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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 Final Report - Phase 1 Page 1 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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 Final Report - Phase 1 Page 2 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 12.0 13.0 14.0 6/23/06 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 Final Report - Phase 1 Page 3 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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 Final Report - Phase 1 Page 4 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 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 Final Report - Phase 1 Page 5 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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. Final Report - Phase 1 Page 6 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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. Final Report - Phase 1 Page 7 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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. Final Report - Phase 1 Page 8 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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 Final Report - Phase 1 Page 9 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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 Final Report - Phase 1 Page 10 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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 Final Report - Phase 1 Page 11 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 4.0 6/23/06 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. Final Report - Phase 1 Page 12 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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 Final Report - Phase 1 Page 13 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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 Final Report - Phase 1 Page 14 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 = 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 Final Report - Phase 1 Page 15 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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. Final Report - Phase 1 Page 16 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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 Final Report - Phase 1 Page 17 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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 Final Report - Phase 1 Page 18 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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. Final Report - Phase 1 Page 19 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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 Final Report - Phase 1 Page 20 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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 @ Final Report - Phase 1 Page 21 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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) Final Report - Phase 1 Page 22 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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 Final Report - Phase 1 Page 23 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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 Final Report - Phase 1 Page 24 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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. Final Report - Phase 1 Page 25 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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. Final Report - Phase 1 Page 26 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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. Final Report - Phase 1 Page 27 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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. Final Report - Phase 1 Page 28 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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. Final Report - Phase 1 Page 29 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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 Final Report - Phase 1 Page 30 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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 Final Report - Phase 1 Page 31 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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 Final Report - Phase 1 Page 32 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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 Final Report - Phase 1 Page 33 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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. Final Report - Phase 1 Page 34 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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) Final Report - Phase 1 Page 35 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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 Final Report - Phase 1 Page 36 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 Summer Load Forecast Final Report - Phase 1 Page 37 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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. Final Report - Phase 1 Page 38 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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. Final Report - Phase 1 Page 39 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 Winter Load Forecast Final Report - Phase 1 Page 40 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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. Final Report - Phase 1 Page 41 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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. Final Report - Phase 1 Page 42 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations Final Report - Phase 1 6/23/06 Page 43 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations Final Report - Phase 1 6/23/06 Page 44 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations Final Report - Phase 1 6/23/06 Page 45 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations Final Report - Phase 1 6/23/06 Page 46 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations Final Report - Phase 1 6/23/06 Page 47 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 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 Page 48 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 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 Final Report - Phase 1 Page 49 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 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 Final Report - Phase 1 Page 50 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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 Final Report - Phase 1 Page 51 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 Final Report - Phase 1 Page 52 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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. Final Report - Phase 1 Page 53 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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 Final Report - Phase 1 Fiscal Year Page 54 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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 Final Report - Phase 1 Page 55 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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. Final Report - Phase 1 Page 56 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations Final Report - Phase 1 6/23/06 Page 57 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations Final Report - Phase 1 6/23/06 Page 58 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations Final Report - Phase 1 6/23/06 Page 59 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations Final Report - Phase 1 6/23/06 Page 60 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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 Final Report - Phase 1 Page 61 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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. Final Report - Phase 1 Page 62 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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 Final Report - Phase 1 Page 63 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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 Final Report - Phase 1 Page 64 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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. Final Report - Phase 1 Page 65 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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% Final Report - Phase 1 Page 66 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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 Final Report - Phase 1 Page 67 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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 Final Report - Phase 1 Page 68 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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 Final Report - Phase 1 Page 69 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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 Final Report - Phase 1 Page 70 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 isolation for the other equipment on feeder 9, and provides for some growth at both building 61 and at the DSL. Final Report - Phase 1 Page 71 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations Final Report - Phase 1 6/23/06 Page 72 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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 Final Report - Phase 1 Page 73 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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 Final Report - Phase 1 Page 74 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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, Final Report - Phase 1 Page 75 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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 Final Report - Phase 1 Page 76 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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 Page 77 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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. Final Report - Phase 1 Page 78 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 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 Final Report - Phase 1 Page 79 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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 Final Report - Phase 1 Page 80 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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. Final Report - Phase 1 Page 81 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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 Final Report - Phase 1 Page 82 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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. Final Report - Phase 1 Page 83 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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. Final Report - Phase 1 Page 84 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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. Final Report - Phase 1 Page 85 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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 Final Report - Phase 1 Page 86 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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, Final Report - Phase 1 Page 87 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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. Final Report - Phase 1 Page 88 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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, Page 89 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 2006, and April, 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 Final Report - Phase 1 Page 90 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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, Final Report - Phase 1 Page 91 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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. Final Report - Phase 1 Page 92 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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. Final Report - Phase 1 Page 93 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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 Final Report - Phase 1 Page 94 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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 Final Report - