Download Strategic Master Plan For South Pole Energy

UNITED STATES ANTARCTIC PROGRAM
National Science Foundation
2006 Report on South Pole Energy Issues
and Recommendations
June 23, 2006
RSA
National Science Foundation
2006 Report on South Pole Energy Issues & Recommendations
Final Report - Phase 1
6/23/06
Page 2
National Science Foundation
2006 Report on South Pole Energy Issues & Recommendations
6/23/06
2006 Report on South Pole Energy Issues &
Recommendations
Table of Contents
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
Executive Summary
Introduction
Historical Background
Present and Forecast Electrical Load Data
4.1
Forecasting Electrical Loads
4.2
Load Descriptions
4.3
Impact Caused by Additional Loads
4.4
Potential Solutions to Meeting Demand Load
Fuel Issues
5.1
Fuel Arch Usable Fuel Capacity
5.2
Above Ground Fuel Capacity
5.3
Station Opening/Emergency Fuel Allocation
5.4
Total Station Net Fuel Capacity
5.5
Impact of Power Generation on Fuel
5.6
Historical and Projected Fuel Flights
5.7
Surface Transportation of Fuel
Electrical Distribution
6.1
Transformer and Substation Capacities
6.2
Feeder Capacity Relative to Present and Planned Loads
6.3
Proposed Feeder Demolitions
6.4
Switchgear Capacities and Limitations
6.5
Distribution One-Line Documents
6.6
South Pole Telescope Voltage Drop Study
6.6.1
Overview
6.6.2
Methodology
6.6.3
Assumptions
6.6.4
Conclusion
6.6.5
Recommendations
Controls on Future Loads
7.1
Science Project Energy Use Analysis
7.1.1
Energy Conservation Buy-In with Science
7.1.2
Standardized Energy Use Project Guidelines
7.1.3
Population Control
Electrical Generation Issues
8.1
Generator Output Capacity
8.2
Actual De-Rated Site Capacity
8.3
Limiting Electrical Production Factors
8.3.1
Site Elevation
8.3.2
Fuel Energy Values
8.3.3
Exhaust Gas Temperatures
8.3.4
Engine Room Temperature Limitations
8.3.5
Fuel Energy Values
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8.4
9.0
10.0
11.0
Supplemental Energy Opportunities
8.4.1
Alternate Energy Options
8.4.1.1 Solar Heating
8.4.1.2 Solar Photovoltaic Power
8.4.1.3 Wind Power Generation
8.4.1.4 Cold Weather Turbine Project Research Program
8.4.2 Alternative Energy Summary
8.4.3 Alternate Energy Integration Complexities
8.5
Load Shedding
8.5.1
Load Shedding Procedures
8.5.2
Load Shedding Equipment
8.5.3
Essential Load Definition
8.5.4
Off Peak Loads
8.6
Emergency Power Generation
8.6.1
Location of Emergency Generators
8.6.2
Capacity of Emergency Generators
8.6.3
Planned Uses for Emergency Power
8.6.4
SOP for Emergency Power Use
8.6.5
Science Requirements for Emergency Power
Power Monitoring
9.1
Portable Power Monitor
Cost Model
10.1 Cost of Fuel Calculation
10.2 Cost of Power Calculation
10.3 Cost of Heat Calculation
Energy Efficiency Opportunities
11.1 Parasitic Electrical Losses
11.1.1 Power Factor Definition
11.1.2 Power Factor Improvement
11.1.3 Power Factor Problems from Electronic Equipment
11.1.3.1 Power Factor Correction Payback
11.1.4 Transmission Losses
11.1.5 Transformer Losses
11.2 Specific Solutions
11.2.1 Energy Forecasting
11.2.2 Conserve
11.2.3 Refine Distribution
11.2.4 Demand Management
11.3 Lighting Energy Efficiency Opportunities
11.3.1 Replace Magnetic Ballasts with Electronic Ballasts
11.3.1.1 Power Savings Estimate with Retrofit
11.3.1.2 Prohibited Locations Due to Electrical Noise
11.3.1.3 Technical Obsolesce of Old Magnetic Ballasts
11.3.2 Lighting Fixture Upgrades
11.3.2.1 Use of T-5 Lamps in Place of T-8
11.3.2.2 LED Exit Signs
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13.0
14.0
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11.3.3 Motion Detector Light Switches
11.3.3.1 Existing Locations
11.3.3.2 Proposed Additional Locations
11.3.4 Dimming Switches/Daylight Sensors
11.3.5 Lighting Level Survey
11.4 Thermal Energy
11.4.1 Verify Ventilation Levels Relative to CO2 Tracers
11.4.2 Monitor Boiler Efficiencies
11.4.3 Electric Boilers
11.4.4 Electric Duct Heaters
11.4.5 Electric Water Heaters
11.4.6 Add BTU Meters to Track Use of Energy
11.4.7 Survey Buildings for Heat Loss with Infra-Red Camera
11.4.7.1 List of Buildings by Priority
11.4.7.2 Data Evaluation Process
11.4.7.3 Building Insulation Adequacy
11.4.7.4 Weather Stripping, Door Seal Adequacy
11.4.7.5 High Resistance Electrical Connections
11.4.8 Thermostat Set Point and Setback Review
11.5 Waste Heat Capture
11.5.1 Stack Heat Losses
11.5.1.1 Contingency Plan if More HX Units Fail
11.5.1.2 Other Manufacturer’s Availability
11.5.2 Jacket Water Waste Heat
11.5.2.1 Heat Exchanger Efficiency
11.5.2.2 BTU Meters at Heat Exchangers
11.5.2.3 Engine Glycol Temperature Problems
11.6 Commissioning
Schedule
12.1 Integrated Master Schedule
12.2 Long Range Plan for South Pole
12.2.1 Current Schedule
12.2.2 Out Year Project Schedule
12.3 Key Activities Affecting Schedule
12.3.1 FY 08 Implementation Efforts for Energy
12.3.2 Energy Projects beyond FY 008
12.3.3 Major Project Timing
12.3.3.1 Design
12.3.3.2 Procurement
12.3.3.3 Shipping
12.3.3.4 Installation
12.3.4 Annual O&M Impact on Schedule
Cost Elements
13.1 FY Timeline for Implementation
13.2 Cash Flow Planning by Fiscal Year
Recommendations in Priority Order
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Acronyms and Abbreviations
ABM
Activity Based Management
ACBAR
Arcminute Cosmology Bolometer Array Receiver
AC
Alternating Current
API
American Petroleum Institute
ARO
Atmospheric Research Observatory
ASTRO
Antarctic Submillimeter Telescope and Remote Observatory
BICEP
Background Imaging of Cosmic Extragalactic Polarization
BOD
Basis of Design
BTU
British Thermal Units
CAT
Caterpillar Machinery Co.
CFR
Code of Federal Regulations
CO2
Carbon Dioxide
CRYO
Cryogenics
DARN
Super Dual Auroral Radar Network
DC
Direct Current
DDC
Direct Digital Control
DSL
Dark Sector Lab
EGHX
Exhaust Gas Heat Exchanger
EGT
Exhaust Gat Temperature
EMI
Electrical Magnetic Interference
F
Fahrenheit
FCC
Federal Communications Commission
FEMC
Facility Engineering Maintenance and Construction
FY
Fiscal Year
H2O
Water
HZ
Hertz
ICL
Ice Cube Laboratory
IT
Information Technology
KHZ
Kilo Hertz
KVA
Kilo Volt Amperes
KVAR
Kilo Volt Amps Reactive
KW
Kilo Watts
KWH
Kilo Watt Hours
LED
Light Emitting Diode
MAPO
Martin A. Pomerentz Observatory
MBH
Thousands of BTUs per Hour
MCC
Motor Control Center
NEC
National Electrical Code
NPP
New Power Plant
NSF
National Science Foundation
PF
Power Factor
PFC
Power Factor Corrected
PG
Peaking Generator
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PIR
PMDE
POC
QUaD
PV
RFI
RMDE
RPSC
SCOARA
SPASE 2
SPRESO
SPSM
SPUC
THD
UPS
USAP
VFD
WC
6/23/06
Passive Infrared
Primary Main Distribution Equipment
Proof of Concept
Quest Experiment on DASI (Degree Angular Scale Interferometer)
Photovoltaics
Radio Frequency Interference
Remote Main Distribution Equipment
Raytheon Polar Services Corporation
Scientific Coordination Office for Astrophysical Research in Antarctica
South Pole Air Shower Experiment
South Pole Remote Earth Science Observatory
South Pole Station Modernization
Science Planning and User committee
Total Harmonic Distortion
Uninterruptible Power Supply
United States Antarctica Program
Variable Frequency Drive
Water Column
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Definitions used in this report are as listed:

Amps (A): This is the current that is drawn at the connected voltage.

Average load: Average loads are sometimes estimated, but actual 24
hour running average loads are based on past measured average loads,
using a power analyzer, as are related demand loads. Average loads are
used to forecast fuel consumption requirements.

Circuit Capacity: Circuit capacity is a function of the rating of the breaker,
the load it is serving, and the equipment served. For example, a feeder
supplying only transformers has to be sized for the nameplate capacity of
the transformers served (NEC 215 B 1). If the feeder serves transformers
in addition to utilization equipment, the feeder must be sized for the sum of
the nameplate ratings of the transformers, plus 125% of the designed
potential load of the utilization equipment that will be operated
simultaneously (NEC 215 B 2). Panel board circuits are rated depending
if they are serving continuous or non-continuous loads. A circuit with an
80% load rated circuit breaker can only carry 100% of the full rated load
for 3 hours or less. Due to the reduced cooling capacity of air at the
station altitude, circuit capacities are typically designed to no more than
80% of the circuit rated capacity.

Connected load: This is a summation of all of the electrical loads
connected to the system, with receptacles being assigned a load of 180
Volt Amps (VA) each, lighting loads at their listed draw, with special
equipment at the nameplate rating. With a facility of this type, many
assumptions have to be made as to how much load will be connected if
the equipment is not yet in place.

Continuous load: A continuous load is defined by the National Electrical
Code (NEC) as “A load where the maximum current is expected to
continue for 3 hours or more”.

Continuous Rating: This is the rating for the engine-generator sets that
sizes the set to allow continuous 24-hour per day generation at that output
level without overloading or overheating the genset. The continuous
rating is typically around 10% lower than the prime rating for the same
equipment.

Demand loads on circuits are the measured sustained peak loads
recorded for 5 minutes. Demand loads help define the required size and
electrical capacity of the generator sets.

Double Firm Contingency: The concept in power plant planning of
assuming that one of the two largest generators will be out of service for
routine or major maintenance while the other is on stand-by. The capacity
of the plant is then the remaining generation capacity. This concept was
used at the South Pole power plant.
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
EMI: The interference in signal transmission or reception caused by the
radiation of electrical and magnetic fields.

Fiscal Year: This is the time period from October 1 until September 31.
For example, FY 06 starts October 1, 2005 and ends September 31, 2006.

Glossary of Abbreviations:
o
VD – Voltage Drop
o
LF – Load Flow
o
PD – Protective Device
o
CBL – Cable
o
XFMR – Transformer
o
XF – Transformer
o
MSG – Main Switchgear
o
SWG – Switchgear

Kilovolt-amperes (kVA):
For single phase circuits, this is kVA=
(V*A)/1000. For three phase circuits it is kVA= (V*A *1.73)/1,000.

Kilowatts (kW): For single phase circuits, kW = (V*A*PF)/1,000. For three
phase circuits, kW= (V*A*PF*1.73)/1,000.

Power Factor (PF): This is the ratio of working power (kW) to apparent
power (kVA). A power factor of 1.0 is a purely resistive load, and is the
best possible scenario, since kVA=kW at that PF.

Prime Rating: This is the rating given to engine-generator sets (gensets)
that sizes the set to provide sufficient power for fluctuating loads up to a
rated level. Short term “peak power” overloads are also permitted under
the prime rating.

RFI: Noise induced upon signal wires by ambient radio-frequency
electromagnetic radiation with the effect of obscuring the instrument
signal.

THD: Total harmonic distortion is the measure of closeness in shape
between a waveform and its fundamental component.

Voltage (V): The Pole generates power at 277/480 volts AC, 3-phase.
Lighting is typically fed at 277 volts, and larger motor or equipment loads
are at 480 volts, 3-phase. Convenience receptacles and small loads are
at 120 volts, single phase. 4160/2400 volts is used for distribution voltage
to remote loads, such as science areas.
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2006 Report on South Pole Energy Issues & Recommendations
1.0
Executive Summary
The Amundsen-Scott South Pole Station is at a critical time for energy usage and
conservation. The Station Modernization was planned around criteria defined in
a document called the Basis of Design (BOD). Every one of the critical energy
driving components of the Station are now far in excess of the BOD. The major
components are listed:





Generation capacity, as defined by demand load, was originally expected to
be 663 kW, but by winter of 2006 it was over 800 kW, and is now forecast to
be around 1,100 kW by the summer of 2007.
Fuel consumption, as driven by thermal loads, population, and average power
generation, is forecast to exceed station winter over capacity, so planned
projects cannot be accommodated with the existing fuel storage capacity,
even if summer fuel flights were unconstrained.
Power distribution cannot accommodate the Dark Sector for the summer of
2007 and beyond. The existing substation at the Dark Sector is undersized
for the expected load, and will require a second substation and dedicated
feeder to the SPT project to handle the projected loads in this area for the
Dark Sector lab.
The station was designed to accommodate a population of 154 people
maximum, and is now peaking in excess of 250 people for the next few years.
This drives electrical and fuel demand higher to provide more water, lighting,
cooking, for miscellaneous electrical consumption, presently estimated at 1.5
to 2.0 kW per person.
Supplemental boiler use is exceeding forecast amounts due to the need to
make more water, heat more water, and to overcome excessive infiltration at
the elevated station.
Simply adding more diesel generation capacity is not the short term answer,
because additional diesel engine power generation relies on more fuel deliveries,
more fuel storage, larger substations, higher capacity transmission lines, higher
capacity switchgear, higher operational costs, and so on. Additionally, there are
some operational concerns which include:
1. Current operation of the New Power Plant (NPP) has shown that high
exhaust gas temperatures at the engines have been limiting power output
capacity. Various efforts are suggested that will increase prime power
output capacity from the existing reduced capacity of 939 kW to 989 kW,
which is the original BOD continuous load capacity. These efforts include
ducting of outside air directly to the generator engines, cooling the arch
temperatures, and better air distribution in the generator room.
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2. To date, there have been five failures of the generator engine exhaust gas
heat recovery equipment, which is jeopardizing optimum heat recovery.
3. Electrical Load forecasting has not been accurate enough to give a
reasonable basis for approving or disapproving future projects.
4. At present, there is inadequate electrical monitoring so it is difficult to
accurately determine where the energy is used or how much energy will
be needed based on current usage. This is an essential component of
making accurate energy forecasts.
5. Thermal heat transfer measurements at heat exchangers and boilers are
inadequate to forecast, monitor and troubleshoot heat loads at various
buildings to maximize waste heat use.
6. Heat loss at the Elevated Station (ES) is excessive due to very high
infiltration. The building envelope needs to be tightened to reduce the
infiltration load by sealing penetrations and assuring a continuous vapor
barrier.
7. Waste heat recovery is inadequate to meet current demand. The addition
of an exhaust gas heat exchanger on the peaking generator, will be
running almost continuously, would provide additional waste heat for the
system.
All of the above concerns are the result of a bottom up energy analysis that
yielded a new forecast, with the detailed projected electrical power requirements
included in the text of this report. NSF should consider assumptions and risks,
which can change the forecasted capacities. Examples of this are:

The Station opening fuel reserve is presently set at 70,000 gallons.

The fuel capacity requirements presently assume a 10% contingency.

The winter period is assumed to be 35 weeks, which is used to forecast
the maximum allowable average power usage.

The forecast loads are based on the sum of measured peaks and
averages, which presently total about 15% above station average and
peak loads for April, 2006, the same time period that many of the 24-hour
recordings were taken.

There are only a few summer load measurements that can be used to
calibrate the load forecast to actual. For this reason, most load forecasts
are based on winter readings, with some adjustment for estimated
summer loads.
2.0
Introduction
The Strategic Master Plan for South Pole Energy focuses on identifying
limitations, and optimizing the use of energy resources while staying within
current station fuel storage and power generation capacities. To accomplish this
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goal, current energy use has been evaluated and is used to predict future
capabilities.
3.0
Historical Background
Power load forecasts for the new station were generated as early as 1994.
These demand, average, and connected load forecasts are only best estimates
of required power based on the information at the time, so they were
understandably different on most of the reports. For example:

The April 14, 1994 M&E, ASA, and J&T working group’s assessments of
the electrical loads for the replacement station show a peak load of 678
kW for summer, and 631 kW for winter. Average loads were estimated at
567 kW summer, and 546 kW winter. The group concluded that there
would be 495.1 MBH of excess waste heat available.

The South Pole Requirements Document approved in 1996 (page 16)
assumed a total connected load of 1,629 kW, with average loads of 541
kW in summer and 522 kW in winter.

A generation and efficiency study by PDC engineering in 1996 (page 5)
predicted a total demand load of 973 kW.

The New Power Plant (NPP) Basis of Design (BOD) printed in 1997
forecast a total connected load of 2,580 kW, an immediate 750 kW peak
load, with future demand loads of 1,000 kW with the use of multiple
engines, and average loads around 500 kW. Fuel requirements were
based on an average load of 500 kW. See page 5-8, 5-9.

The 1999 New Station BOD forecast a connected load of 2,114 kW, with a
demand load of 663 kW, and an average load of 480 kW. See page 6-13.
Since this is the most recent load forecast, it is used for comparison as a
design baseline.

Science demand loads have been forecast to be 279 kW summer demand
and 363 kW winter demand in the 1996 Requirements Document. This
data was repeated in the Basis of Design for the new station, 7-19-99,
page 7-55. Calculated science demand in 2005/2006 was 440 kW in the
summer, and 465 kW in the winter, according to Raytheon’s “2004 South
Pole Power Plant Electrical Capacity Analysis - revised”, dated March 15,
2006.

The total connected science loads reported in the BOD of 7-19-99 were
824 kW at 0.9 PF, or 915 kVA. The connected science load is defined in
the BOD as the sum of the rated power nameplate draw of all science
experiments, instrumentation and equipment installed at the South Pole.
FY07 connected loads are now in excess of 1,200 kVA.

Average running loads for science were estimated in the 3-18-96 South
Pole Requirements document, and again in the 7-19-99 New Station BOD
at 201 kW summer, and 219 kW winter. The same document reported
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average operations running loads of 340 kW summer and 303 kW winter.
Total science and operations average loads combined were estimated at
541 kW summer and 522 kW winter.
Chart 1
1999 Final BOD with NPP Demand Loads
VS.
Installed Site Capacity
1000
BOD PEAK CAPACITY
989 kW
900
PG Unit Operates
800
BOD BASE UNIT CAPACITY
750 kW
Kilowatts
700
BOD TOTAL DEMAND
LOAD 663 kW
600
279
500
363
Excerpt from 1999 Final BOD For the New Station, section on NPP
400
"The number and size of the generation units have been selected to permit the
loads to be properly supplied by the use of only ONE base unit the majority of
the time. When power requirements exceed 90% of the capacity of a single
unit for 15 minutes or 95% of the rating for 5 minutes, the Peaking Generator
is started, warmed and brought on line to increase power availability and
stability."
300
200
384
300
100
0
1999 FORECAST
SUMMER DEMAND
1999 FORECAST
WINTER DEMAND
BOD SCIENCE LOAD
BOD - OPS LOAD
Chart 2
Total Connected Load
3,600
3,470
3,500
3,400
3,355
Killowatts
3,300
3,180
3,200
3,194
3,106
Ttl Conn
3,100
3,000
2,962
2,900
2,800
2,700
FY06
FY07
FY08
FY09
FY10
FY11
Fiscal Year
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Present and Forecast Electrical Load Data
Beginning with the summer 2006, a number of planned events caused an
increase in power generation and delivery system usage above that predicted in
the South Pole Station Modernization (SPSM) BOD. These events include:
additional construction projects such as Dark Sector Lab, South Pole Telescopes
(10 Meter and BICEP), and Ice Cube - large science projects that were only in
the conceptual stages at the time the SPSM BOD was developed. There has
also been a delay in the completion of SPSM. The station population has
increased above that originally planned for ’05 and ’06 and will continue to rise
until the station population is leveled to its design intent of supporting 154
persons. The demolition of older buildings has been postponed in order to house
the additional required staff. These buildings and concomitant population
(estimated at 1.5 to 2.0 kW/day) also consume an amount of power and fuel
above that originally planned for the current time period and the near future.
Some specific additional items that have affected these load projections are
listed below:

The demolition of existing buildings at the South Pole has been delayed
throughout the construction phase of the project causing more buildings to
be on line than were designed for electrically.

