procurement? Owner-performed work? Robust Division 01 Specs CUP Operations Equipment Protections Critical Hours Strictly define outage tolerances 100% continuous operation? Temperature float allowed? Financial Implications?
16 CONSTRUCTION PHASING DESIGN CONSIDERATIONS Equipment Pathway Seasonal loading Zero or low load periods? Alternate means to meet load? Controls expectations? Valve inventory.can they be trusted? Interdependent systems Clear communication of plan
17 CONSTRUCTION PHASING CONSTRUCTION CONSIDERATIONS Work in an operating CUP Additional protections Reduced labor efficiency Confirm Rigging/Pathway Diligent Communication
18 NEXT STEPS FINISH THE FIGHT! Boiler #1, #3, #4 Replacement Early Design Underway Secondary Pump replacements Construction Complete Fall 2018 Chiller Replacement Construction Starting in Fall ,000 tons installed 2-year duration with phasing Continuous Improvement Maintenance Programs Optimization Strategies Photo Courtesy of Denver International Airport
19 QUESTIONS? Photo Courtesy of Denver International Airport Haven Cassidy, PE Project Manager p: e: Jeff Easton, PE, CEM Project Manager p: e:
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