ALASKA VILLAGE ELECTRIC COOPERATIVE

Transcription

1 ALASKA VILLAGE ELECTRIC COOPERATIVE ENERGIZING RURAL ALASKA SINCE 1968 ENHANCING HEAT RECOVERY BY USING MARINE MANIFOLDS RURAL ENERGY CONFERENCE SEPTEMBER 25, 2014 ANCHORAGE, ALASKA Mark Bryan, Operations Manager Alaska Village Electric Cooperative

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3 A non-profit member-owned electric cooperative providing electric service to 56 communities 74 Anchorage-based employees 16 Bethel-based employees 95 Local Plant Operators 49 power plants 162+ diesel generators 17 heat recovery systems 500+ fuel tanks 8.5 million gallons of diesel 34 wind turbines serving 15 villages 3

4 The need to lower community fuel costs Fuel prices have sharply increased in the past decade AVEC s average fuel price in 2003 was $1.49/gal AVEC s average fuel price in 2013 was $4.19/gal AVEC has partnered with AEA, ANTHC and School Districts to develop heat recovery projects in our communities. AEA developed the Caterpillar 3456 with a marine manifold and had great success increasing heat output and maintaining fuel efficiency. 4

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6 Introducing the Series 60 Detroit Diesel 12.7L Series 60 Excellent fuel efficiency Inline 6 cylinder, four cycle diesel engine Uses Detroit Diesel s electronic controls (DDEC) Has increased horsepower with each revision Almost 1/3 of our generators are Series 60s 22 at 1200 rpm - rated up to 236 kw 30 at 1800 rpm - rated up to 363 kw 6

7 Detroit Series 60 7

8 The Series 60 Marine Manifold Project Alaska Village Electric Cooperative The Alaska Energy Authority Pacific Power Products Gray Stassel Engineering Partnered to develop a Series 60 generator outfitted with a marine manifold 8 Our expectations: 1. Maintain fuel efficiency 2. Maintain performance 3. Measure heat increase

9 Test components Three turbochargers were selected to test with the marine manifold to ensure we maintained the best fuel efficiency and performance. 9 Our stock dry turbo Wastegate Marine - water jacketed Tests to be conducted with both an 1800 rpm unit and a 1200 rpm unit.

10 RPM Detroit Diesel, Series 60 DDEC Liter, Fuel Efficiency (kwh/gal) kwh/gal Dry Stock Turbo 1800 Wet Wet Turbo 1800 Wet Waste Gate 1800 Wet Stock Turbo kw Load 10

11 RPM Detroit Diesel, Series 60 DDEC Liter, Heat Rejected to JW Wet Wet Turbo 1800 Wet Stock Turbo Wet Waste Gate Btu/kWh Dry Stock Turbo kw Load 11

12 RPM Detroit Diesel, Series 60 DDEC Liter, Fuel Efficiency (kwh/gal) kwh/gal Dry Stock Turbo 1800 Wet Wet Turbo kw Load 12

13 RPM Detroit Diesel, Series 60 DDEC Liter, Heat Rejected to JW Wet Wet Turbo Dry Stock Turbo Btu/kWh kw Load 13

14 Series rpm test results: The wet manifold with marine (wet) turbo configuration maintained fuel efficiency and performance comparable to the dry manifold and stock turbo. Heat output increased 25% to 68% depending on load. Wet-Wet vs Dry Stock load (kw) % Increase Btu/Hr Increase 26 25% % % % % % % % % % % % % % 790 At 150 kw, this displaces approximately 1 gallon of heating fuel per hour or 6,000 additional gallons for a nine month heating season. 14

15 1200 RPM Detroit Diesel, Series 60 DDEC Liter, Fuel Efficiency (kwh/gal) Dry Stock Turbo kwh/gal 10.0 Wet Waste Gate Wet Wet Turbo kw Load 15

16 RPM Detroit Diesel, Series 60 DDEC Liter, Heat Rejected to JW Wet Wet Turbo 3000 Wet Waste Gate Dry Stock Turbo 2500 Btu/kWh kw Load 16

17 RPM Detroit Diesel, Series 60 DDEC Liter, Fuel Efficiency (kwh/gal) Dry Stock Turbo kwh/gal Wet Waste Gate Turbo kw Load 17

18 RPM Detroit Diesel, Series 60 DDEC Liter, Heat Rejected to JW Wet Waste Gate Turbo 1200 Dry Stock Turbo 2500 Btu/kWh kw Load 18

19 Series rpm test results: The wet manifold with waste gate turbo configuration maintained fuel efficiency and performance comparable to the dry manifold and stock turbo. Heat output increased 25% to 68% depending on load. Wet-Waste Gate vs Dry Stock load (kw) % Increase Btu/Hr Increase 25 2% % % % % % % % 654 At a 75 kw load, it displaces 1/3 gallon of heating fuel per hour or about 2500 additional gallons for a nine month heating season. 19

20 Series 60 with marine manifold (factory photo) 20

21 Other AVEC marine manifold projects: Stebbins Four CAT 3456 units recently installed 21

22 New Stuyahok: Marine manifold retrofit on an existing CAT