From the Draft Utility Transition Plan (Tab 2, page 7, Section F, number 5
a), the Dome Galley and Freshie Shack were to be taken out of service
and removed in FY02. The Galley was not taken off line until early winter
FY05.

From the same above section, number 6 a), the Bio-med building was to
be taken out of service and removed in FY03. This building was taken
down in the winter FY05.

The Science/Annex/Upper Berthing buildings were to be taken out of
service and removed FY03. They were all in full operation until FY 06,
with the exception of the old greenhouse, which was taken off line early in
the winter season of FY05.

The Skylab Building was taken off line in the summer of FY06 so it is cold
and de-energized. It is now scheduled to be removed in the summer of
FY 07.

The Dark Sector was originally planned to have 174 kW connected
according to the Basis of Design. (Volume 5 SPSM-Design of the New
Station Electrical/Communications/Food Services, Appendices, Final
Submittal April 09, 1999, Section Electrical Calc E1.1.1 Page 1 of 3.)
Currently the Dark Sector has 417 kW connected. This connected value
does not include the coming additions of 238 kVA for the South Pole
telescope, 191 kVA for the Counting House, and 18 kW for Bicep. Even
with the removal of both ASTRO and VIPER in the FY06 season, these 3
additions exceed the capacity of the dark sector feeder substation.
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The following additional items are factors in the current problems of power and
fuel usage at the South Pole Station.
1. With summer populations in excess of 250 people, more buildings,
including the inefficient Jamesway units and toilet modules in Summer
Camp must be held open to provide workspace and berthing. These
excess buildings require more electrical power and heat supply than
anticipated.
2. As science continues to increase at South Pole, it demands more
electrical energy to provide support as well as to power its projects.
Without properly analyzing each new load or each load left on beyond its
planned removal date, the station electrical grid will be put in jeopardy of
major failure.
4.1
Forecasting Electrical Loads
Forecasted electrical loads have been historically accurate only to
+/- 40%. The forecast loads had been computed using connected
loads, with a factor later applied for average and peak loads. For
these reasons, 24 hour “snapshot” monitoring of key loads was
recently (February through April, 2006) performed using a portable
power analyzer, in order to “calibrate” historical detail load
estimates with actual. This data is shown in red on the “Projected
Electrical Power Requirements” chart below. The electrical average
and peak data given in the March 2006 Sitreps compared to within
about 8% of the “Projected Electrical Power Requirements” for
FY06 given below. The updated calibration compares within 7%,
without counting a contingency. There have been only a few 24
hour snapshot power analyzer readings during summer conditions,
so most actual loads for the summer period have not been
calibrated to the spreadsheet. It was forecast in the BOD, and is
expected that summer science loads will drop, while summer
operations loads will increase due to additional population at the
Station. See the “Projected Electrical Power Requirements” below.
Each of the line items on the forecast is described in more detail
below as a back-up to the forecast so it is better understood what
the function of the load is, and how the load was estimated or
verified.
4.2
Load Descriptions
1. ARO
Summer Operations
Purpose: The ARO is used primarily for conducting studies to
determine and assess the long-term buildup of trace atmospheric
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constituents that influence climate change and the ozone layer.
Meteorological data is collected from an instrumented tower on the
boundary of the Clean Air Sector. NOAA also collaborates with
climate modelers, diagnosticians and coordinates science
experiments in atmospheric chemistry.
Aurora based studies are conducted in Thermospheric and
Mesospheric dynamics to understand the interaction of the Sun’s
energy in a region between 60 and 180 kilometers above the
earth’s surface. Research into the sources and energization
mechanisms of aurora particles in the Magnetosphere is also being
carried out. These experiments may not have been in the original
BOD of ARO as they came originally from SkyLab.
The final purpose of ARO is the Spectroradiometer Ultraviolet
(SUV) Network of which South Pole represents the polar plateau
component for the southern hemisphere.
Users: The primary tenant of the ARO is NOAA. Their research
goals are accomplished by flask sample collection, in-situ
measurements and operation of light collecting instrumentation in
the visible and ultraviolet wavelengths. Data collection is ongoing
24/7 for 365 days a year
1 Five different flask sample experiments are collected by electromechanical equipment and field scientists then sent back to
CONUS for analysis
2 Five different in-situ measurements and light collection are
accomplished by electro-mechanical equipment and data
acquisition systems
The aurora studies consist of three separately funded experiments.
One experiment has instrumentation residing underneath two
optical viewing domes, while the other populates underneath three
optical viewing domes. The third experiment is an optical all-sky
proton imager underneath a single viewing dome. All six
instruments have associated data acquisition systems. These
experiments are connected to the power grid in the austral summer
for the purposes of calibration and maintenance.
The SUV Network component has four instruments connected with
two data acquisition systems. Data collection is ongoing for the six
month polar day (i.e. Sep 21 to Mar 21).
Measured peak: 40.8kVA
Building component – 23.7 kVA The building has electric heat.
Science component – NOAA + AURORA + SUV = 6.0 + 7.4 + 2.0
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= 15.4kW Peak Power (17.1 kVA)
Winter Operations
Purpose: Same as for summer operations.
Users: Same as for summer operations.
Measured peak: 40.8kVA
Building component – 23.7 kVA
Science component – NOAA + AURORA + SUV= 15.4kW Peak
Power
Core Functions:
The statements below reflect the opinion of RPSC South Pole
Science Support and would need to be validated by the Principle
Investigators for each experiment.



Due to the continuous nature of long term data sets, most to all
of the NOAA core functions are not available for load shedding.
Since the aurora based studies only take data during the polar
night, then some of their equipment may be available for load
shedding during the austral summer. This depends on the
calibration frequency of the instruments and maintenance
schedule for a given field season.
Since the SUV Network only takes data during the polar day,
then some of their equipment may be available for load
shedding during the austral winter. This depends on the
calibration frequency of the instruments and maintenance
schedule for a given field season.
2. AST/RO
This project is complete, and is not carried in the forecast.
3. MAPO
Summer Operations
Purpose: MAPO is used for science experiments in astronomy and
astrophysics. This science studies polarization phenomenon of the
Cosmic Microwave Background (CMB), Supernova and extragalactic high-energy neutrino point sources.
Its infrastructure provides for telescope towers/platforms & control
rooms, data acquisition systems and lab space. At present science
experiments inhabit the second floor while the support
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infrastructure is located on the first floor.
Users:
Science
The QUaD experiment utilizes the DASI telescope mount on which
rests the QUaD telescope, cryostat and receiver. The control room
and diagnostics lab are located on the east side of the second floor.
QUaD will observe all winter and as long into the summer as
possible depending on the prevailing atmospheric conditions.
The AMANDA experiment consists of over 600 optical modules on
19 vertical strings connected to a large data acquisition system
located on the west side of the second floor. AMANDA observes
24/7 for 365 days/year.
The RICE experiment consists of 4 strings of RF neutrino detectors
located on the upwind side of MAPO in the ice. A data acquisition
system is co-located within the large data acquisition system room
on the second floor.
Science Support Infrastructure
On the first floor MAPO houses the machine shop for the Dark
Sector and the Liquid
Nitrogen (LN2) plant. The machine shop contains equipment
capable of cutting, grinding, milling and general fabrication of raw
metal materials. The machine shop is used heavily in the austral
summer in support of all science and minimal station operations
assistance.
The LN2 plant produces approximately 100 liters/day of cryogenic
liquid for use in telescope cryostats and receiver calibration
purposes. Currently the LN2 plant runs 24/7 for 365 days/year. It
also serves as a supplemental heat source for the first floor of
MAPO.
Measured peak: 61.6 kVA
Building component – 7.6 kVA (assumes LN2 plant not operating
during measured peak)
Science component – QUaD + AMANDA + RICE = 10.0 + 10.0 +
0.9 = 20.9kW Peak Power (23.2 kVA)
Science Support component – Machine Shop + LN2 Plant = 5.0 +
26.0 = 31.0kW Peak Power (34.4 kVA)
Winter Operations
Purpose: Same as for summer operations.
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Users: Same as for summer operations.
Measured peak: 61.6 kVA
Building component – 7.6 kVA
Science component – QUaD + AMANDA + RICE = 10.0 + 10.0 +
0.9 = 20.9kW Peak Power
Science Support component – Machine Shop + LN2 Plant = 5.0 +
26.0 = 31.0kW Peak Power
Core Functions:
The statements below reflect the opinion of RPSC South Pole
Science Support and would need to be validated by the Principle
Investigators for each experiment.




AMANDA & RICE run continuously so would not be available for
load shedding without direct impact to the stated science goals.
QUaD undergoes a maintenance and calibration period during
the austral summer, so some of their equipment may be
available for load shedding.
The Machine Shop provides year-round but intermittent support
for science and station operations, so some of that equipment
may be available for load shedding.
The LN2 plant provides year round cryogenic nitrogen fluids to
science experiments. It would only be available for load
shedding if QUaD & BICEP were not in operation for periods in
the austral summer.
4. DSL / BISCEP
Summer Operations
Purpose: DSL is used for science experiments in astronomy and
astrophysics. This science studies polarization phenomenon of the
Cosmic Microwave Background (CMB) related to the primordial
gravitational wave signature, surveying galactic clusters and
addressing questions surrounding Dark Energy and Dark Matter.
Its infrastructure provides for telescope towers/platforms & control
rooms, data acquisition systems and lab space. At present one
science experiment inhabits the second floor with a second
occupant planned in the near future.
Users:
The BICEP experiment located on the east side of the second floor
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employs a telescope mount & cryostat/receiver system that is
operated by control electronics and connected to a data acquisition
system. This experiment will observe all winter and as long into the
summer as possible depending on the prevailing atmospheric
conditions.
Measured peak: 25.7 kVA
Building component – 14.6 kVA
Science component – BICEP = 10.0kW Peak Power (11.1 kVA)
Winter Operations
Purpose: Same as for summer operations.
Users: Same as for summer operations
Measured peak: 25.7kVA
Building component – 14.6 kVA
Science component – BICEP = 10.0kW Peak Power (11.1 kVA)
Core Functions:
The statements below reflect the opinion of RPSC South Pole
Science Support and would need to be validated by the Principle
Investigators for each experiment.

BICEP undergoes a maintenance and calibration period during
the austral summer, so some of their equipment may be
available for load shedding
5. B2 Science Wing
Summer Operations
Purpose: B2 Science Wing was designed to house a large portion
of the science experiments that transitioned out of SkyLab. These
experiments study space physics & space weather phenomenon
including precipitation of relativistic charged particles & magnetic
fluctuations resulting from interactions with the solar wind. This
science discipline collaborates with several satellite based efforts to
coordinate the overall studies of Sun-Earth connections. Many of
these experiments are part of a conjugate network of high latitude
science in both the Arctic and Antarctic.
Its infrastructure is comprised of lab space for instrumentation
diagnostics, optical viewing domes and a suite of rack mounted
data acquisition systems. Research Associates monitor these
systems and hence have dedicated workspaces in this area as
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well.
B2 currently has the only lab space that avails itself for wet
chemistry as it is equipped with a fume hood, compressed air/gas
outlets, running water taps & drains.
Seismic data acquisition systems and data storage control
computers for in support of astrophysics flank each side of the open
area designated as “Future Science”.
Users:
CUSP Science: This group of instruments is comprised of six
separate receiver antenna arrays that are electrically connected via
power & data cables from the CUSP antennae field. These
experiments operate 24/7 for 365 days/year.
Aurora Science: This group of experiments utilizes the optical
viewing domes during the austral winter of which there are three
hatch spaces currently occupied. These experiments take data
during the austral polar night ( Mar 21 to Sep 21)
The footprint of AMANDA previously located in the Back of Science
under the dome has transitioned to this wing. Included are several
computers for overall monitoring of the large data acquisition
system located in MAPO.
The SPRESO data acquisition system and display seismometers
are also located in this wing. This receives data and transmits
instruction to the remote seismic vault
In addition Meteorology data acquisition systems are located in this
wing in support of flight operations and various science
experiments.
Measured peak: 12.9 kVA
Building component – Further analysis required
Science component – CUSP + Aurora + AMANDA-B2 + SPRESO +
Meteorology
= 1.8 + 1.0 + 5.0 + 1.0 + 1.0 = 9.8 kW Peak Power (10.9
kVA)
Winter Operations
Purpose: Same as for summer operations.
Users: Same as for summer operations, except the AMANDA
footprint will be decreased to three winter-overs.
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Measured peak: 12.9 kVA
Building component – Further analysis required
Science component – CUSP + Aurora + AMANDA-B2 + SPRESO +
Meteorology
= 1.8 + 1.0 + 3.0 + 1.0 + 1.0 = 7.8kW Peak Power (10.9
kVA)
Core Functions:
The statements below reflect the opinion of RPSC South Pole
Science Support and would need to be validated by the Principle
Investigators for each experiment.





Due to the nature of the CUSP experiments long term data sets
they are probably not available for load shedding without
adversely impacting the stated science goals
Since the Aurora experiments only observe during the austral
polar night then some of their equipment may be available for
load shedding during the austral summer. This depends on the
calibration frequency of the instruments and maintenance
schedule for a given field season.
AMANDA runs continuously so would not be available for load
shedding without direct impact to the stated science goals
SPRESO runs continuously so would not be available for load
shedding without direct impact to the stated science goals
Meteorology instruments run continuously so would not be
available for load shedding without direct impact to the stated
science goals or flight operations during the austral summer
and/or winfly
6. Balloon Inflation Tower
Summer Operations
Purpose: The Balloon Inflation Tower houses the requisite
infrastructure to store, fill, and launch meteorological balloons for
science and station use.
Users:
Science
NOAA uses this facility to launch weather and other atmospheric
balloons.
Science Support Infrastructure
Equipment includes a helium filling station, weather balloons, and
SCBA compressor. Its infrastructure provides for storage space,
data acquisition systems, work space, and weather balloon filling
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space.
Measured peak: 6.1 kVA
Building component – 3.9 kVA
Science Support component - Radiosonde & data acquisition
system = 2kW Peak Power (2.2 kVA)
Winter Operations
Purpose: The Balloon Inflation Facility (BIF) houses the requisite
infrastructure to store, fill, and launch meteorological balloons for
science and station use. The use in the winter is the same as the
use in the summer.
Users: Same as for summer operations.
Measured peak: 6.1 kVA
Building component – 3.9 kVA
Science Support component – Radiosonde & data acquisition
system = 2kW Peak Power per RPSC estimate.
Core Functions:
This facility is used 24/7/365 and is not a candidate for shedding
consideration.
7. Cryogen Storage
Summer Operations
Purpose: The Cryogenics Facility is used to store liquid helium
(LHe) for use by the Astrophysical projects in the Dark Sector. The
facility also stores the requisite cryogenics equipment to house and
maintain the LHe supply. It is used to compress helium gas into
halfracks for Meteorology and NOAA use.
Users:
Science
None
Science Support Infrastructure
Equipment includes vacuum pumps, helium compressors,
refrigeration systems, and various sized storage dewars. Its
infrastructure provides for storage space, data acquisition systems,
work space, and lab space.
Measured peak: 45.0 kVA
Building component – Needs Further Analysis
Science Support component – 3 cold head refrigeration units @
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16kW per system + vacuum pump + helium compressor +
computer, power tools = 48 + 3 + 2 = 53kW Peak Power (58.9 kVA)
Winter Operations
Purpose: The Cryogenics Facility is used to store liquid helium
(LHe) for use by the Astrophysical projects in the Dark Sector. The
facility also stores the requisite cryogenics equipment to house and
maintain the LHe supply. Helium gas is not compressed into
halfracks for Meteorology and NOAA use in the winter.
Users: Same as for summer operations.
Measured peak: 45.0 kVA
Building component – Needs further analysis
Science Support component – 3 cold head refrigeration units @
16kW per system + vacuum pump + computer, power tools = 48 +
2 = 50kW Peak Power (58.9 kVA)
Core Functions:
During the transition year from the old Cryogenics Facility to the
new one the cold head refrigeration system will be shut down for a
period of time in the summer. At all other times the cold head
refrigeration system will operate 24/7/365.
8. SPRESO
Summer Operations
Purpose: The South Pole Remote Earth Seismic Observatory
(SPRESO) is the only component of the Global Seismic Network
located on the polar plateau. This site represents the quietest site
on earth at present in terms of relative background noise.
Users:
The Incorporated Research Institution for Seismology (IRIS) is the
main tenant of SPRESO site. The instrument suite consists of three
borehole seismometers and two surface seismometers.
There is also a CTBTO component with a surface seismometer that
sends data concurrent with the main SPRESO data steam.
Measured peak: 6.0 kVA
Building component – 5.1 kVA (Electric heat in vault)
Science component – SPRESO = 0.8kW Peak Power (.9 kVA)
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Winter Operations
Purpose: Same as for summer operations.
Users: Same as for summer operations
Measured peak: 6.0 kVA
Building component – 5.1 kVA (Electric heat in vault)
Science component – SPRESO = 0.8kW Peak Power
Core Functions:
The statements below reflect the opinion of RPSC South Pole
Science Support and would need to be validated by the Principle
Investigators for each experiment.

Due to the nature of the SPRESO experiments long term data
sets they are probably not available for load shedding without
adversely impacting the stated science goals
10. New Cryo (Future)
Summer Operations
Purpose: The Cryogenics Facility will be used to store liquid helium
(LHe) for use by the Astrophysical projects in the Dark Sector. The
facility will also store the requisite cryogenics equipment to house
and maintain the LHe supply. It will be used to compress helium
gas into halfracks for Meteorology and NOAA use. The liquid
nitrogen (LN2) plant will be housed in the Cryogenics Facility for
production of LN2 for science and station use.
Users: Science
Science Support Infrastructure
Equipment includes vacuum pumps, helium compressors,
refrigeration systems, LN2 plant, and various sized storage dewars
for LN2 and LHe. Its infrastructure provides for storage space, data
acquisition systems, work space, and lab space.
Measured peak: 108 kVA Based on RPSC updated and revised
projections
Building component – 20.2 kVA
Science Support component – 3 cold head refrigeration units @
16kW per system + vacuum pump + helium compressor +
computer, power tools + LN2 plant = 48 + 3 + 2 + 26= 79kW Peak
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Power (87.8 kVA)
Winter Operations
Purpose: The Cryogenics Facility will be used to store liquid helium
(LHe) for use by the Astrophysical projects in the Dark Sector. The
facility will also store the requisite cryogenics equipment to house
and maintain the LHe supply. The liquid nitrogen (LN2) plant will
be housed in the Cryogenics Facility for production of LN2 for
science and station use. Helium gas is not compressed into
halfracks for Meteorology and NOAA use in the winter.
Users: Same as for summer operations.
Measured peak: 108 kVA Based on RPSC projections
Building component – 20.2 kVA
Science Support component – 3 cold head refrigeration units @
16kW per system + vacuum pump + computer, power tools + LN2
plant = 48 + 2 +26 = 76kW Peak Power (87.8 kVA)
Core Functions:
During the transition year from the old Cryogenics Facility to the
new one the cold head refrigeration system will be shut down for a
period of time in the summer. At all other times the cold head
refrigeration system will operate 24/7/365.
12. SPT/DSL
Summer Operations
Purpose: DSL is used for science experiments in astronomy and
astrophysics. This science studies polarization phenomenon of the
Cosmic Microwave Background (CMB) related to the primordial
gravitational wave signature, surveying galactic clusters and
addressing questions surrounding Dark Energy and Dark Matter.
Its infrastructure provides for telescope towers/platforms & control
rooms, data acquisition systems and lab space. At present one
science experiment inhabits the second floor with a second
occupant planned in the near future.
Users:
The SPT experiment will be located on the west side of the building
and connected via a walkway to the telescope & control room
structure roughly 25m adjacent to the main building. Details of the
telescope, cryostat/receiver and control room electronics are in the
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final stages of development.
Projected peak: 112.0 kVA
Building component – Shown in DSL
Science component – SPT w/o power conditioner= 167.0 kW Peak
Power (185.6 kVA)
Science component – SPT with power conditioner = 101.0 kW Peak
Power (112.2 kVA)
Winter Operations
Purpose: Same as for summer operations.
Users: Same as for summer operations
Projected peak: 201.0 kVA
Building component – 34 kVA
Science component – SPT w/o power conditioner = 167.0 =
167.0kW Peak Power (185.6 kVA)
Science component – SPT with power conditioner = 101.0 =
101.0kW Peak Power (112.2 kVA)
Core Functions:
The statements below reflect the opinion of RPSC South Pole
Science Support and would need to be validated by the Principle
Investigators for each experiment.

SPT may undergo a maintenance and calibration period during
the austral summer, so some of their equipment may be
available for load shedding
15. NPP MCCA
Summer Operations
Purpose: The NPP “Motor Control Center A” is used for glycol
circulating pumps that cool power production generators and warm
the station heating loop. This panel is supplied from the Primary
Main Distribution Equipment (PMDE) feed. Pumps P-11A, P-3A, P1A, P-2A, P-3A, P-4A, P-10A, AC-1, and Air Handling Unit AHU-1
are powered from NPP MCCA. Pumps and air handler alternate
use with those powered by MCCB.
Users: MCCA is used year round by facilities operations for
producing heat and water for the station while cooling the
generators that provide station power.
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Measured peak: 22.4 kVA (April on-site power survey)
Winter Operations
Purpose: Winter operations are the same as summer operations.
The glycol circulating pumps powered by NPP “Motor Control
Center A” are in heavy use during winter operations to heat the
Elevated Station.
Users: Same as summer operations, although additional heat is
needed for the station during the winter.
Measured peak: 22.4 kVA (April on-site power survey)
Core Functions:
MCCA is critical to station operations and cannot be used for load
shedding.
16. Panel 0-103HA
Summer Operations
Purpose: The power plant houses equipment for year-round
power generation, power distribution, and water production and
storage for the station population. The area also serves as a hub
for data cables, a core network switch, CCTV cameras, the directdigital control (DDC) system, and temperature-sensitive equipment
storage. The Power Plant control room is staffed year-round, 24hours a day, 6 days a week, and covered by periodic checks on
Sundays and Holidays.
The loads on Panel 0-103 HA are pumps, lighting and other house
loads for the New Power Plant.
Users: Panel 0-103-HA is used by facilities operations to operate
the Power Plant and its systems.
Measured peak: 29.4 kVA (January on-site power survey)
Winter Operations
Purpose:
Summer and winter purpose is the same.
Users: Same as summer operations.
Measured peak: 30.5 kVA (April on-site power survey) --operations
load only.
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Core Functions:
Panel 0-103-HA is critical to station operations and cannot be used
for load shedding.
17. Elevated Station Pod A
Summer Operations
Purpose: Pod A of the Elevated Station has four wings. Wing A-1
has 49 berthing rooms (including a ward room) and bathrooms.
Wing A-2 contains the food preparation and service area, the
sauna, recycling room, SCBA lockers, and mechanical/utilities
rooms for the Pod. Wing A-3 has medical facilities, a computer lab
and office area, SCBA lockers, a laundry room, the food growth
chamber, the station store, comms and storage closets, and a quiet
reading lounge. Lastly, Wing A-4 has 66 berthing rooms and
bathrooms.
Users: Wing A-1 berthing rooms are slightly larger than standard
berthing rooms and are intended for habitation year-round.
Similarly, Wing A-2 is a year-round working area for food service,
sauna, and mechanical/utility systems. Four meals are served,
seven days a week (breakfast, lunch, dinner, midrats) to
accommodate a larger population and multiple shifts.
The
mechanical systems in A2 include a heating/cooling system and a
water tank for the station’s sprinkler system. These areas must be
maintained and monitored all year.
Wing A-3’s second floor
medical office and examination room is staffed year round by a
doctor and physician’s assistant. Medical inventory is kept on the
first floor. The medical facilities are critical loads all year. The
computer lab on the 2nd floor houses 24 public computers and
twelve semi-private cubicles, all of which are used in the summer
season. The laundry, the growth chamber, and quiet reading room
on the 1st floor of A-3 and are not considered critical. Wing A-4
summer berthing rooms and bathrooms will be used as needed.
Measured peak: 135.5 kVA (January on-site power survey, did not
include full operation of Wing A-4 as it was still under construction)
Winter Operations
Purpose: Pod A winter operations are the same as for summer,
except a smaller population is served, and Wing A-4 is not needed
for berthing nor bathrooms. Wing A-4 can be used as winter
storage area (and cooled) or left empty.
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Users: Wing A-1 is the primary winter berthing area as the rooms
are slightly larger for and more comfortable for the long dark night.
Wing A-2 harbors the food service area, the utilities, mechanical
systems, and the sauna. These facilities are utilized by everyone on
station throughout the year. Cooking volumes are reduced with
population and meal frequency: three meals served per day, six
days a week. Sundays the population eats left overs or volunteers
to cook meals. There is a moderate reduction in the use of cooking
equipment during the winter, and the sauna is not considered to be
critical, but the A-2 utilities and mechanical systems are. Wing A-3
medical has on-call staff 24/7 and regular day-time office hours.
The computer lab on the 2nd floor is used for winter offices and
public computer use, although 1/3 of the computers are shut off for
the winter. The medical facilities are critical loads all season. Parts
of the computer lab, the laundry, the greenhouse and the quiet
reading room in A-3 and are not considered critical loads.
Measured peak: 122.8 kVA (March on-site power survey). April
survey indicated a measured peak of 116.8 with the air handlers
running less. The average temperature of the A4 pod this winter is
45F.
Core Functions:
The kitchen equipment, heating and cooling equipment, sprinkler
system, A1 berthing, medical facility, and some loads in the
computer lab should not be used for load shedding. A4, sauna,
parts of the computer lab, laundry room, growth chamber, and the
quiet reading room are available for load shedding.
18. New Power Plant Panel 0-103HC
Summer Operations
Purpose: Panel 0-103 HC provides the power for the rapid-start
glycol heaters for the generators and is only used in emergencies.
Users: Panel 0-103-HC is used by Operations for the rapid start
glycol heaters on the generators.
Measured peak: 2.0 kVA -- This is an operations load and is only
used in an emergency.
Winter Operations
Purpose: Same as summer operations.
Users: Same as summer operations.
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Measured peak: 2.0 kVA -- This is an operations load and is only
used in an emergency.
Core Functions:
Panel 0-103-HC is critical to station operations and cannot be used
for load shedding.
20. RF Building
Summer Operations
Purpose: The Radio Frequency (RF) facility consists of a sheltered
antenna platform and a separate building housing equipment for
satellite communication systems, backup network systems, Iridium
links, HF radios and other data functions for the station. Three
satellites provide approximately 12 hours of coverage per day, but
satellite pass times change throughout the season.
Users: RF operations are maintained by the IT department for
satellite data sending and receiving of science, administrative, and
personal data. Backup network management, HF communications,
and Iridium links in the RF facility are also maintained by IT in
concert with primary systems located in the Elevated Station. On
the RF building feeder in the New Power Plant, there is also a load
for the Meteor Radar science project.
Measured peak: 31.1 kVA (April 29, 2006 on-site power survey)
This is an operations and science load.
The science load is 2.0 for the summer.
Winter Operations
Purpose: Similar to summer operations, the RF building is active
all winter and is used for satellite communications and other data
functions for the station. Winter load includes a slightly higher
science project load for the Meteor Radar.
Users: Same as Summer Operations.
Measured peak: 31.1 kVA (April on-site power survey)
This is an operations and science load.
The science load is 3.0 kVa for the winter.
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Core Functions:
The satellite data sending and receiving, network operations, and
HF communications are considered critical to the station and
should not be considered for load shedding.
21. NPP MCCB
Summer Operations
Purpose: The NPP “Motor Control Center B” is used for glycol
circulating pumps for cooling of the generators, and running
radiator fans and air handler. MCCB is supplied from the Primary
Main Distribution Equipment (PMDE) feed. Loads on NPP MCCB
include remote radiators RR-1, RR-2, RR-3, and RR-4, pumps P3B, P-4B, P-11B, P-9B, P-2B, and P-10B, and Air Handling Unit
AHU-2, and Boiler B-1.
The MCCB pumps and air handlers
alternate use with those powered by MCCA.
Users: MCCB is used by facility operations for both the primary
and backup system of removing the heat from the generators. The
glycol pumps, air handling unit, and boiler powered by MCCB
provide heat to the station.
Measured peak: 9.3 kVA (April on-site power survey)
Winter Operations
Purpose: Winter operations are the same as those listed above for
summer.
Users: MCCB winter and summer users are the same.
Measured peak: 9.3 kVA (April on-site power survey)
Core Functions:
MCCB is critical to station operations and cannot be used for load
shedding.
22. Building 101 Garage/Shops
Summer Operations
The Garage/Shops building is used for maintenance trades work
centers (carpentry, UT, plumbing, and electrical), a vehicle
maintenance facility, parts storage, and office space (2 offices).
The area also houses a mechanical area containing a 10,000
gallon pressurized water tank for fire suppression sprinkler system
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for the garage, a boiler for the garage, an electrical closet and a
communications closet. Early designs included plumbing (both
drainage in the VMF floor and a lavatory), but the existing facility
has none.
Users: The Garage/Shops are used by Operations for maintenance
of the station buildings and equipment, heavy and light vehicle fleet,
small machinery, and fueling operations. Staff include: VMF
Supervisor, Heavy Mechanics, Light Mechanics, General Assistant,
Work Order Scheduler, Maintenance Specialists, and some trades
staff.
Shops and equipment bays are used on 2 shifts and are in
operation 24 hrs/day, 6 days per week.
Measured peak: 39.5 kVA (on site data taken April 30, 2006)
Winter Operations
Similar to summer operations, the Garage/Shops building is used
for trades, station maintenance, and vehicle maintenance shops
and parts/equipment storage.
Users: The carpentry and electrical/plumbing shops become the
primary work centers for tradesmen on station. The UT shop is
fully staffed. The VMF is heavily used for major equipment work as
well as operational vehicle maintenance.
Shops and equipment bays are used 12 hrs/day, 6 days per week.
Measured peak: 39.5 kVA (on site data taken April 30, 2006)
Core Functions:
The Garage/Shops are considered task critical and can be used for
load shedding for short periods.
23. Rodwell Tunnel– Panel 0-103HB
Summer Operations
Purpose: Panel 0-103 HB provides power to the subsurface outfall
tunnel heat trace, lights and outlets as well as power for the
Rodriquez water well. Load on 0-103HB also includes heat trace
from the Rodwell to the summer camp head module.
For Rodwell operations, water is obtained from a subsurface ice
cavity of melted water that maintains it’s formation by constantly
circulating water using a 7.5 hp submersible pump at a rate of 25
gallons per minute from the well to a waste heat exchanger and
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back down into the cavity. A small percentage of the flow is
diverted before being heated to the station’s water storage facility in
the New Power Plant. The water that is not stored in the station is
heated using waste heat from the power plant and is returned to the
well to continue the melting process. The water circulation loop
from the 800 square foot mobile water well building to the power
plant is approximately 2900 ft away. The supply and return water
lines are enclosed within an insulated bond strand pipe with heat
trace. The water needs to be constantly circulated to prevent
freezing of the pipes and the water well. The well was designed for
a 150-person summer station and a 50-person winter station at a
daily consumption rate of 25 gallon per day. Strict water
conservation is a critical to the waterwell operation. The sevenyear design life of a well with the above parameters is shortened by
the increase in summer and winter population. The average power
load for the water supply system, sewer line heat trace, and the
limited tunnel lighting is 65 kW.
Users: Panel 0-103-HB is used by station operations for the water
production and distribution and sewer disposal.
Measured peak: 68.6 kVA (data taken April 28, 2006)
Winter Operations
Purpose: Same as Summer Operations: Provide power to the
subsurface outfall tunnel heat trace, lights and power, and generate
and distribute water to station inhabitants.
Users: Panel 0-103-HB is used by operations for the water and
sewer for the Elevated Station. Summer Camp heat trace and
water production is not included in winter operations.
Measured peak: 68.8 kVA (April on-site power survey)
Core Functions:
Panel 0-103-HB is critical to station operations and cannot be used
for load shedding. The waterwell, in particular, is a critical system
and has a high priority to maintain constant power. The well
system will start to freeze within 3 hours. Critical freeze protection
steps must be taken which include the complete drainage of both
the supply and return water lines and the manual lifting of the
submersible pump above the water level. The ambient temperature
is –50 F in the access hole. The volume of water within the cavity
is over 1.2 million gallons. The water temperature is 34 F. If the
system is not started up quickly, a layer of ice will form on the top of
the waters surface and will continue to grow in thickness. From
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experience, it is known that eight months after a shut down of the
well the ice lenses with be over 14 ft thick. Water will remain within
the center of the cavity and the well can be reactivated but
significant operations will be necessary to accomplish the task.
The emergency water supply system is a labor-intensive operation
and strict water conservations will be placed on the station.
24. Fuel Storage Facility (NPP CB 14)
Summer Operations
Purpose: The Fuel Storage Facility houses the station’s primary
fuel supply in 45 10,000-gallon steel tanks. The fuel distribution
piping system and pump house are also housed in the fuel arch.
The arch area is lit with incandescent and halogen bulbs, but the
lights are only used when someone is in the facility during daily
checks, maintenance, or filling/sounding tanks. These fuel arch
tanks are used to receive the fuel delivered by aircraft and for
supplying the station and equipment with fuel.
Users: The New Power Plant circuit breaker #14 provides the
power to the fuel storage facility for operations to deliver fuel to the
station generators, the vehicle fleet, boilers, and other fuel needs.
One of the two alternating pumps run constantly to circulate fuel
through the station fuel loop to maintain adequate pressure in the
system. Presently this feeder also carries the temporary load for
residual dome and old garage arch facilities.
Measured peak: 40.6 kVA (May 2nd on-site power survey after
dome and old garage arch loads were added; April 4 th on-site
power survey indicates that the fuel arch, alone, has a peak usage
of 14.02 kVA)
Winter Operations
Purpose: Same as summer operations, although no fuel is
received into the tanks.
Users: This is an operations load for distributing fuel to the station
and equipment. The two alternating pumps in the fuel arch run
constantly circulating fuel through the station fuel loop to maintain
adequate pressure in the system and prevent fuel from gelling is
extreme temperatures. Following a power outage on April 06 which
affected an Old Power Plant breaker, the feed from circuit breaker
14 in the New Power Plant was rewired to include dome lights, air
plenum return, old garage, OPP lights, as well as the fuel arch
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lights and pump house. Upcoming demolition project will eliminate
all loads except for the fuel arch pump house and lights.
Measured peak: 40.6 kVA (April on-site survey indicates 14.02
kVA for fuel arch loads, independently due to the temporary dome
wiring described above)
Core Functions:
The Fuels Arch is critical to Station Operations and should not be
considered for load shedding. The fuel pump house is electrically
heated to maintain minimal operating temperatures for pumping
equipment and DDC systems.
26. Cargo Arch (NPP Circuit Breaker 15)
Summer Operations
Purpose: The Cargo Arch load (NPP Circuit Breaker 15) is slated
for the future Logistics Facility in the area that is now called the Old
Garage Arch. This load is temporarily supplying power to the new
Cryogenics Facility, under construction, and the Balloon Inflation
Facility. This load currently is unrelated to the Cargo Office, which
is a separate outbuilding fed from building 68 (among the loads on
feeder 7 in the New Power Plant)
Users:
Schedule dependent.
Current use by construction,
science, met, and facilities does not reflect planned summer
operations.
Measured peak: 30.2 kVA (from March on-site power survey)
Winter Operations
Purpose: See summer purpose for explanation.
Users: The loads on this feeder are currently used by science and
meteorology for balloon inflation and data monitoring, facilities for
SCBA tank filling, and construction of the new cryogenics facility.
This load will change as construction schedules progress.
Measured peak: 30.2 kVA (from March on-site power survey)
Core Functions:
Currently, the BIF operations are critical to atmospheric science
projects and meteorology, but are not critical to station operations.
Construction activities are schedule dependent and are subject to
load shedding.
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30. Construction Loads
Summer Operations
Logistics Facility
Users: Construction of the new Logistics facility building will utilize
waste heat from the NPP as its primary heat source. Electrical
loads will be for blowers, hand tools, etc. utilized during the course
of normal construction.
Projected peak: 20 kVA (Estimated)
Winter Operations
Users: Winter and summer loads will vary depending on
components that are exposed to outside ambient conditions.
Projected peak: 60 kVa Estimated (not yet operational to measure)
Core Functions:
Once completed the facility will be the receiving station for all
materials arriving at and waste leaving the station. DNF materials
utilized by the entire station including science will be housed within
the facility.
31. Construction Loads
Summer Operations
Rodwell 3
Users: Rodwell 3 will be brought on line during the summer of
FY07. Rodwell 3 is required to run for almost 1 year before it
becomes the stations primary water source to ensure the bulb and
water capacity are adequate.
Load is operations only.
Construction of the facility will utilize portable generators therefore
no load on grid projected. Fuel for portable gens is in Ops fuel
projections.
Projected peak: (38.6 kVA Rodwell only, 69 kVA with piping heat
trace)
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Winter Operations
Users: Rodwell 3 load will remain constant during winter.
Projected peak: 38.6 kVA Rodwell Development only (69 kVA
with piping heat trace)
Core Functions:
The facility is entirely a core function as it will be the primary water
source for the station.
33. Construction Loads
Summer Operations
Purpose: Construction on platform for new satellite system.
Users: The SPTR 2 platform and antennae will be powered from
the RF building.
Construction will primarily utilize portable
generators. Construction load will be minimal after power is on
grid.
Projected peak: 10 kVA (Portable gensets)
Winter Operations
Users: Winter and summer loads will vary depending on
components that are exposed to outside ambient conditions.
Projected peak: 10 kVA (Portable gensets)
Core Functions:
This will be an operations core function
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Summer Load Forecast
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Summer Loads Notes
1 ARO 24-hr data taken 4-28-06 40.82 kVA max, 37.57 Av. Data taken 3-17 was 38.23 max kVA, 35.97 kVA av. Used data of 4-28
2 AST/RO loads off FY06 is original forecast.
3 Mapo 24 hr readings originally in error, measured only one of 2 feeders. New data taken 5-15 indicates 57.36 kVA av, 61.55 kVA peak.
N2 generator is moved to new cryo facility in FY07, assumed 15 kVA continuous and peak load reduction.
4 DSL 24-hr data originally taken 3-31-06. 30.92 kVA projected building only load per Carlton Walker spreadsheet. Science (VP) shows 5 kW av,
10 kW pk.
51 kW electric boiler is not included in estimate. Other loads must be locked out before energizing boiler, est to be less than 1% of time due to
wind direction.
Added the science loading beginning in FY07, using VP estimate of 5 kW av, 10 kW peak, per his 5-17-06 science load update.
5 24-hr readings taken on B-2 lab panels E107UPSC, 107LC, summed both. Data apparently missing. Science loads are 10.5 kVA summer &
winter per RPSC breakdown, 2.0 kW per Vlad spreadsheet. Changed spreadsheet to 12.9 kVA Pk, to include building, 12 kVA av est.
6 BIF data taken 4-2-06, close to previous. Assumed constant in out years.
7 Cryogen facility will be replaced with new. No update needed.
8 SPRESO loads per RPSC detail. Measured peak 6.0 kVA, 5.1 kVA bldg heat, .8 kW science power. Assumed av close to peak because
closed bldg.
9 SPASE II readings taken 3-28-06. Projected building load is 4.79 kVA per Carlton spreadsheet, Science is 5.5 kVA av, 7.7 kVA peak.
Advised during IceCube annual review that SPASE II will be turned off after FY07. Eliminated all loads after FY07, summer and winter 5-27-06.
10 New Cryogen facility data is based on RPSC projections of connected load, demand factor. Reduced 5-11 per Floyd Dial based on approved
change request 32CR009. FY06 data from amprobe 4-28-06
11 Ice Cube Lab data used "Estimated IceCube Power Requirements 2006-2011", dated 4-28-06, by Andrew Laundrie. Data was converted to
kVA by dividing
by 0.9. See linked spreadsheet "Ice Cube Basis" for data that was used.
Ice Cube feels the heat from electronics will heat the building. FY06 data taken 4-1-06, but this is a construction load.
12 New loads per VP 5-17-06 showing 72 kW av (80 kVA); 101 kW peak (112.2 kVA) using conditioner.
13 Bldg 61 hub data based on connected loads
14 Logistics facility assumes 20 kW construction load FY07 summer & winter; 60 kW FY08 and beyond for operation. DNF heaters causing
heavy load.
15 NPP MCCA data to be updated 5-3
16 NPP 0-103HA data taken 4-26-06 was used for winter, and data taken on 1-28-06 was used for summer.
17 Summer data taken 1-23-06 shows 72.3 kVA av, 84.47 Max. Winter Elevated station Pod B data was taken 3-16 at 109.6 kkVA pk, 81.8 kVA av
Used summer data as most representative for summer, and used winter data for winter forecasts.
18 Genset electric heaters converted to hydronic. Loads are only misc loads off panel. Data taken 3-5-06.
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19 Summer Pod A reading was 135.54 kVA pk, 100.54 kVA av on 1-26. Full operation of A-4 was not complete, so numbers increased 20 kW
per RPSC.
20 RF building data taken 4-29-06. Upgrades planned will take approximately the same power. Avery/Palo experiment fed from RF. Summer
down 1 kVA
Added 4 kVA to av and peak, starting FY09 per Kevin Culin email of 5-12 for SPTR2 modifications.
21 NPP MCCB data taken with 24 hr analyzer on 5-4-03.
22 Garage shops data taken 4-30-06; prior data 3-10-06 26.16 kVA av, 38 kVA peak.
23 Rodwell & tunnell heat trace 24-hr data taken 4-27-06 was 68.62 Max kVA, 64.76 kVA av. Prior data was 3-18-06, 47.45 kVA max, 43.19 kVA av.
Higher in April due to colder WX. Current RPSC av power load forecast is 65 kW. Assume PF=1 for incandescant lights and heat trace.
24 Fuel arch was rewired to NPP Fuel Arch Feeder, and dome lights, air plenum return, old garage, OPP lights, fuel arch. Construction coming
year will drop
all loads except for the fuel arch itself, so loads will reduce. Loads after FY07 assumed to return to original readings of 4-4-06. Current data
taken 5-2-06.
25 Summer camp loads for summer are estimated by Carlton Walker 5-3-06 email, at 286 kVA connected; 78.3 kVA projected average.
Peak estimated.
using 25% additional load, typical of housing units in main building. Carlton's average load is based on load over last few years. Rodwell
3 pipeline not included.
Eliminated all head bolt heater loads on 5-27 using the assumption that the equipment can run on idle to maintain heat when not in use,
since this will
reduce electrical load considerably. Assumed that cranes, vehicles, all equipment will have to be left running on Sunday to keep warm.
26 Cargo arch data taken 3-3-06. New data shows only cargo office, taken 4-13, reading 2.24 kVA max, 0.98 kVA av. Used data from 3-3-06.
Reduced cargo arch loads when Logistics goes on line so it is lights only.
27 Old power plant taken off line and cold, so no readings.
28 RPSC original estimated loads for construction.
29 Hard surface runway data per George Blaisdell, email 5-4. Assumed PF=1 for engine heaters, so kW=kVA.
30 RPSC original estimated loads for construction.
31 Rodwell #3 will be constructed during summer and winter, FY07. Load data per Floyd Dial, email of 5-4-06. Both Rodwell #2&3 will operate
for FY07.
32 RPSC original estimated loads for construction.
33 SPT load estimates taken from RPSC summer FY06 estimate, and projected to FY07.
34 RPSC original estimated loads for construction.
General All final values were adjusted upward by 10% for an estimating contingency, as discussed and agreed on 5-8-06 during power meeting.
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Winter Load Forecast
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Winter Loads Notes
1 ARO 24-hr data taken 4-28-06 40.82 kVA max, 37.57 Av. Data taken 3-17 was 38.23 max kVA, 35.97 kVA av. Used data of 4-28.
28 kVA electric heat/lights for building per Carlton Walker spreadsheet for operations loads only in building.
2 AST/RO loads off FY06 is original forecast, off line FY07.
3 Mapo 24 hr readings originally in error, measured only one of 2 feeders. New data taken 5-15 indicates 57.36 kVA av, 61.55 kVA peak.
FY07 drops N2 generator
N2 generator reported to take 15 kVA (13 kW) average according to email from VP dated 5-5-06.
4 DSL 24-hr data originally taken 3-31-06. 30.92 kVA projected building only load per Carlton Walker spreadsheet. Science (VP) shows 5 kW av,
10 kW pk.
5 24-hr readings taken on B-2 lab panels E107UPSC, 107LC, summed both. Data apparently missing. Science loads are 10.5 kVA summer &
winter per RPSC breakdown, 2.0 kW per Vlad spreadsheet. Changed spreadsheet to 12.9 kVA Pk, to include building, 12 kVA av est.
6 BIF data taken 4-2-06, close to previous. Assumed constant in out years.
7 Temprory Cryogen storage measured 4-28-06 with amprobe at 32.745 kVA. Estimated 45 kVA peak, since no 24 hour measurement.
8 SPRESO loads per RPSC detail. Measured peak 6.0 kVA, 5.1 kVA bldg heat, .8 kW science power. Assumed av close to peak because
closed bldg.
9 SPASE II readings taken 3-28-06. Projected building load is 4.79 kVA per Carlton spreadsheet, Science is 5.5 kVA av, 7.7 kVA peak.
Advised that
SPACE II will be turned off at the end of FY07 during IceCube Annual review, so eliminated loads FY08 and beyond, summer and winter.
10 New Cryogen facility data is based on RPSC projections of connected load, demand factor. Reduced 5-11 per Floyd Dial based on approved
change request 32CR009. FY06 data from amprobe 4-28-06
11 Ice Cube Lab data used "Estimated IceCube Power Requirements 2006-2011", dated 4-28-06, by Andrew Laundrie. Data was converted to
kVA by dividing by 0.9. See linked spreadsheet "Ice Cube Basis" for data that was used. Connected loads are not available, so are set to
peak load. Ice Cube feels the heat from electronics will heat the building. FY06 data taken 4-1-06, but this is a construction load.
12 New loads per VP 5-17-06 showing 72 kW av (80 kVA); 101 kW peak (112.2 kVA) using conditioner.
13 Bldg 61 hub data based on connected loads
14 Logistics facility assumes 20 kW construction load FY07 summer & winter; 60 kW FY08 and beyond for operation. DNF heaters causing heavy load.
15 NPP MCCA data to be updated 5-3
16 NPP 0-103HA data taken 4-26-06. Previous data, 23.3/29.12 taken 2-28-06; good coorelation.
17 Elevated station Pod B data shown is 4-22-06, 74 kVA max, 66.9 kVA av. Previous reading 3-16-06 was 109.6 kVA max, 81.77 av. RPSC
recommends using 3-16 data in email dated 5-15-06 from Floyd Dial, so this data was used.
18 Genset electric heaters converted to hydronic. Loads are only misc loads off panel. Data taken 3-5-06.
19 Pod A data taken 4-21-06, with AHU running less. Prior reading was 122 kVA max, 102 kVA av taken March 15, 2006. Higher peak recorded.
20 RF building data taken 4-29-06. Upgrades planned will take approximately the same power. Data from 3-7-06, 12/13 kVA, disregarded.
Winter sci=3 kVA.
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Added 4 kVA to av and peak, starting FY09 per Kevin Culin email of 5-12 for SPTR2 modifications.
21 NPP MCCB data taken with 24 hr analyzer on 5-4-03.
22 Garage shops data taken 4-30-06; prior data 3-10-06 26.16 kVA av, 38 kVA peak.
23 Rodwell & tunnell heat trace 24-hr data taken 4-27-06 was 68.62 Max kVA, 64.76 kVA av. Prior data was 3-18-06, 47.45 kVA max, 43.19 kVA av.
Higher in April due to colder WX
24 Fuel arch was rewired to NPP Fuel Arch Feeder, and dome lights, air plenum return, old garage, OPP lights, fuel arch. Construction coming
year will drop all loads except for the fuel arch itself, so loads will reduce. Loads after FY07 assumed to return to original readings of 4-4-06.
Current data taken 5-2-06
25 Summer camp data taken 4-25-06, and is summer camp only. RPSC concurs with estimate-see Floyd Dial email of 5-4-06.
Assume one of three cranes will be heated in prep for work during winter FY07-FY11 at 6 kW pk. Could have fuel oil fired heaters by
FY08 if approved.
26 Cargo arch data taken 3-3-06. New data shows only cargo office, taken 4-13, reading 2.24 kVA max, 0.98 kVA av. Used data from 3-3-06.
27 Old power plant taken off line and cold, so no readings.
28 Data taken from RPSC original estimate.
29 Hard surface runway data per George Blaisdell, email 5-4. Assumed PF=1 for engine heaters, so kW=kVA.
30 Data taken from RPSC original estimate. Assume logistics building is complete by winter of FY07.
31 Rodwell #3 will be constructed during summer and winter, FY07. Load data per Floyd Dial, email of 5-4-06. Both Rodwell #2&3 will operate
for FY07.
32 Data taken from RPSC original estimate.
33 Data taken from RPSC original estimate.
34 Data taken from RPSC original estimate.
35 TOSS 1&2 data taken with amprobe 4-5-06 Measured 14.9 kVA. Connected and peak are per Science Power Estimates for FY07. Loads PF=1.
General: All final values were adjusted upward by 10% for an estimating contingency, as discussed and agreed on 5-8-06 during power meeting.
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4.3
6/23/06
Impact Caused by Additional Loads
The additional power requirements to support the upcoming
science projects far outweigh the outgoing demolition power
reductions. These additional forecast loads have will exceed the
BOD operating capacity, and also exceed the capacity of the
generators. They will also exceed the winter over fuel capacity, and
they have exceeded the Dark Sector substation capacity.
Peak demand values exceed BOD generation capacity starting in
FY07, and will continue to exceed installed capacity through the
summer of FY11, the extent of the forecast timeframe. See chart 3
for the projected demand as compared to the BOD, the base load
generator unit, and the combined base load generator as well as
the peaking generator. The new power plant BOD stated “The
number and size of the generation units have been selected to
permit the loads to be properly supplied by the use of only one
generator unit the majority of the time.” The 1999 New Station
BOD assumed a demand load of 663 kW, while the current FY07
forecast demand load is in excess of 1,100 kW, almost twice the
design assumption.
Chart 3 - Projected Demand kW
Science Pk kW
Operations Pk kW
Constn Pk kW
1400
1200
84
15
29
29
584
584
35
989 kW
Max Capacity
584
750 kW
Max Base
Load Unit
663 kW
BOD Max
Demand
1000
Kilowatts
581
800
35
600
542
400
581
497
526
504
507
490
200
245
0
FY06
FY07
FY08
FY09
Fiscal Year
Final Report - Phase 1
FY10
FY11
Note: All numbers include a 10%
contingency
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4.4
6/23/06
Potential Solutions to Meeting Demand Load
Long Term
The power plant switchgear has been designed for a future
capacity of 1,500 kW (1,200 kVA) peak load. The peaking
generator, now at 239 kW, could be replaced with another base unit
sized genset, 750 kW, to increase peak load capacity to 1,500 kW,
or 1,200 kW average. This effort would require additional fuel
storage, an exhaust gas heat exchanger for the new unit (there is
no EGHX on the existing peaking generator) additional generator
room cooling, and other miscellaneous upgrades. The initial EIS
document has to also be reviewed to see if the permitted emissions
will allow the increased output in generation capacity.
Short Term
While it is physically possible to operate two base units in parallel to
generate up to 1500 kW, this is not recommended. The power
plant was designed with a double firm contingency approach, which
means that the largest generator has to be assumed to be down for
major maintenance, and the next largest unit must be on stand by,
leaving the remaining gensets available for power, which would be
one base unit and one peaker, for 989 kW. The plant has been
operating for 5 years now, and all of the base units are approaching
time for a major overhaul, which is a 2-3 week process. If the
station assumed it could operate two base units as an operating
mode, this would create a very high risk that power will not be
available since one base unit will be down for major overhaul, and
the others will be waiting for overhaul. Moreover, additional fuel
would be required to support the additional power generation,
additional cooling for the engine room will be needed, and other
detailed design assumptions would have to be examined.
Moreover, the EIS maximum emissions may be violated, so that
also needs to be examined.
Since operating two base units for an extended time is not
recommended, other recommendations include:
 Maximize the original design capacity of the power plant by
correcting the EGT problem.
 Implement energy saving recommendations outlined
elsewhere in the report.
 Implement the energy monitoring recommendation so power
forecasts can be made more accurate using more current
and detailed information.
 Begin funding and design efforts to expand the power plant
to a capacity of 1,500 kW.
 Begin funding and design efforts to double the size of the
fuel arch by designing and building a completely separate
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
5.0
6/23/06
fuel arch and pump house. This would be more prudent
than just adding additional fuel pods to the existing fuel arch,
since a fire, fuel leak, or major failure in the existing fuel arch
system could create an immediate station emergency.
Curtail any new or additional science projects until the
availability of fuel and power to support them is confirmed.
Fuel Issues
5.1
Fuel Arch Usable Fuel Capacity
The fuel arch storage tank gross measured capacity is 468,135
gallons. The design tank capacity is 450,000 gallons, but due to
variations in individual tank production, each tank has slightly larger
or smaller capacity, with the actual capacity furnished as a tank
calibration chart unique to each tank. In this case, the 45 tanks,
each with a nominal 10,000 gallon capacity, actually exceed the
design by approximately 4%. Tanks are typically filled to 95%
capacity, (the maximum legal tank fill amount to allow for
expansion) so fill capacity is 444,728 gallons. Suction tubes do not
get all the fuel out of the tank, so there are 10,299 gallons at the
bottom of the tanks, as reported by RPSC, or 2.2% not usable from
the bottom. Useable fuel arch capacity with the tanks filled to 95%,
and considering that 2.2% remains on the bottom, is therefore
433,626 gallons of AN-8 (cold volume is typically reported). Fuel is
metered when it is offloaded at the pole, and then distributed to any
of the fuel tanks in the arch or the surface tanks. The fuel tanks are
periodically measured to confirm volumes. This is the cold volume,
which is used for reporting fuel on hand, rather than adjusting the
volumes to API standard 60 degree F volume. Reporting cold fuel
volumes is done to avoid errors and maintain simplicity.
5.2
Above Ground Fuel Capacity
An additional 75,799 gallons of surface storage is available,
including all emergency cache tanks and building fuel tanks. At a
95% fill level to leave room for expansion, and unusable fuel at the
bottom of the tanks, the usable fuel storage capacity is 72,808
gallons. There are also about 3,000 gallons in fuel oil located in the
various Jamesway furnace tanks over each winter, which is not
included above, since it is only emergency fuel.
5.3
Station Opening/Emergency Fuel Allocation
Fuel reserve needed to support 4 weeks of normal summer
operations would be 70,000 gallons at 17,500 gallons per week.
5.4
Total Station Net Fuel Capacity
The total net fuel storage capacity for the station, counting the net
arch capacity and the net above ground capacity, excluding
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Jamesway tanks, is 506,434 gallons. Deduct the 70,000 gallon
station opening reserve, and the net fuel capacity is 436,434
gallons. This quantity is the amount of fuel that should be
considered available for winter over if all tanks are filled to 95% of
their capacity. For a 35 week winter period, this would allow a
weekly usage rate of 12,470 gallons per week.
Fuel Usage Calculation Tool
South Pole Annual Power Production
1,000,000
270
Note: South Pole will consume approximately 390,000 gallons
during FY06 to generate power.
260
250
900,000
240
230
220
210
200
190
700,000
180
170
600,000
160
150
140
500,000
130
120
110
400,000
100
90
300,000
80
500
600
700
800
900
1000
1100
1200
1300
1400
1500
Continuous Demand (kW)
During the first 5 weeks of the winter season in 2006, 57,624
gallons of fuel were used, for a weekly average consumption of
11,525 gallons per week. Assuming a 35 week winter period,
403,375 gallons of fuel would be required at that 5-week burn rate.
The FY06 winter started with a Sitrep reported quantity of 426,865
gallons of fuel on 2-25-06. The Sitrep does not report if this
quantity of fuel on hand is usable or gross volume stored, but it
appears to be the gross volume. Average power production during
the same 5 week reporting period was 664 kW, and the average
maximum demand was 787.8 kW. (The BOD average consumption
was 480 kW, and the maximum demand was supposed to be 663
kW.) This generation rate consumed 40,739 gallons of fuel, or
70.7% of the total fuel usage for that period. This represents an
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LC-130 Flights to Deliver
Fuel to Produce Power (gal)
800,000
National Science Foundation
2006 Report on South Pole Energy Issues & Recommendations
6/23/06
abnormally high generation fuel use due to station winter
preparation activities. If the assumptions of a 35 week winter, and
a required 70,000 gallon emergency storage capacity are correct,
the current station winter over power production is close to
maximum in terms of fuel storage capacity, without a 10%
suggested contingency.
5.5
Impact of Power Generation on Fuel
Power generation typically represents about 62% of the total fuel
forecast consumption at the station, followed by IceCube, building
heat, and equipment. See the pie chart depiction on Chart 4.
Chart 4 - FY 07 Fuel Usage Percentages
Special projects
0%
Other science direct
6%
Equipment operations (total)
9%
Ice Cube use
11%
Equipment operations (total)
Power Production
Aircraft fuel
2%
Building heat
Aircraft fuel
Building heat
10%
Ice Cube use
Other science direct
Special projects
Power Production
62%
The measured efficiency of the generator sets during the winter of
FY06 through the beginning of April has been 13.6 kWh/gallon of
cold fuel. Generator efficiencies improved during April because
only the base unit was operating, resulting in efficiencies around 14
kWH/Gallon. Using the average generation rate forecast in Table
1, “projected Electrical Power Requirements”, times the 13.6
kWh/gallon efficiency, gives the expected fuel consumption for the
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period. The projected average kW rates are shown pictorially on
chart 5, “Projected Average kW”, by fiscal year.
Chart 5 - Projected Average kW
Science Av kW
Operations Av kW
Constn Av kW
900
54
800
16
5
16
19
700 kW
Winter Fuel
Maximum
Capacity
700
14
434
KiloWatts
600
434
437
437
500
437
480 kW
BOD Average
Load
432
400
300
359
200
100
360
362
349
364
213
0
FY06
FY07
FY08
FY09
Fiscal Year
FY10
FY11
Note: All numbers include a 10% contingency factor.
Once the average kW rates are established, a projected fuel
consumption forecast can be made for any given time period. The
RPSC has projected the fuel needed for all functions. The updated
power average forecast was then inserted into the model and a
new projected fuel requirement was established. See chart 6 and
chart 7 for graphic projections of winter fuel requirements as
compared to capacity. Chart 6 shows storage amounts Vs
requirements, and chart 7 shows fuel use by application, with the
maximum net storage available. Both charts show that the existing
fuel storage cannot accommodate requirements over the winter.
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Chart 6 Fuel vs Capacity at Forecast
Average Generation Power with Winter Limitation
Available Winter
Over Fuel Less
Opening Reserve
is 436,434
Gallons
436,434
506,434
433,626
544,662
436,434
433,626
506,434
533,519
436,434
506,434
517,597
506,434
436,434
433,626
Gallons
400000
433,626
500000
547,325
600000
300000
200000
Winter fuel requirements
Available arch
Available Arch and AG
100000
Available less Opening Reqt
0
FY07
FY08
FY09
FY10
Fiscal Year
Chart 7 Winter Projected Fuel Requirements
600000
49,757
500000
48,502
47,054
Gallons - Winter Only
70,000
400000
0
38,329
70,000
0
45,457
49,515
70,000
70,000
0
42,677
0
51,917
Maximum
Winter Fuel Avail,
leaving 70,000 gallon
Fuel required counting
70k gallons opening
reserve, but no
contingency.
Contingency 10%
300000
Opening reserve
Special projects
Other science direct
200000
379,289
362,391
345,136
Ice Cube use
363,280
Aircraft fuel
Building heat
100000
Power Production
Equipment operations (total)
0
9950
9950
9950
9950
FY07
FY08
FY09
FY10
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Fiscal Year
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National Science Foundation
2006 Report on South Pole Energy Issues & Recommendations
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Total annual fuel requirements are also forecast. Again, RPSC
models were used to build this forecast, with the new projected
power generation average kW inserted. This forecast predicts fuel
requirements in excess of 800,000 gallons in FY07. See chart 8 for
the annual fuel requirements forecast.
Chart 8 Total Annual Fuel Requirements
1000000
883,244
900000
54,980
800000
745,14
6 480
700000
116,144
12120
Gallons
600000
500000
543,143
480
24,000
24055
118298
681,99
0
50000
4,980
92,800
17,280
86,974
95,744
779,663
480
103,200
18,000
84,527
785,45
0 480
788,090
0
92,800
92,800
12,860
10,180
Special projects
80,270
86,390
Other science direct
12520
Ice Cube use
94070
Aircraft fuel
Building heat
64446
Power Production
400000
Equipment operations (total)
551,738
300000
395,904
370,176
76450
102200
104500
FY04
FY05
FY06
500,756
526,340
528,020
79,473
72,700
72,700
70,700
FY07
FY08
FY09
FY10
353,712
200000
100000
0
Fiscal Year
6.0
5.6
Historical and Projected Fuel Flights
A comparison of the number of flights on continent vs. gallons of
fuel delivered at Pole can be viewed below.
5.7
Surface Transportation of Fuel
The South Pole Traverse is no longer funded and was cited to bring
cargo only. The operational phase of the traverse was recently
requested to be funded in FY07. New equipment needs to be
secured, so it will not be run in FY07.
Electrical Distribution
1,000,
000
500,0
00
F Y1 0
F Y0 7
0
A basic one-line of the power distribution system is shown on Sheets 1-4
below for an orientation of the generation and distribution system at the
Pole. Most of the feeders and transformers are adequately sized, except
as described below.
The present electrical power distribution capability to the South Pole Dark
Sector is inadequate to support all planned new science projects. The
major new planned and approved science projects are the South Pole
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Telescope and the Ice Cube Lab. The present Dark Sector electrical
distribution system (Elevated Substation, Building 61) can support a
maximum capacity of 300 kilo-volt amperes (kVA). Engineering
calculations indicate that, when the two new projects come on line, the
electrical demand will be on the order of 400 to 500 kVA. The station
presently can not properly accommodate that power to the Dark Sector
due to inadequate substation capacity. Without increasing the electrical
distribution capacity it is highly probable that the Dark Sector facilities will
experience undesirable voltage drops and power interruptions at peak
operating times. It is necessary to either increase the Dark Sector
substation from a capacity of 300 kVA to 500 kVA, or construct a new,
dedicated feeder from the NPP step-up transformer directly to DSL in
support of the SPT requirements, and to move the summer camp off the
feeder 9 system to assure an adequate power supply to the Dark Sector
science projects. Transformer taps will also need to be raised on the
480/600 volt transformers from Building 61 to ICL to avoid undesirable
voltage drops. See further discussion on the voltage drop study.
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6.1
Transformer and Substation Capacities
The current 300 kVA (270 kW) capacity at the Dark Sector has
experienced a maximum peak demand load of nearly 200 kW
without the projected new science loads, which total a combined
307 kW. Expanding Building 61 to allow for the placement of a new
500 KVA transformer will satisfy current and future electrical
demands, however voltage sags and disturbances from STP will
still create undesirable side effects on the balance of science in the
Dark Sector. See the voltage study below for further discussion.
6.2
Feeder Capacity Relative to Present and Planned Loads
As a result of the voltage study conducted and discussed below, all
feeder cables presently do not have adequate capacity for the
planned projects in the Dark Sector. The feeder from building 61 to
the ICL would have undesirable voltage drops if both ICL and STP
are fed from the existing medium voltage feeder from the NPP step
up transformer to building 61. See the voltage study below for
further discussion.
6.3
Proposed Feeder Demolitions
All existing feeders originating at the Old Power Plant distribution
switchgear are planned to be removed and either relocated to the
NPP PMDE/RMDE or demolished. Feeders 1 and 2 will be
demolished when the Dome is dismantled. See the South Pole
Utility Transition Plan for additional information.
6.4
Switchgear Capacities and Limitations
The capacity of the NPP PMDE/RMDE switchgear is 1,600 kVA
(1,494 kW) at 100% of the rating of the main breakers. This
capacity is adequate to handle the present generator configuration
unless more than two base unit size generators are operated under
full load.
6.5
Distribution One-Line Documents
Sheets 1-4 above depict simplified one-line diagrams of the
generation and distribution system at the Pole, including existing
and proposed power meters.
6.6
South Pole Telescope Voltage Drop Study
6.6.1 Overview:
The purpose of this study is to determine the voltage drop
impact caused by adding the South Pole Telescope and
IceCube loads to Feeder 9 of the South Pole Station’s power
distribution system. It is also the purpose of this study to
determine the voltage drop caused by load surges on the
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system created by the operation of the Telescope, as well as
the level to which those surges should be limited to prevent
disturbances to other equipment on Feeder 9. The study
includes existing system conditions on Feeder 9, the addition
of IceCube loads, the combined loads of IceCube and the
South Pole Telescope (SPT) to the feeder, the addition of a
new feeder from the existing medium voltage step up
transformer at the power plant to feed the Dark Sector Lab
and the new SPT, and a new separate isolated feeder from
the generator switchgear to the Dark Sector Lab (DSL) and
the SPT.
6.6.2 Methodology:
The voltage drop calculations were done utilizing a software
package called “SKM’s Powertools”. A simple one-line was
constructed within the program to model the existing Dark
Sector feeder power distribution system based on the
available site one-line diagrams and Raytheon Polar
Services Company (RPSC) field personnel input. The
devices modeled were selected to fit the design criteria and
used available modeling information within the SKM
standard library. Default settings for equipment were used
where specific information was not available. The load flow
study was run with the following settings: no source
impedance, exact solution, and connected loads.
6.6.3 Assumptions:
Existing Distribution System
The one-line constructed for the model represents the
Feeder 9 circuitry from the generator to the DSL. The Motor
Control Center at the DSL (MCC9-110A) represents the bus
furthest from the generator (the source) and therefore will be
used as a comparison point for subsequent studies. Loads
on Feeder 9 are based on the highest peak loads that have
been measured to date, which were projected for future
power requirements starting in FY07 and extending to FY11.
The load location shown on the one-line is based on the
station one-line diagrams and station personnel input. The
system power factor (PF) was set to .9, which is typical of
the measured site PF. Conductors are copper with standard
National Electric Code ampacities.
The transformer
impedances were set to 5.75% per RPSC, and taps were set
to 0% or no change to output voltage. These assumptions
carry over to all subsequent studies unless otherwise noted.
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IceCube
The load for IceCube was added to Feeder 9 at Panel 9-61C
located in Building 61 with the load being from Winter FY07
projected power requirements.
Voltage drop discussed
under the conclusions for IceCube requires that all
transformers on Feeder 9 up to Building 61 be changed to
boost output voltage by 2.5% to prevent the voltage at
Building 61 from being unacceptably low. This tap setting is
available on all transformers and all later studies will
incorporate this change.
Ice Cube and SPT
The SPT load is based on information provided by Steve
Padin with the University of Chicago and has been modeled
as a 67 kW base load with surge loads to 167 kW peak. In
order to keep voltage drops to within industry standards a
power conditioner is required to be used on the SPT to limit
the surge peaks loads to 101 kW with a base load of 72 kW.
The SPT’s proposed connection point is on MCC9-110A
located in the DSL. As noted above, all transformer taps
have been set to have a 2.5% boost to the output voltage.
This study looked at surge loads increasing in 10KW steps
from the base load of the SPT up to the maximum rated
power to determine the allowable surge on the system. The
situation where a power conditioner was utilized to reduce
the peak surges was also simulated at in 10 kW steps from
the base load of 72 kW to the peak load of 101 kW.
New Feeder from Existing Medium Voltage Transformer to
DSL and SPT
Due to the large voltage drops on Feeder 9 with the new
SPT added, a new 4160/480V, 300 kVA low impedance
transformer (Z = 3%), and taps set at 0% taps should be
used to separately feed the existing DSL and SPT loads. A
new 4,200 foot, #6 AWG, 4,160 Volt, three phase feeder
should be tapped at the existing medium voltage switchgear
on the secondary side of the existing 480/4160V, 500 kVA
transformer located in the Power Plant. This new proposed
feeder will feed the new 300 kVA transformer for the DSL
once the load from summer camp is removed from the step
up transformer and switchgear. The existing 600 volt feeder
that connects the DSL to Building 61 is proposed to be
disconnected and abandoned in place. Voltage drops on the
new feeder due to the base load up to the maximum kW
surge load of the SPT were evaluated in 10 kW steps for
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both the non-conditioned (67-167 kW) and conditioned (72101 kW) scenerios.
New Feeder From the Generator to DSL and SPT with New
Step Up Transformer
Steps of 10KW at the SPT for both the conditioned and nonconditioned situations were also modeled on a new feeder
for the DSL and SPT using a new step-up transformer. The
new feeder consists of a new step up 480/4160V, 500KVA
low impedance transformer (Z = 3%). Then a 4200 foot run
of #4 AWG medium voltage copper conductors to a step
down 4160/480V, 500KVA low impedance transformer that
feeds directly into MCC9-110A. New transformer taps have
been left at 0%. The existing feeder that connects DSL to
building 61 is to be disconnected so that DSL and the SPT
are electrically isolated from the rest of feeder 9.
6.6.4 Conclusion:
Existing Distribution System
The furthest busses from the source are the panel 9-61C in
building 61 and MCC9-110A in DSL.
Based on the
assumptions on existing loads, equipment, and distances
discussed above, the voltage drop at panel 9-61C is 3.56%
and on MCC9-110A is 4.69% before any planned new loads
are added. See Table 11 for voltage drops in the existing
distribution system with the existing loads for feeder 9 and
proposed changes to feeder 9.
IceCube
With the addition of IceCube on the system at panel 9-61C
the voltage drop at MCC9-110A jumps to 13.37% (see Table
11), well above standards. To counter this 8.68% (see Table
11) jump in voltage drop from existing, it was determined
that setting each transformer’s tap to provide a 2.5% boost
to output voltage would reduce the voltage drop on MCC9110A to 3.39% (see Table 11). This is enough to
accommodate the addition of only the IceCube load. Any
additional changes made within this study assume that all
existing transformer taps have been changed to 2.5%
boosting voltage to account for the IceCube load.
IceCube and SPT
Table 1 shows the voltage drops at the telescope bus for
various loads without the use of a power conditioner to lower
peak load. The first row explains what the telescope bus
voltage drop would be with no load and it shows that the
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system is within accepted industry standards (below 5%).
Adding the constant 67kW load of the SPT will increase the
voltage drop at the bus by 7.99% creating an unstable
situation. The peak rated load of the SPT is 167KW causing
a 24.19% voltage drop at the telescope. This peak load has
now been reduced to 101kW with a conditioner.
TABLE 1
DSL/SPT WITH NO CHANGE OR CONDITIONER
VOLTAGE DROP AT SPT
LOAD
VOLTAGE DROP
VOLTAGE DROP
(KW)
(%)
(Delta %)
0 (No Load)
3.39%
0.00%
67 (Base)
11.38%
7.99%
77 (10 Surge)
12.61%
9.22%
87 (20 Surge)
13.85%
10.46%
97 (30 Surge)
15.10%
11.71%
107 (40 Surge)
16.36%
12.97%
117 (50 Surge)
17.63%
14.24%
127 (60 Surge)
18.92%
15.53%
137 (70 Surge)
20.22%
16.83%
147 (80 Surge)
21.53%
18.14%
157 (90 Surge)
22.85%
19.46%
167 (100 Surge)
24.19%
20.80%
Column 1 in Table 1 represents the various loads for SPT.
Column 2 is the actual voltage drop at the SPT bus in
percentage. Column 3 is the change in voltage drop from a
no load condition in percentage. For example when the load
is 147KW the voltage drop increased 18.14% from the no
load condition (3.39%) and is now 21.53%.
Table 2 uses the same operating parameters with the
addition of the power conditioner, which places the constant
KW load of the SPT at 72KW and a peak of 101KW. The
addition of the power conditioner does not allow for the
running of the SPT within appropriate voltage drop
conditions.
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TABLE 2
DSL/SPT NO CHANGE, WITH CONDITIONER
VOLTAGE DROP AT SPT
LOAD
VOLTAGE DROP
VOLTAGE DROP
(KW)
(%)
(Delta %)
72 (base)
11.99%
8.60%
82 (10 Surge)
13.22%
9.83%
92 (20 Surge)
14.47%
11.08%
101 (30 Surge)
15.60%
12.21%
The columns in Table 2 represent the same data as that
presented in Table 1 except with a power conditioner limiting
the peak KW for the SPT. Note that the no load condition for
this table is referenced from Table 1.
The conditions at IceCube are also affected by the addition
of the SPT. Table 3 and 4 are the voltage drops at the bus
feeding IceCube under the same SPT loads.
TABLE 3
SPT/DSL ON FEEDER 9, NO CONDITIONER
IMPACT OF SPT/DSL ON ICECUBE
LOAD
VOLTAGE DROP
VOLTAGE DROP
(KW)
(%)
(Delta %)
0 (No Load)
4.61%
0.00%
67 (base)
9.28%
4.67%
77 (10 Surge)
10.01%
5.40%
87 (20 Surge)
10.75%
6.14%
97 (30 Surge)
11.49%
6.88%
107 (40 Surge)
12.25%
7.64%
117 (50 Surge)
13.01%
8.40%
127 (60 Surge)
13.79%
9.18%
137 (70 Surge)
14.57%
9.96%
147 (80 Surge)
15.37%
10.76%
157 (90 Surge)
16.17%
11.56%
167 (100 Surge)
16.99%
12.38%
Column 1 in Table 3 represents the various loads for SPT.
Column 2 is the actual voltage drop at the IceCube bus in
percentage. Column 3 is the change in voltage drop from a
no load condition in percentage. For example when the load
is 147KW the voltage drop increased 10.76% from the no
load condition (4.61%) and is now 15.37%
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TABLE 4
SPT/DSL ON FEEDER 9 WITH CONDITIONER
IMPACT OF SPT/DSL ON ICECUBE
LOAD
VOLTAGE DROP
VOLTAGE DROP
(KW)
(%)
(Delta %)
72 (base)
9.64%
5.03%
82 (10 Surge)
10.38%
5.77%
92 (20 Surge)
11.12%
6.51%
101 (30 Surge)
11.79%
7.18%
The columns in Table 4 represent the same data as that
presented in Table 3 except with a power conditioner limiting
the peak KW for the SPT. Note that the no load condition for
this table is referenced from Table 3.
New Feeder from Existing Medium Voltage Transformer to
DSL and SPT
Moving SPT and DSL to a higher voltage feeder reduces the
amount of voltage drop and reduces its impact on other
loads on feeder 9. The voltage drop at every load peak
(Table 5) for the SPT is shown to be significantly smaller
than with it at the end of feeder 9 as shown on Table 1. With
a power conditioner (Table 6) all peak loads are below
industry standards
TABLE 5
NO SUMMER CAMP, NO CONDITIONER, SPT/DSL ON MEDIUM
VOLTAGE TRANSFORMER AT SPT
LOAD
VOLTAGE DROP
VOLTAGE DROP
(KW)
(%)
(Delta %)
0 (No Load)
0.23%
0.00%
67 (base)
2.56%
2.33%
77 (10 Surge)
2.91%
2.68%
87 (20 Surge)
3.26%
3.03%
97 (30 Surge)
3.61%
3.38%
107 (40 Surge)
3.96%
3.73%
117 (50 Surge)
4.31%
4.08%
127 (60 Surge)
4.66%
4.43%
137 (70 Surge)
5.01%
4.78%
147 (80 Surge)
5.36%
5.13%
157 (90 Surge)
5.71%
5.48%
167 (100 Surge)
6.06%
5.83%
Column 1 in Table 5 represents the various loads for SPT.
Column 2 is the actual voltage drop at the SPT bus in
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percentage. 3 is the change in voltage drop from a no load
condition in percentage. For example when the load is
147KW the voltage drop increased 5.13% from the no load
condition (0.23%) and is now 5.36%
TABLE 6
NO SUMMER CAMP, WITH CONDITIONER, SPT/DSL ON MEDIUM
VOLTAGE TRANSFORMER AT TELESCOPE
LOAD
VOLTAGE DROP
VOLTAGE DROP
(KW)
(%)
(Delta %)
72 (base)
2.74%
2.51%
82 (10 Surge)
3.08%
2.85%
92 (20 Surge)
3.43%
3.20%
101 (30 Surge)
3.75%
3.52%
The columns in Table 6 represent the same data as that
presented in Table 5 except with a power conditioner limiting
the peak KW for the SPT. Note that the no load condition for
this table is referenced from Table 5.
Tables 7 and 8 represent the impact on IceCube at the
various loads produced at the SPT. Comparing them to
Tables 3 and 4 there is a significant gain in moving the
DSL/SPT to a new medium voltage feeder.
TABLE 7
NO SUMMER CAMP, NO CONDITIONER, SPT/DSL ON MEDIUM
VOLTAGE TRANSFORMER IMPACT ON ICECUBE
LOAD
VOLTAGE DROP
VOLTAGE DROP
(KW)
(%)
(Delta %)
0 (No Load)
2.11%
0.00%
67 (Constant)
2.85%
0.74%
77 (10 Surge)
2.96%
0.85%
87 (20 Surge)
3.07%
0.96%
97 (30 Surge)
3.18%
1.07%
107 (40 Surge)
3.29%
1.18%
117 (50 Surge)
3.40%
1.29%
127 (60 Surge)
3.52%
1.41%
137 (70 Surge)
3.63%
1.52%
147 (80 Surge)
3.74%
1.63%
157 (90 Surge)
3.86%
1.75%
167 (100 Surge)
3.97%
1.86%
Column 1 in Table 7 represents the various loads for SPT.
Column 2 is the actual voltage drop at the IceCube bus in
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percentage. Column 3 is the change in voltage drop from a
no load condition in percentage. For example when the load
is 147KW the voltage drop increased 1.63% from the no load
condition (2.11%) and is now 3.74%
TABLE 8
NO SUMMER CAMP, WITH CONDITIONER, SPT/DSL ON MEDIUM
VOLTAGE TRANSFORMER IMPACT ON ICECUBE
LOAD
VOLTAGE DROP
VOLTAGE DROP
(KW)
(%)
(Delta %)
72 (Constant)
2.90%
0.79%
82 (10 Surge)
3.01%
0.90%
92 (20 Surge)
3.12%
1.01%
101 (30 Surge)
3.23%
1.12%
The columns in Table 8 represent the same data as that
presented in Table 7 except with a power conditioner limiting
the peak KW for the SPT. Note that the no load condition for
this table is referenced from Table 7.
Moving the SPT and DSL to a new medium voltage tap from
feeder 9 meets industry standards it does not take in to
account very much room for growth on either DSL or building
61.
TABLE 9
NEW FEEDER FROM GENERATOR TO DSL/SPT, NO CONDITIONER
AT SPT
LOAD
VOLTAGE DROP
VOLTAGE DROP
(KW)
(%)
(Delta %)
0 (No Load)
0.47%
0.00%
67 (0 Surge)
1.96%
1.49%
77 (10 Surge)
2.18%
1.71%
87 (20 Surge)
2.40%
1.93%
97 (30 Surge)
2.62%
2.15%
107 (40 Surge)
2.84%
2.37%
117 (50 Surge)
3.07%
2.60%
127 (60 Surge)
3.29%
2.82%
137 (70 Surge)
3.51%
3.04%
147 (80 Surge)
3.73%
3.26%
157 (90 Surge)
3.96%
3.49%
167 (100 Surge)
4.18%
3.71%
Column 1 in Table 9 represents the various loads for SPT.
Column 2 is the actual voltage drop at the SPT bus in
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percentage. Column 3 is the change in voltage drop from a
no load condition in percentage. For example when the load
is 147KW the voltage drop increased 3.26% from the no load
condition (0.47%) and is now 3.73%
TABLE 10
NEW FEEDER FROM GENERATOR TO DSL/SPT, WITH
CONDITIONER AT SPT
LOAD
VOLTAGE DROP
VOLTAGE DROP
(KW)
(%)
(Delta %)
72 (0 Surge)
2.07%
1.60%
82 (10 Surge)
2.29%
1.82%
92 (20 Surge)
2.51%
2.04%
101 (30 Surge)
2.71%
2.24%
The columns in Table 10 represent the same data as that
presented in Table 9 except with a power conditioner limiting
the peak KW for the SPT. Note that the no load condition for
this table is referenced from Table 9.
6.6.5 Recommendations:
Based on the studies previously discussed the following
recommendations are suggested for the Dark Sector power
infrastructure:




Set all transformer taps in feeder 9 to boost output
voltage by 2.5% to accommodate the IceCube project.
Remove the summer camp from the existing 480/4160V,
500KVA NPP step up transformer.
Provide a new 4,200 ft. run of #4 AWG medium voltage
conductors connected to the existing 480/4160V step up
transformer at the NPP, and a new 4160/480V, 300KVA
low impedance high efficiency step down transformer at
DSL to feed the DSL and SPT projects.
Require that the SPT project provide a power conditioner
that will limit recurring surges to 20 kW or less. This level
miminizes the possibility of concurrent surges from both
SPT and other heavy loads, such as the kitchen electric
cooking equipment, from taking the generators off line if
they are functioning at a very high load. The 20 kW
surge limit also reduces the potential amount of wear or
damage on the generator torsional couplings, windings,
insulation, and other components.
The above recommendations will allow the use of the
existing NPP transformer equipment, provides a margin of
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isolation for the other equipment on feeder 9, and provides
for some growth at both building 61 and at the DSL.
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7.0 Controls on Future Loads
7.1
Science Project Energy Use Analysis
In order to best manage South Pole Facilities and provide for
science support excellence, it is imperative that all entities; NSF,
Science, and RPSC FEMC, work collaboratively on decisions
henceforth. Annual review of the Strategic Master Plan for South
Pole Energy should be completed with NSF Engineering,
Operations, and Science ABM’s and RPSC FEMC within 2 weeks
of submission to NSF from RPSC. Until this review is complete, no
decisions on additional projects should be made in order to
minimize confusion between science support capabilities and
power grid capabilities at that time.
Existing science projects that expire in FY06 but have requested
extensions that have not yet been approved should be reviewed in
terms of energy supportability.
Pending science projects that have not yet been approved also
need to be reviewed in terms of energy supportability. Examples
are:








Super Darn – estimated 9.5 kVA connected, 6.3 kVA demand
Inan – no estimate
Besson – no estimate
Palo-no estimate
Anandakrisan – South Pole stopover only, no declared reqts
Sterns –no estimate
Albert-no estimate
Taylor-no estimate
Prior to any projects being approved for deployment at South Pole,
all parties (NSF operations and science ABM’s for Pole and RPSC
FEMC) need to review project impact and sign documentation
affirming support. Early and accurate reporting of planned power
usage by Science will be instrumental in deciding what projects are
supportable. The current form used in the SIP reports does not
address the entire electrical information needed for proper power
management of the station. This form needs to be changed to
address the needs of Station Facilities Management, and will
require that they are filled out accurately. Actual power monitoring
of science mock-up projects provide the best confirmation of
forecast load levels.
A formal process needs to be created for incoming science projects
to report, date, and document intended power usage. Any changes
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to the initial plan need to be reviewed by RPSC and documented
for future reference.
The science energy budget will be derived from known actual
science power requirements, including projected new science
projects that are already approved by NSF. Power and fuel
capacity constraints will be considered in the energy budget.
7.1.1 Energy Conservation Buy-In with Science
Gain consensus of known constituents.
A group called Scientific Coordination Office for
Astrophysical Research in Antarctica (SCOARA) will
prioritize power allotment to the various science projects. A
scheduled meeting needs to take place upon presentation of
the Strategic Master Plan where details can be discussed
and debated. This will allow for all involved parties to be the
proverbial same page and understand their responsibilities
to make this plan a success. NSF (Jerry Marty) and RPSC
(Steve Kottmeire) will act as part of the new ABM "ops
review" assignment, which will include the following:
1. Prepare a checklist for all future science project
supportability, which will include power requirements, and
will establish the distribution of data for input into
forecasting.
2. Prepare a summary chart of all South Pole science
projects and grant expiration dates. This chart will also
include currently obtained experiment specific power
electrical demands and original SIP power projections.
7.1.2 Standardized Energy Use Project Guidelines
All prospective users should fill out the Science Power
Profile equipment data worksheet (available from RPSC
Electrical Engineer) with the most complete and accurate
information available at the time of making application for
project approval to the NSF. Load data presented in the
user profile will be utilized for the determination of
supportability.
7.1.3 Population Control
The population at the station is limited, and must be tightly
controlled since each additional person uses power, water,
food, and further consumes available energy in addition to
limited bed space. It is estimated that each person at the
Pole requires 1.5 to 2.0 kW of power just for personal needs,
including cooking, hot water, lights, PC power, etc. The
population of the station is expected to reduce to the original
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design limit of 153 people with the completion of
construction, as shown on the attached population graph.
South Pole
Total Population
* New Station Completed
300
250
248
245
245
245
245
245
245
FY05
FY06
FY07
FY08
FY09
FY10*
FY11
FY12
250
200
150
100
8.0
Electrical Generation Issues
8.1
Generator Output Capacity
The NPP BOD final submittal, dated January 31, 1997 is used as a
basis for design assumptions. The BOD states that the prime rating
of the base load engine-generator set (genset) is 797 kW and the
bid specifications reduced that rating to 750 kW at 12,000’ elevation
to make it generic so other vendors could bid, as confirmed with
Steve Theno, of PDC, the design engineer. The ratings assume a
power factor of 0.80, using AN-8 fuel. The peaking generator that
was installed is prime rated for 239 kW at the station, whereas the
BOD anticipated a 330 kW genset at sea level.
The prime rating is defined by Caterpillar as: “Prime power – output
available for peak demand of a variable electric load including peak
shaving and programmed outages. The average demand during
any 24-hour period should not exceed the corresponding industrial
engine continuous rating. All prime power ratings, except D series,
have 10% overload for emergency use.” The continuous rating is
the load that can be sustained continuously on the genset, and it is
typically about 20% less than the prime rating according to
Caterpiller mechanic Rick Abrams. With this understanding, the
prime rating of the base load plus the peaker is 989 kW at 0.8 PF,
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and the continuous rating is around 80% of that. We have,
however, shown the power plant capacity at 939 kW until the
exhaust gas temperature problems are resolved.
Peaking generator (PG): A peaking generator was provided to start
and share load with the base generator unit when the station load
exceeds preset levels. According to the NPP BOD, when power
requirements exceed 90% of the capacity of the single unit for 15
minutes or 95% of the rating for 5 minutes, the peaking unit is
started, warmed up and brought on line to increase power
availability and stability. If the power requirements drop below and
remain below 85% of the larger unit’s rating for longer than 15
minutes or drop below 75% of its rating for 5 minutes, the peaking
unit will be removed from the buss, cooled down and shut off.
8.2
Actual De-Rated Site Capacity
The actual site generation design prime rated capacity, after the
equipment is de-rated for fuel and altitude, is 750 kW for the base
loaded units and 239 kW for the peaking both prime ratings.
Remedial work is on-going to be able to produce this level of power
without destroying the equipment, as discussed below. For this
reason, the assumed capacity of the power plant at present is taken
at 939 kW instead of the published 989 kW.
8.3
Limiting Electrical Production Factors
8.3.1 Site Elevation
The manufacturer has de-rated the generator set from sea
level to a physiological altitude of 12,000 feet to account for
worse case barometric fluctuations at the Pole.
8.3.2 Fuel Energy Values
The rating of the engine generators took into account the
energy value for the fuel being used, AN-8, when they derated the set from sea level to the application at the Pole.
The AN-8 fuel has an API degree of 43.5 at 60 degrees F.
When compared to the Caterpillar baseline, #2 diesel,
Caterpillar requires their engines to be de-rated by 0.7% per
API degree above the basis of 35. Therefore, the generators
should have been de-rated by 6% to reflect the difference in
the API degree. PDC Engineering has confirmed that the
fuel duration has been taken into account to establish the
989 kW prime ratings.
8.3.3 Exhaust Gas Temperature (EGT)
High exhaust gas temperature readings are limiting the
output of the gensets. Up until May 2006, the base unit
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gensets were reaching high EGT levels at loads of around
700 kW, depending on the genset. This was limiting the
practical continuous capacity of the power plant from 989 kW
to 939 kW. While the engines could run hotter for a short
time, continuous operation at or above 1140 degrees EGT
will further degrade the engines and cause permanent
damage. Further considerations are:
Final Report - Phase 1

According to the BOD, EGTs entering the exhaust
gas heat exchanger (EGHX) were forecast to be
1,054 degrees F at 797 kW, and 1024 degrees at 717
kW. Actual operating EGT temperatures are about
200 degrees higher than predicted, in the 1200 to
1250 degree range at and below full load, depending
on the genset. Typical gensets at close to sea level
have EGT readings of 750-900 degrees. Caterpillar
recommends that sustained operation of the engine
should not occur with the EGT readings above 1140
degrees F, and the high EGT temperature alarm on
the switchgear is 1342 degrees F. Operation of the
engines at elevated EGT levels will cause the valves
to anneal into the cylinder heads, causing damage to
the valves, valve seats, turbos, and the cylinder
heads. As the valves seat into the heads, the EGT
temperatures will rise even more, as was observed by
RPSC. The interim fix has been to do top end service
with valve adjustments each 500 hours instead of
each 1,000 hours as recommended by CAT. If
nothing is done to correct the problem, adjustments
will become impossible due to the lack of additional
adjustment range of the rocker arms. Also, there is
no thermocouple on the peaking generator, so EGT
practical maximum levels may also be exceeded on
the peaking generator. It is essential to furnish EGT
thermocouples on all engines so this critical
parameter can be monitored.

Design calculations show that the engine exhaust
backpressure should be 10.35 inches of H2O, and the
manufacturer has a maximum pressure limit of 27
inches of H2O. If the backpressure is excessive, than
this would increase the EGT as seen. The
backpressure was measured on site, and that data
indicated backpressures to be very low, 3” to 4” WC,
which is well below expected values.
Typical
backpressure values at sea level are 15-18” WC, but
never less than 10” WC. It is recommended that
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permanent Caterpillar backpressure gauges be
installed in each of the exhaust pipes so that the
backpressure can be validated and monitored. This
will be an indication of soot or blockage in the exhaust
gas heat exchangers.

RPSC has proposed the installation of a separate
ducting system for the engine combustion air, with a
mixing arrangement to temper the combustion air to 0
degrees F. This would also make the air richer in
oxygen, and will provide more power to the engine.
For every 1 degree F. drop in engine inlet air, we
should expect to see a 3-degree drop in EGT
according to CAT. With this reasoning, if the engine
room is presently operating at 80 degrees F and we
duct the engine inlet air mixed to 0 degrees F (the
lowest recommended by Caterpillar); we should
expect to see a 240 degrees F reduction in EGT. A
temporary hose duct was installed on one generator
unit with arch air used to feed the engine. This test
confirmed that the EGT will be reduced significantly if
cooler air is used. Site measurements have revealed
that the temperature of the combustion intake air is
much higher than room ambient due to the local
heating around the engine. Ducting of outside air,
with a mixing damper, has been underway during May
2006. Final results are pending.
8.3.4 Engine Room Temperature Limitations
A contributing cause of high EGT readings is the elevated
temperature of the engine room. This condition can also
cause engine overheating, reduced equipment life and early
equipment failure. The arch is the source of the cooling air
for the air handlers, and the temperatures within the arch
have been higher than anticipated by the design team.
Reduction of arch temperatures will help cooling in the
engine room. If the engine combustion air is ducted directly
from the arch rather then from the room, the air handler unit
may then be balanced properly to provide more even cooling
air distribution.
8.3.5 Fuel Energy Values
According to the NPP BOD, the use of AN-8 fuel was
considered by Caterpillar when determining site ratings of
the equipment.
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8.4
6/23/06
Supplemental Energy Opportunities
8.4.1 Alternate Energy Options
Given the many scientific research projects proposed, it
does not appear that the load on the power plant will
diminish and steps need to be taken to ease power plant
demand. About one half of the flights to the South Pole are
fuel flights. These flights alone consume over 800,000
gallons of fuel per year at a projected cost of more than 1.6
million dollars. A potential solution to this problem is the
implementation of alternative energy production. Specifically,
wind power, solar heating, and solar photovoltaic are
suggested.
8.4.1.1 Solar Heating
Currently, solar heating has been used in the past in
some outlying buildings with success. Past research
has indicated that solar heating in non-waste heat
buildings can have a payback of 5-years or less.
The remote or out-lying buildings should be given
top priority. A solar heating assessment should be
done for all South Pole facilities. Solar heating has
the potential to decrease the number of fuel flights
to the South Pole.
8.4.1.2 Solar Photovoltaic Power
There have been many studies done on solar
photovoltaic (PV) power for the South Pole. The
findings so far indicate that the short-term savings
have paybacks in excess of 10 years. However, if
energy conservation is justifiable on more than just
short-term economics, then further study in solar
photovoltaic power is recommended, especially for
smaller remote buildings that are only used in the
summer time. Consideration should be given to
installation of flat PV units on the roof of Pod A and
Pod B of the elevated station.
8.4.1.3 Wind Power Generation
There have been studies done on wind power for
the South Pole with over a million dollars invested to
date. The study findings of a one year (1997) turbine
installation test at the South Pole indicates that wind
power may be a candidate for reducing fuel use.
The Northwind 100 wind generator is a direct drive
wind generator that has been undergoing testing in
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Kotzebue, Alaska. This unit is less maintenance
intensive than other competitors that were tested
because it is a direct drive unit. The challenge here
is the average wind speed at the Pole is about 10
mph, but the wind generator presently produced
only begins to generate power at that wind speed.
Therefore, this unit would only produce about 10%
of its capacity most of the time.
A USAP Wind Power project proposal including $7
million for a stand-alone South Pole Wind Power
project was submitted in June of 2005. It is
recommended that this or some similar project be
started with a proof of concept phase.
8.4.1.4 Cold Weather Turbine Project Research Program
The National Renewable Energy Laboratory of
Golden, Colorado provided an evaluation of various
wind turbines that were developed as part of the
Next Generation Product Development of the U.S.
Department of Energy (DOE) Turbine Research
Program in conjunction with Northern Power
System’s Polar Turbine Development Program.
One of the turbines developed under this program
was installed in Kotzebue, Alaska in May 2002. We
contacted Craig Thompson with Kotzebue Electric
Association (KEA) to follow up on the study and get
first hand information on their experience with wind
turbines.
KEA has two wind turbines in operation one
manufactured by Atlantic Orient Corporation (AOC)
and the other by Northern Power Systems. The
AOC wind turbine that KEA has in operation has tip
brakes to slow the turbine down under high wind
conditions. The AOC turbine is an induction type
machine that requires a fairly robust distribution
system to provide a stable voltage source for
excitation and reactive power support. KEA has
experienced a fair amount of problems with the tip
brake system. The Northern Power Systems turbine
that KEA is using is a Northwind 100 unit that
consists of a direct drive alternator at the top of the
tower that delivers power to a double conversion
(AC to DC to AC) inverter located inside the tower at
ground level.
The Northwind 100 utilizes
electrodynamic braking to prevent overspeed of the
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wind turbine. To date, the Northwind 100 turbine
has proved to be the more reliable unit and KEA
likes the unit better as it presents a 1.0 power factor
load to the utility due to the double conversion
process.
KEA has lost blades on both turbines due to icing
problems and icing is a continuing issue with the
turbines. Craig Thompson noted that the most
important issue is selecting the right turbine and that
low cost is not necessarily the most economical
option (the AOC machine costs approximately
$85,000 each vs. $250,000 for the Northwind 100).
Both wind turbines require constant maintenance
however the Northwind 100 has required less
maintenance than the AOC unit and has proven to
be more reliable.
8.4.2 Alternative Energy Summary
Phase 1 - Development of an extreme cold weather “Proof
of Concept” wind energy design for the Pole’s “one of a kind”
location is recommended. A part of this phase will
specifically be addressing the location of the turbine, ways to
increase output at an average wind speed of 10 mph, and
the potential for vibrations and noise related to the
turbine. This phase is a prerequisite to the next phase.
Phase 2 – Installation of the proof of concept turbine, and
observation of results.
Phase 3 - Increase the number of turbines to the number of
economically justifiable wind turbines.
It should be reiterated that this is a proof of concept (POC)
project. The South Pole is a one of a kind location and there
can always be unexpected problems associated with
weather and/or science projects. It should also be noted that
the snow/ice might beneficially reduce the vibrations and
noise and thus minimize/eliminate any affects on science.
This POC approach is also recommended because it will
reduce the cost of the product refinement, which would
ultimately reduce the cost of the full project. The POC
approach also reduces the duration of the project and
results in quicker savings and reduced fuel flights.
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8.4.3 Alternate Energy Integration Complexities
Alternate electrical energy source outputs can be integrated
into the South Pole Power grid only if they are known to be
in-phase as well as voltage and frequency matched. These
requirements can only be accomplished through the
utilization of automatic load transfer equipment that has the
capability of performing the phasing, voltage and frequency
monitoring of the alternate source and then effecting transfer
of the alternate power to the grid only when all parameters
are matched. This type of automatic sequencing and
paralleling equipment is complex and expensive.
At
Kotzebue, the wind generators produce power at AC, the AC
gets converted to DC, and the DC gets converted back to
AC with an inverter to keep the power in phase with the grid.
8.5
Load Shedding
8.5.1 Load Shedding Procedures
It will take a considerable team effort to develop a load
shedding protocol.
All members of the South Pole
community should participate in that effort. Initial load
shedding candidates (estimated at 75 kW total if everything
were on and than turned off to shed load) in case the station
load approaches generation maximum include:
 Sauna – est 15 kW
 Growth chamber- est 17 kW
 Computer lab sections – est 4 kW
 Laundry room – est 10 kW
 Quiet reading room – est .5 kW
 Gym AHU, lights – est 3.5 kW
 MAPO Machine Shop – 10 kW
 N2 Production – 15 kW
8.5.2 Load Shedding Equipment
Automatic load shedding equipment can be installed at
selected loads using power contactors. The signal to drop
selected loads can be delivered through the DDC control
system so the procedure becomes automatic as the loads
approach critical levels.
8.5.3 Essential Load Definition
Essential loads are defined in the Emergency Utilities, South
Pole Station plan.
8.5.4 Off Peak Loads
Loads that can be put on line during off peak times, such as
cryogenic gas production, could be programmed as off peak
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loads so the prime time peak loads can be reduced. This
was examined, but the load signature at the station for the
winter months appeared to be relatively constant between
day and night, so there may not be much opportunity for load
leveling at the Station. The demand load variation will
continue to be studied for load leveling potential.
8.6
Emergency Power Generation
8.6.1 Location of Emergency Generators
Two diesel engine driven generators are located in the B-1
emergency power plant, on the first floor.
8.6.2 Capacity of Emergency Generators
There are two 239 kW emergency generators located in the
B-1 emergency power plant. The generators can both be
operated in parallel for summertime operation, but it is
intended that winter emergencies will only use one generator
at a time. Automatic switchgear will start the second 239 kW
generator when the load reaches 220 kW for 10 seconds, or
it will be started immediately when the load reaches 239 kW.
8.6.3 Planned Uses for Emergency Power
Emergency power is installed for life support systems only.
8.6.4 SOP for Emergency Power Use
There is an “Emergency Utilities, South Pole Power”
document presently out for review that addresses this issue.
8.6.5 Science Requirements for Emergency Power
During an emergency, no power will be available from the
emergency power plant for ongoing science. The NPP
cannot be paralleled with the emergency power plant, so no
supplemental power will be supplied during operation of the
emergency power plant.
9.0
Power Monitoring
The existing energy monitoring system for the new South Pole power plant
is inadequate for this project. Without proper monitoring equipment, it is
impossible to accurately forecast future loads, optimize energy efficiency
or lower operating costs. Increased electrical and heat loop monitoring is
required in order to gain a better understanding of the distribution of
energy at the South Pole Station. Power meters will be needed on all
electrical feeders and ahead of the main branch circuit panels for the
major power users.
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Currently there are 12 Power Logic meters tied to software to be able to
remotely monitor and download data. Those locations are: 1 meter on
the PMDE, 1 meter on the RMDE, and 10 meters in the old power plant
distributed amongst the 10 feeders. In the New Power Plant, each main
breaker on the PMDE is a Square D Smart Breaker that is tied to the
Power Logic software and will give a reading of three phase amps at a
determined interval. Currently the station records that data on 15 minute
intervals for the breakers that are in use.
There are Power Logic meters that are set up as stand alone units, at
DSL, Garage/Shops, and ARO. The station does not currently do any
tracking that is recorded due to the difficulty and logistics and hand
logging of the data. These units could be equipped with additional
hardware to allow them to talk, over the network, to a software package
that opens up significant additional monitoring capabilities.
The station electrical as-built drawings are currently being updated and
will effectively change the drawings for the metering proposal. The
expected date of completion for this drawing set is July 5, 2006. Proposed
new power monitoring equipment is shown on the one-line diagrams
earlier in this report.
The goal of this project is to set up adequate monitoring equipment on
both the electrical distribution system (all feeders and major loads) and the
heating loops on station. With this information, a thorough energy report
can be compiled and the station can work to increase efficiency and
decrease operating costs.
This project will not increase the NPP’s ability to supply power to science
sectors at the station, but will allow data to better plan power requirements
in the future and better manage current power requirements as well as
identify conservation options.
9.1
Portable Power Monitor
The station presently has a portable power analyzer that can be
used to spot check loads on feeders, branches, or individual loads.
That analyzer is presently being used to measure 24-hour power
signatures on selected loads throughout the station so interim
power usage levels can be established or confirmed.
This
equipment was used to measure snapshot loads at various
locations to establish the existing power forecasts in this report.
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10.0 Cost Model
10.1
Cost of Fuel Calculation
The cost of one gallon of AN-8 fuel delivered to the South Pole has
been reported to be $10.11 per gallon. The cost is known to be
low, and may go up to $15.00 per gallon when NSF releases the
final budgetary costing. This cost does not include the cost of
storage or additional handling. This data was taken from the “South
Pole End User Energy Costs” document for FY 06.
10.2
Cost of Power Calculation
The generators have an electrical efficiency of 32-35%. During the
4-week period March 4-25, 2006, the Sitrep reports that 450,081
kWh of electricity were generated, and 33,005 gallons (cold
volume) of fuel were consumed to fuel that generation. This would
equate to a fuel efficiency of 13.64 kWH/gallon of cold fuel. The
cold fuel is estimated to be at –56 degrees F. In order to normalize
this efficiency to 60 degrees F, which is the standard API
temperature, the fuel quantity would have to be increased by an
estimated 6.44%. The temperature corrected fuel quantity used in
the March time period examined, if it were at 60 degrees F, would
be 35,131 gallons. This would yield a generator efficiency of 12.81
kWH/gallon of 60 degree F fuel. Since fuel is purchased at a
corrected volume to 60 degrees F, this is the appropriate basis for
determining the cost of fuel to make electricity. At a fuel cost of
$10.11/gallon, the base cost of producing electrical energy is
$0.789 per kWh without consideration of waste heat recovery. The
total actual cost of producing electricity would include operator
labor and overhead, capital cost amortization, maintenance,
lubricating oil, major overhauls, depreciation, building, parasitic
losses, etc. This actual cost cannot be determined without a
significant amount of actual cost data. Therefore, payback costs for
energy saving proposals will be actually significantly shorter than
presented if the cost of $.789/kWH is used.
10.3
Cost of Heat Calculation
Fuel fired heating costs for the South Pole, using a fuel cost of
$10.11/gallon, a burner efficiency of 83%, and a fuel energy value
for AN-8 of 129,506 BTU/Gallon, are $.0647/thousand BTU. As an
example, a 100,000 BTU furnace operating at 83% efficiency would
cost $6.47/hr in AN-8.
The waste heat reclaim efficiency from the existing generators is
42.8%. The value of the recovered waste heat is $3.19 per gallon of
fuel.
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11.0 Energy Efficiency Opportunities
Federal Requirements:
Energy Policy Act of 2005, (EPAct 2005)
establishes new energy efficiency goals for existing federal buildings.
These standards increase by 2% each year in order to achieve a 20%
increase in efficiency by 2015.
With these new standards come new benefits. Government facility
managers now have the opportunity to reuse the budget dollars they save
from increased energy efficiency.
Under the EPAct 2005 guidelines, federal agencies can now retain all
savings from energy, water, and wastewater improvements, but must use
these savings for energy, water, and wastewater improvements.
Previously, all federal agencies, except for the Department of Defense,
could only retain half of savings.
Energy-saving magnetic fluorescent ballasts standards apply to ballasts
manufactured on or after January 1, 2009, sold by a manufacturer on or
after October 1, 2009, or incorporated into a luminaire on or after July 1,
2010. This means that replacement magnetic fluorescent ballasts will most
likely not be available after January 1, 2009.
11.1
Parasitic Electrical Losses
11.1.1 Power Factor Definition
Power factor (PF) is a measure of how effectively we are
using electricity. Various types of power are at work to
provide electrical energy: Working power, reactive power,
and apparent power. The true or real power used in all
electrical appliances to perform the work of heating, lighting,
motion, etc is expressed in kilowatts (kW). Purely resistive
loads have a power factor of one, since there is no reactive
component. An inductive load, like a motor or ballast, also
requires reactive power to generate and sustain a magnetic
field to operate. This inductive portion of the load is non
working power, measured as kilovolt-amperes-reactive
(kVAR). Apparent power, commonly called kVA is the total
power used, calculated as kilovolts times amps. Power
factor is the ratio of working power to apparent power, using
the formula PF=kW/kVA. Most electrical utilities charge their
customers a penalty if their loads have a low PF, typically if it
is less than PF=0.9, because their switchgear, transformers,
and wiring all have to be sized large enough to carry the
reactive power (which is not sensed by the kW meter) as
well as the working power. As the power factor drops the
system becomes less efficient. A drop from a PF of 1.0 to
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0.9 results in about 10% more current being required for the
same load.
11.1.2 Power Factor Improvement
Improving power factor can maximize current-carrying
capacity, improve voltage to equipment, reduce power
transmission losses, and improve overall distribution
capacity through reduction in electrical current (amps). The
simplest way to improve power factor on induction (not
synchronous) motors is to add PF correction capacitors to
the electrical system at non Variable Frequency Drive (VFD)
controlled motors. The capacitors help offset the nonworking power used by transformers, induction motors or
lighting ballasts. Power factor correction at VFD controlled
motors is not necessary as the VFD itself does this by using
DC internally to produce AC output to the motor. In fact,
VFD manufacturers warn against installing capacitors at the
VFD output, since PF correction capacitors act as reactive
current generators.
Also, lightly loaded induction motors
can create a poor (low) power factor, so proper motor sizing
relative to the load is important for an efficient system. Since
power factor at the station overall is quite good (PF=.9), no
further effort is proposed for overall power factor reduction.
11.1.3 Power Factor Problems from Electronic Equipment
Modern UPS or computer power supplies need to have
power factor correction because they have a characteristic of
distorted input current. Quite different from resistive heaters,
toasters and tungsten light bulbs, typical switched-mode
power supplies such as used in personal computers draw
input current in short pulses at the beginning of the
waveform, rather than in smooth sine waves. In order to
deliver the same amount of power in short pulses, the
current peaks are much higher, especially when all of the
supplies are taking their power at the exact time in the
waveform throughout the building. When a facility has a
large number of computers or UPS supplies using switchedmode power supplies, the surges created by non power
factor corrected power supplies can create poor power
waveforms, poor power factor, stress wiring, and limit
capacity of the electrical system. Since the wave surges are
of short duration, they might not trip circuit breakers, but
could still make a fire by overloading circuits. The PFC
power supplies are available from most computer or UPS
manufacturers to match their equipment. According to
power supply manufacturer Condor D.C. Power Supplies,
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Inc “Without power factor correction circuitry, typical
switched-mode power supplies have power factors of
approximately 0.6, and have considerable odd-order
harmonic distortion (third harmonic often as large as the
fundamental, with higher order harmonics decreasing as
their frequency increases). With full power factor correction
(PFC), today’s switched mode power supplies can approach
the ideal case, with power factors of 0.99 and harmonics well
below 5%”. For the above reasons, the NSF recommends
that all new power supplies feeding electronic equipment be
furnished with power factor correction circuitry.
11.1.3.1 Power Factor Correction Payback
With a station overall power factor of 0.9, it is
difficult to find equipment or systems that will
substantially improve the overall power factor at a
reasonable cost.
The use of power factor
corrected switched power supplies for electronic
equipment, however, has a payback of cleaner
power for the science community, as well as an
improved safety from less stressed circuits, lower
amplitude current surges, and better power factor.
The switched circuit power supplies therefore do
have a significant payback, and should be
required on all large volumes of fixed computers or
UPS devices at the station.
11.1.4 Transmission Losses
The power grid transmission losses are minimized by the
specification and installation of only high conductivity, class
B stranded, annealed soft copper feeder circuit conductors.
These feeder conductors are always sized to maintain the
voltage drop, over the length of the run, at three percent
(3%) or less. Specifying and sizing feeder conductors to
these standards keeps the grid transmission losses at a low
level. See also the voltage drop study presented earlier in
this report.
The fact that a large number of the lengthier feeder runs are
installed directly in the ice further reduces transmission
losses. At lower ambient temperatures conductors are
capable of carrying a larger current. Since voltage drop
calculations do not account for this increased current
carrying capacity, the true “low ambient” feeder voltage drop
is less than for the same feeder installed at normal ambient
temperature.
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11.1.5 Transformer Losses
Transformers utilized within the power grid are
predominately specified and installed as high efficiency, low
temperature rise, copper wound units. The typical
transformer efficiencies are between 96% at loads equal to
the full nameplate rating and 98% at load levels of one-half
to one-third of the rating.
11.2
Specific Solutions
11.2.1 Energy Forecasting
Additional monitoring equipment will need to be approved,
purchased, and installed to allow for a higher level of data
collection needed to facilitate power management and
accurate forecasting. To date, the station has the ability to
monitor power generation and some heat recovery
processes but it has an insufficient number of monitoring
points to perform a building-by-building power or thermal
load analysis. (There are no flow meters on the gas side of
the exhaust gas heat exchanger; so only recovered BTUs
are recorded.) Additional monitoring points will allow for fine
tuning of heating and electrical systems to reach maximum
efficiencies.
With monitoring equipment in place, an
integrated forecasting program could be written that can
update actual loads to forecast, so outyear forecast loads
can be updated and made more accurate. The impact of not
having accurate forecast loads could be power outages, or
fuel shortages which are unacceptable risks for the Pole,
especially during winter over. The model could then be
extended to include fuel requirements forecasts, and alert for
any storage constraints. Specific input will be needed from
NSF regarding assumptions made in the energy forecasting,
such as:
Final Report - Phase 1

The Station opening fuel reserve is presently set at
70,000 gallons.

The fuel capacity requirements presently assume a
10% contingency.

The winter period is assumed to be 35 weeks, which
is used to forecast the maximum allowable average
power usage.

The forecast loads are based on the sum of
measured peaks and averages, which totaled about
8% above station average and peak loads for March,
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contingency.

2006,
6/23/06
not
counting
a
10%
There are only a few summer 24-hour load
measurements that can be used to calibrate the load
forecast to actual.
For this reason, most load
forecasts are based on winter readings, with some
adjustment for estimated summer loads.
11.2.2 Conserve
Operating procedures, technology advancements in
equipment, and station awareness will be critical to energy
conservation. Each arriving group on station will be briefed
by the Facilities Group on energy conservation and how
each individual can do their part to aid in energy
conservation.
Snow maintenance schedules will be
reviewed and adjusted to save equipment fuel usage.
Specific energy saving suggestions are listed in various
places in this report, and are summarized here:
 Change lighting ballasts
 Install dual technology motion sensing light switches
 Reduce air infiltration to building
 Meter boilers to monitor fuel use for thermal use
 Commission building controls and mechanical
systems
 Perform an energy audit, and adopt recommendations
 Set up demand load leveling to reduce peak loads
 Fix the exhaust gas heat exchanger problem
 Fix the generator exhaust gas temperature problem
 Fix the generator room overheat problem
 Reduce the arch temperature
 Add an exhaust gas heat exchanger to the peaking
generator
 Perform a lighting survey and reduce lighting if
needed
 Replace incandescent exit signs with LED signs
 Tune all boilers for maximum combustion efficiency
 Monitor AHU outside air damper positions to reduce
Outside air
11.2.3 Refine Distribution
Electrical power is presently distributed to the station
facilities from the Primary/Remote Main Distribution
Equipment (PMDE/RMDE) switchgear in the new power
plant (NPP). The old power plant distribution switchgear is
fed from the PMDE/RMDE and has existing feeders still in
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service. Those existing feeders from the old power plant
that will be used after the old power plant is demolished are
planned to be transitioned totally to the NPP. For example,
Feeder 9 to the Dark Sector was moved from the old power
plant switchgear to the NPP in December of 2005. 200 kW of
additional capacity will need to be added to the distribution
system feeding the Dark Sector to bring the total capacity to
500 kW in order to keep up with the latest forecast electrical
demand, which exceeds original demand forecasts.
11.2.4 Demand Management
As demand for electrical power increases across the
distribution grid, areas of the infrastructure will be pushed
beyond upper limits without proper management. In order to
address this issue, demand management and load shedding
will be implemented. Some load shedding suggestions are
listed previously in this report. Demand limiting contactors
may be required on certain large nonessential loads such as
the Liquid Nitrogen Plant, MAPO machine shop,
Garage/Shops Welders and mills, the Ice Cube Lab electric
duct heat coils, the Dark Sector Lab electric boiler, etc. The
contactors should be prioritized and automatically activated
through a core demand limiting controller with programmable
load dropout set points. The effect on the operation needs
to be evaluated as part of a load shedding program as noted
later in the report. With planning, heavy loads could be
shifted to the evening, thus leveling the loads and leaving
more capacity for daytime peak demand.
If that is not sufficient, additional load shedding or demand
management will be also implemented. A group has been
formed, defined as the SCOARA group, which will be tasked
with determining their science priorities. See section 7.2.1.
This group will be responsible for creating a solution to
optimize power usage for all science consumers. Demand
management and load shedding procedures will be
developed in this plan.
The South Pole Telescope project has a unique opportunity
to reduce demand by peak-shaving the intermittent power
loads required to accelerate the telescope. Their power
requirements originally reported have a continuous load of
70 kW, and than they add 84 kW (total 154 kW) each time
the telescope accelerates (2-3 seconds), then they drop
back to 70 kW for 20-30 seconds. A power conditioning unit
will be installed to store the short term surge requirements,
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so the power plant will not see these short term peak
demands, nor will the feeders or transformers. Additionally,
the entire Dark Sector would not be exposed to the probable
voltage drops that would be occasioned by the 84 kW short
term demand loads. The SPT will utilize a stored energy
device (battery UPS) to condition the load to minimize
repetitive power peaks to less than 20 kW, and to maintain a
voltage drop on their feed of 5% or less.
11.3
Lighting Energy Efficiency Opportunities
11.3.1 Replace Magnetic Ballasts with Electronic Ballasts
When the elevated station was being designed, there was a
requirement placed on the designers around 1996 that only
magnetic ballasts be used for all of the lighting fixtures on
the station, due to concern for EMI/RFI electrical noise.
Newer design electronic ballasts have improved, with
compliance to FCC regulation 47 CFR part 18 interference
requirements, and less than 10% total harmonic distortion
(THD). Ballast manufacturers do not publish the levels of
EMI/RFI produced other than to state compliance with FCC
regulation 47CFR Part 18. Furthermore, the electronic
ballasts are much quieter, with a reported 75% reduction in
audible noise than conventional electromagnetic ballasts.
RFI could, however, increase due to the higher frequency
used by most high frequency electronic ballasts. EMI will be
typically controlled by the metal ballast/fixture housings and
the use of metallic circuit raceways. RFI emission levels
could be reduced through the use of RFI filters that are
supplied within the ballast circuit, although RFI may still be
emitted through the lamps themselves.
11.3.1.1 Power Savings Estimate with Retrofit
The elevated station, DSL, and cargo facility
lighting fixtures bill of materials indicates that 899
fixtures using T8 lamps and magnetic ballasts
were shipped, each using a 2-lamp fixture. The
installed ballast make and model used for these
fixtures
are
Magnetek,
model
number
M232SR277C. The input wattage of the specified
magnetic ballasts is 70 watts for each ballast and
2-tube 32 watt T-8 lamp combination, making the
total connected load for the light fixtures with T8
lamps 62,930 watts. At an assumed demand
factor of 60%, this system uses 37,758 watts of
power for lighting.
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If the decision is made to retrofit the station with
new electronic ballasts using, for example, the
Universal Lighting Technologies, Inc, ULTim8
“EL”, model Bx32IyyyEL, (.77 ballast factor) the
new input power would be only 47 watts to power
the ballast and 2-tube T-8 lamp combination. This
retrofit would result in a total connected load of
42,253 watts. The reduction in connected load
from existing is 20,677 watts. Assuming a 60%
demand factor with the lights, the retrofit to these
electronic ballasts would result in a savings of
12,406 watts. At an electric cost of $.789/kWH,
this would save $108,676/year. This assumes a
low power level lighting system, which would
reduce the light output as well by about 20%.
Magnetic ballasts have a ballast factor of 0.95,
and the light levels are directly proportional to the
ballast factor.
If the fixtures presently installed are only
producing marginal light at present, we would then
suggest the standard electronic light level ballast
system, which has a ballast factor of .87, and uses
54 watts with two T-8 lamps. It would draw 29,128
watts at a 60% demand. This system would have
no significantly lower light output than existing, but
would still save 8,630 watts over the magnetic
ballast system assuming a 60% demand for light
operation. This would save $75,598/year.
If EMI/RFI is a concern with the new electronic
ballasts that produce 42 kHz frequency, there is a
60 Hz electronic ballast that uses 62 watts input
load, rapid start. (The concern with the RFI has
been that the high frequency operation of the
lamps created electrical noise by using the lamps
themselves as transmitters of the RFI noise.) This
low frequency ballast would be an Advance
“Power Cut” model VK2532TP. This model still
saves 14 watts per fixture over the magnetic
ballast, for an overall potential energy savings at
60% demand factor of 7,550 watts. This would
save $66,138/year.
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11.3.1.2 Prohibited Locations Due to Electrical Noise
Since electronic lighting ballasts generate a higher
frequency, and could have a higher RFI level, we
should test the electronic ballasts at locations
where science projects may be susceptible to
radio frequency interference. If it is found that the
electronic ballasts create objectionable RFI
through the lamps, than those locations should be
identified as susceptible to RFI, and either the
magnetic ballasts should continue to be used
there, or the Advance “Power Cut VK2532TP”
ballasts should be considered, which operate at 60
Hz instead of 42 kilohertz.
11.3.1.3 Technical Obsolesce of Old Magnetic Ballasts
The Energy Policy Act of 2005 has mandated that
energy efficiency improvements in magnetic
ballasts be implemented by manufacturers no later
than January 1, 2009. Therefore, replacements of
the existing magnetic ballasts may not be
available in the future.
11.3.2 Lighting Fixture Upgrades
11.3.2.1 Use of T-5 Lamps in Place of T-8
Lighting manufacturers have now developed a
fixture that can utilize the latest technology T-5
lamps. These lamps are smaller than the T-8
lamps, but are much brighter.
Initially after
introduction of the T-5 lamps, they were found to
be too bright for office space, but would work well
for hangars, warehouses, and high bay lighting
applications.
Lithonia has now developed a direct/indirect lens
that diffuses the light sufficiently to provide
volumetric lighting, with the bright point source.
While new construction projects should consider
the T-5 fixtures, a retrofit of all the fixtures to T-5 is
not cost effective at present. Electronic ballasts for
two T5 fluorescent lamps consume 3 watts more
than the electronic ballasts for two T8 lamps (66
watts vs. 63 watts). The total light output for a pair
of T5 lamps is 5,800 lumens compared to the total
light output of 5,900 lumens for a pair of T8 lamps.
T5 lamps are 46 inches long instead of 48 inches
like other four-foot fluorescent tubes. This length
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difference would require replacement of the lamp
fixture. The optical efficiency for the new fixtures
is approximately 82%. The published photometric
efficiency is higher due to the fact that the lamp is
operating at a peak output of 3,050 lumens in the
fixture. Based on these criteria, the use of T5
lamps in place of the T8 lamps presently in use is
not in the best interest of the energy savings
goals.
11.3.2.2 LED Exit Signs
The station presently has an assortment of exit
signs. The new elevated station specifies F5TT,
5-watt lamps, with 277 volt ballasts, in addition to
un-powered phosphorescent painted signs. Older
parts of the station use higher power exit signage.
Incandescent exit lights use as much as 24 watts
and fluorescent fixtures use 12 to 16 watts. LED
life is nearly twenty-five years compared to roughly
20,000 hours for the long-life incandescent tube
lamps and compact fluorescent lamps.
RPSC has begun a project to retrofit all of the
powered exit signs with new technology LED
fixtures. Industry standard power for LED exit
signs, in order to be bright enough to be effective,
indicates that 5 watts of LEDs are needed. For
this reason, there is marginal payback to
retrofitting the 5-watt lamped exit signs with LED
signs installed at the new station, although other
locations using higher power lamps would have a
payback. RPSC presently estimates a payback of
14.6 kWH/year with this retrofit.
11.3.3 Motion Detector Light Switches
11.3.3.1 Existing Locations
Motion detector light switches are a very effective
way to control lighting in places that are not
continuously occupied. Areas of the new station
that had them installed, such as the restrooms,
had to be re-wired to traditional light switches. The
lights would go out on people in the toilets, which
became a safety issue for egress from the spaces.
There is a higher technology motion detector
switch that uses both ultrasound and infra-red
technology to prevent switching off the lights when
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a person is still in the space. The combination
Passive Infrared (PIR) motion detector units
respond to changes in the infrared background by
turning lights ON when people enter space being
monitored, and OFF when the space is
unoccupied. The Ultrasonic (US) units transmit an
ultrasound signal and monitor changes in the
signals return time to detect occupancy. MultiTechnology units combine PIR and US sensing
technologies for highly accurate monitoring with
minimum false triggering. There are sensors for
monitoring
conference
rooms,
restrooms,
stockrooms, stairwells and warehouses. It is
recommended that the station retrofit to the new
technology motion detector light switch to avoid
the nuisance switching, and to keep the
technology in place rather than replace the motion
detector switches with standard manually operated
switches, which has already happened in the
restrooms.
There are several areas of the new facilities that
are wired with motion sensor detection lighting
control. The garage building # 101 has detectors
throughout the building. The power plant building
#103, has them in the water treatment,
transformer room, fuel storage, auxiliary
equipment rooms and bathroom.
Facilities that would see a benefit from sensor
lighting could include vestibule areas on any new
facilities. Mechanical rooms and work spaces tend
to be bad locations for this type of light control
because the sensors can not always be located in
a way that they do not inadvertently turn off the
lights while people are engaged in low motion act
ivies in the space. The new multi-technology
motion detector switches should be tried in these
spaces.
Areas that would benefit from the installation of
motion sensor lighting would be any lounge area
or recreation room. This would include 4 rooms in
the elevated station. Vestibules and mechanical
spaces in the outlying buildings of DSL, Ice Cube
counting house, MAPO, ARO, Cryo and RF
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building should all get motion detector switching.
These applications would include 12 rooms.
Building #61 would be 1 room. Any future
buildings should be reviewed for the suitability of
motion sensor switched lighting. At current time
there are 17 known candidate rooms, not counting
the restroom retrofits where the old style single
technology motion detector switches are used.
The station should budget for 50 new multitechnology switches, and should specify specific
switches for intended occupancy to achieve
reliable switching results.
11.3.3.2 Proposed Additional Locations
An energy audit should be done on site to
determine if other locations would be appropriate
for application of new multi-technology motion
detector light switching.
11.3.4 Dimming Switches/Daylight Sensors
Fluorescent dimming switches, with specialized ballasts, are
available. These dimming switches can respond to existing
outside light, and brighten or dim the light fixtures as needed
to maintain a constant light output. Because the pole station
has few windows, and because the station does not see 24
hour day/night cycles, this option is not a likely candidate for
retrofit. Also, dimming switches may introduce unwanted
RFI to the space.
11.3.5 Lighting Level Survey
It is recommended that a lighting level survey be performed
at station to determine if the lighting levels are appropriate to
the occupancy. The outcome would be an increase or
decrease in lighting types or fixtures to match more closely
the actual occupancy requirements. Along these same lines
there has been a call for the re-design of the dining facility
lighting to add the capability to reduce the amount of light
during the winter months which would also be a cost saving
feature.
11.4
Thermal Energy
The FY04, FY-05, and FY-06 winter have all showed the effects of
not decommissioning buildings on schedule while continuing to
build new ones. Fuel usage is still high for the winter season due to
the need to run boilers to supplement heat to the stations hydronic
heating system.
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From the South Pole Station Draft Utility Transition Plan, April 13,
1998, and Basis of Design-Volume 4 SPSM Design of the New
Station, Mechanical Appendices, Final Submittal April 09, 1999, the
following numbers have been recorded or extrapolated:
The amount of available heat recovered and distributed by the
hydronic heating system in the New Power Plant is approximately
1,950,000 BTUs at a 541 kW average electrical load.
Pod A of the Elevated Station requires approximately 1,836,549
BTUs under Case III for station operation.
Pod B of the Elevated Station requires approximately 635,567
BTUs under Case III for station operation.
The Garage/Shops require approximately 1,205,535 BTUs under
Case III for station operation.
The Rodwell requires approximately 360,000 BTUs under Case III
for station operation.
The sum of these numbers leaves the hydronic heating system
approximately 2,000,000 BTU/hr short of heating the buildings for
heat recovery alone. These numbers are from a peak winter load
summary. These numbers must be adjusted to see what is
currently occurring on station.
Recommendations for the current heat loading issues at South Pole
Station are as follows:

Efficiently use occupied/unoccupied temperature settings in
buildings controlled by DDC.

Increase the level of monitoring and points available through the
DDC to facilitate data useful to system tuning.

Verify all DDC set points and system operation.

Verify all sensor calibration for DDC during commissioning
11.4.1 Verify Ventilation Levels Relative to CO2 Tracers
Discharge air on all air handlers is controlled by CO2 levels
and mixed air temperature, per control drawings. Settings
will need to be verified in a field audit summer FY07.
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11.4.2 Monitor Boiler Efficiencies
The combustion efficiency should be checked quarterly due
to the high usage on the boilers. Expected efficiency is 8385%, depending on the amount of excess air being
consumed by the burner. Boilers around the station have
been checked for combustion efficiency. The results are as
listed below
OPP 78.3%
NPP 80.0%
A2 84.2%
B1 84.7%
DSL 83.5%
Rodwell 85.1%
11.4.3 Electric Boilers
There is only one electric boiler on site, and it is located at
the DSL. This boiler is to be used as a redundant heating
system only.
11.4.4 Electric Duct Heaters
The present design for the Ice Cube Lab building uses
electric heat duct coils rated at 39.5 kW. Offsetting this
load, however, is the heat dissipated by the electronics in
the ICL building. It is forecast that the need for heat in the
building will diminish from 30 kW in FY07 to zero by the
summer of FY10.
Alternatively, several Monitor or Toyostoves, which burn
AN-8 and are direct vented through the outside wall, could
be located around the building. They operate at 93%
efficiency due to their condensing burners that have
modulated firing rates. The units are extremely efficient,
and can be installed in several places to provide just the
heat needed without ductwork. These units are very
popular with people in northern Alaska villages because of
their fuel efficiency and ease of installation with only a
through-the-wall vent, with AN-8 fuel and cord and plug
power connections required.
11.4.5 Electric Water Heaters
There is only one electric water heater, located in the old
Power Plant, and it is scheduled to be demolished this
winter.
11.4.6 Add BTU Meters to Track Use of Energy
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The addition of flow meters at key heat exchanger
locations, along with temperature in/out probes, can be
used to compute BTU usage at the heat exchanger, and
can also be used to measure flow rates to determine if
proper flows exist or if scaling or some other problem
needing attention arises.
11.4.7 Survey Buildings for Heat Loss with Infra-Red Camera
There is a contract in place to perform infra-red scanning of
the elevated station buildings. This is a follow up to a
previous scan that identified significant heat loss through
construction where vapor barriers were not installed, or
where other construction was not adequate.
The proposed camera would be used to inspect all electrical
connections and building envelopes for possible energy
losses.
11.4.7.1
Final Report - Phase 1
List of Buildings by Priority
This is a list of locations at the South Pole that can
be considered for investigation of heat loss. The
buildings are in order of heat load and buildings
with susceptible integrity issues. Buildings in the
science areas for example have penetrations for
instruments to pass through that make them more
of a potential for energy loss through those
penetrations.
Bl106
Pod A Elevated Station
Bl107
Pod B Elevated Station
Connect Link Connects Pod A To Pod B
Bl023
Atmospheric Research Observatory
Bl046
Mapo/Dasi/Viper
Bl090
Inferno, Mech Room, And Ice
Palace
Bl090-A
Inferno Head Module (Summer)
Bl090-B
Inferno/Ice Palace Mech Room
Bl090
Ice Palace Head (Summer Camp)
Bl110
Dark Sector Lab (DSL)
Bl111
Mobile Water Well Building (Spsm)
Bl101
Garage/Shops (Spsm)
Bl103
New Power Plant (Spsm)
Bl104
Fuel Pump house Module (Spsm)
Bl118
New Cryogen/Balloon Inflation
Bl108
RF Building
Bl120
Telescope Building, 10 Meter
Bl061
Electrical Substation 'B' (Elevated)
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Spase 2/Gasp Building
11.4.7.2 Data Evaluation Process
All data would be evaluated by the Facilities
Engineer, who would seek additional training to
ensure that their knowledge level is kept up to
date.
11.4.7.3 Building Insulation Adequacy
The use of an infra-red camera would allow RPSC
to make comparative results between building
types and insulation levels.
11.4.7.4 Weather Stripping, Door Seal Adequacy
This season, RPSC has installed door sweeps on
the exterior doors to the Elevated Station as a
result of observations that the doors were not
capable of being adjusted to maximum sealing
potential. Additional doors on station for other
buildings are being evaluated.
11.4.7.5 High Resistance Electrical Connections
The use of an Infrared camera could save the
station electrical losses in this field, coupled with
the already existing PM’s on transformers, panels,
heaters and switch gear that are preformed on an
annual basis.
11.4.8 Thermostat Set Point and Setback Review
An energy audit will be performed, as part of a
commissioning process. This audit will review and correct
improper set points in the DDC control system.
11.5
Waste Heat Capture
11.5.1 Stack Heat Losses
There has been a series of failures on the exhaust gas heat
exchangers on the generators in the power plant. The first
one occurred on the # 2 generator in 2002. The second
failure was on the # 1 unit in Jan. 2004. The third unit, # 3
failed in Feb. 2004. The # 2 unit failed again in Dec. 2004.
The # 1 unit failed again in Aug. 2005.
These units are shell and tube type exchangers. Each failure
has been on a tube where it passes through the tube sheet.
These points have had a tack weld where the tube passes
through the sheet. Each failure, except the last on the # 1
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unit in 2005, has been repaired on site. The repairs have
been completed by station pipe fitters that pass the 6G
welding certification as part of their hiring process. The initial
repairs were facilitated by welding the tubes that had leaked.
When the # 2 unit failed for a second time the repair included
welding the entire tube sheet instead of just the failure
points.
A new tube bundle was ordered as a replacement for any
further failures of these units. This unit arrived on station in
Feb. 2005. Due to safety concerns that arose when working
on these units several items were identified and procured to
do any work on these units in the future. Several chain falls
and come-alongs had to be rigged in tandem to get the units
lowered to the floor. These had to be operated from step
ladders and the force required to operate them made this a
less than ideal work platform. A portable lift was identified to
provide a platform to disconnect, lower, raise and connect
the units. Once on the floor the units had to be separated
with hammers, pry bars, and chisels. Cargo straps and chain
falls were used to assist in this separation process and had
to be attached to the pump skids and building structural
cross bracing. Again this was a less than ideal situation.
Several hydraulic spreaders and pullers were identified to
aid in the disassembly of the units after they are lowered to
the floor.
RPSC have been in contact with the current vendor, Maxim
Silencers, about the problems with these units. The original
vendor, Beard Industries was acquired by Maxim after the
initial purchase of the exchanger units. In conversations with
the representative he said that they were using thicker
walled tubes and a different annealing process in the units
compared to the ones that were provided to the Pole. The
representative never explained a reason for this, but it is
assumed that there was a problem with the units, since the
manufacturer chose to make a change in the production of
them. RPSC discussed having the tube bundle made of 316
stainless steel as an alternative to the steel units on station.
The price of a stainless steel unit came in at over $25,000.
Other potential causes of the failures include over heating
due to the excessive exhaust gas temperatures, as well as
potential cold shocking. Tom Waxham of Maxim Silencers
advises that 1200 degrees is too hot for mild steel, and
stainless steel is required for sustained temperatures in this
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range. The original designer assumed a maximum of 1050
degrees on the inlet of the units. Cold shocking could occur
if one of the tubes is partially or completely plugged,
preventing expansion of the tube along with the others.
Alternately, if the flow to one or more tubes is blocked by a
steam pocket, high differential expansion may cause a failed
weld. Corrosion caused by a failure to follow the design
sequence of recirculating glycol and modulating the exhaust
gas gates is also a likely cause of the problems.
11.5.1.1 Contingency Plan if More HX Units Fail
The vendor approved method of repair for failed
units consists of welding the tube junction to the
tube sheets. This will continue to be the method of
repair for failed units until such time that the failure
cause is determined and corrected.
11.5.1.2 Other Manufacturer’s Availability
The exhaust gas heat exchanger is a relatively
unique piece of equipment, and no other
manufacturer’s unit would just fit into the space of
the existing unit. A search has not been performed
to see if alternate manufacturers are available.
11.5.2 Jacket Water Waste Heat
11.5.2.1 Heat Exchanger Efficiency
Heat exchanger efficiencies should be compared
with design parameters to check for poor heat
transfer or improper flows. Also, more monitoring
points are recommended to aid in performing a heat
exchanger evaluation.
11.5.2.2 BTU Meters at Heat Exchangers
As mentioned in a previous section, flow meters
should be installed at heat exchangers. When
combined with existing temperature in and out
temperatures, the DDC system will then be able to
compute total heat exchanged for monitoring.
11.5.2.3 Engine Glycol Temperature Problems
RPSC does not believe that there is an engine
glycol problem at this point.
11.6
Commissioning
Commissioning, as proposed here, is a process that will be used to
verify that all building mechanical systems are operating as
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intended by the design. The process requires confirmation of
hydronic flow rates, temperature settings, control sequences, air
flow rates, damper minimum and maximum settings, pump and fan
speeds, heat exchanger efficiency, and similar functions. The
commissioning process can involve all phases of the project, from
the design, to submittal, in-process construction observation, and
finished system confirmation. Due to the status of this project, the
commissioning scope envisioned here is a confirmation of
completed systems after all punch list items have been completed
and accepted by the design team.
Note: Section 12 and 13 will be prepared and/or finalized as part of Phase II
of this report.
12.0 Schedule
12.1
12.2
12.3
Integrated Master Schedule
Long Range Plan for South Pole
12.2.1 Current Schedule
12.2.2 Out Year Project Schedule
Key Activities Affecting Schedule
12.3.1 FY 07 Implementation Efforts for Energy
12.3.2 Energy Projects beyond FY 07
12.3.3 Major Project Timing
12.3.3.1
Design
12.3.3.2
Procurement
12.3.3.3
Shipping
12.3.3.4
Installation
12.3.4 Annual O&M Impact on Schedule
13.0 Cost Elements
13.1
13.2
FY Timeline for Implementation
Cash Flow Planning by Fiscal Year
14.0 Recommendations in Priority Order (Repairs in Highest Order)
14.1
Troubleshoot and repair the power plant to restore original design
power capacity. The excessive exhaust gas temperatures are
creating accelerated wear on the valves, heads, and tubos. The
top end adjustment intervals had to be cut in half to maintain
reasonable output, which is still below continuous ratings. The
problem must be identified by measuring exhaust backpressure,
checking on the effect of directly ducting the combustion air into the
engine from the arch, reducing the engine room temperatures, and
following up on any other recommendations from the manufacturer.
Once we can rely on a continuous output capacity, we can then
assign an energy budget that is realistic and sustainable. Also,
reduced EGT levels will help resolve the thimble temperature
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problems where the exhaust gas stacks penetrate the arch, since
these excessive temperatures are actually melting the foam
insulation at the roof membrane.
14.2 Solve the exhaust gas heat exchanger failure problems. There
have been six exhaust gas heat exchanger weld failures since
inception of the station. Each failure requires an enormous amount
of work to remove the device, disassemble it, reweld the tube
sheet, and reinstall the heat exchanger.
14.3 Repair infiltration areas in the Elevated Station. To do this, it will be
necessary to first perform an infra-red camera survey of all
buildings for heat loss, and fix heat loss hot spots. While the
survey will save nothing, the closure of heat leaks will potentially
have a huge savings in thermal losses. It is recommended that the
project purchase an IR camera for ongoing use at the station to
confirm heat loss, troubleshoot freezing problems, and check for
high resistance electrical connections.
14.4 Provide commissioning of mechanical and control systems at the
station. As with any new complex facility, there are hundreds of
systems that must be properly programmed, set up, balanced, and
checked. The commissioning process will go through every
mechanical pump, fan, heating device, or controlled device and
verify proper operation. If found to be out of spec, proper balancing
of pumps and fans alone offer the potential of huge electrical and
thermal savings.
14.5 Add electrical monitors to all key feeders and panels to better
forecast use, and enforce energy budget. The only way to refine a
total energy budget is to meter all key loads so the power can be
checked against budget, and adjustments made where necessary.
Current forecasting systems lack detailed backup, making their
accuracy unacceptable.
14.6 Create an integrated energy monitoring and forecasting program
that will take the fuel, thermal and electrical monitored data to
update previous forecasts to actual. This data can then be used to
calibrate future forecasts with far more accuracy.
14.7 Create an energy budget for Science, Operations, Construction,
and IT groups. With increasing demand for power and limited
supply, it is essential to establish a budget for Operations,
Construction, Science, and IT functions so all groups can plan
around a known budget. A 10% future growth factor should be
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included to allow for station expansion, IT upgrades, or science
overruns from budget.
14.8 Implement demand management and load shedding throughout the
station.
If and when electrical demand reaches generation
capacity, demand management will first be used to keep demand
within capacity. If demand continues to rise, load shedding will
need to be implemented to prevent brownouts or total power plant
shutdown.
14.9 Add flow meters to all hydronic heat exchangers to determine total
BTU used, and provide a tool to troubleshoot flow problems. These
meters will enable better forecasting and control.
14.10 Replace all magnetic lighting ballasts with electronic unless very
sensitive equipment cannot tolerate electronic units. This could
reduce connected load by as much as 24.7 kW. Depending on the
type of retrofit ballast selected, energy savings at a 60% demand
factor can range from 7.5 kW to 14.4 kW.
14.11 Require new fixed electronic equipment to use power factor
corrected switched mode power supplies. This would have the
effect of cleaning up power in spaces that have a good deal of
computers or UPS supplies, as well as provide a reduction in power
factor.
14.12 Restrict electric heating equipment, including duct heaters, electric
boilers, electric hot water heaters, electric space heaters to back-up
use only. Minimize the use of electric heat tape to the extent
possible. The electric duct heater would reduce load by 39 kW, the
electric boiler will reduce load by another 50 kW. Electric heat tape
reductions remain to be seen. When the one electric water heater is
taken off line, it will reduce connected load by another 4.5 kW.
14.13 Implement alternate energy programs to use solar heating, solar
photovoltaic, and wind energy options where feasible. The energy
savings will be commensurate with the equipment that is installed.
14.14 Perform an energy audit at the station in December, and implement
energy savings recommendations.
Potential savings will be
commensurate with findings and remedial actions taken.
14.15 Install additional multi-technology motion detectors, and replace
manual switches at restrooms. The extent of these savings will be
proportional with the number of lights switched, and the reduction of
unnecessary light on time.
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14.16 Perform a lighting survey to determine if lower output ballasts,
switched lighting, or fewer fixtures can be used. The energy
savings will again depend on the measured starting and retrofitted
light output. Low ballast factor ballasts can be used to bring down
light output where it is justified, as part of the recommended ballast
replacement program.
14.17 Review lighting systems for potential application of automatic
dimming systems. At the present time, however, potential RFI and
the existence of switched level lighting may make this proposal
mute.
14.18 Install high efficiency stand-alone oil fired high efficiency wall
furnaces in science buildings instead of furnaces, if ducted air
systems are not necessary. One suggested type of wall furnace is
a 93% efficient Toyostove or Monitor stove.
14.19 Change out incandescent or fluorescent exit signs with low wattage
units or LED units.
14.20 Install an exhaust gas heat recovery silencer at the peaking
generator if it is determined that this unit will be operating more
than 25% of the time. The PG was operating continuously at the
time this report was written.
14.21 Require that the SPT project provide a power conditioning unit to
prevent surge demands on the power plant and distribution system.
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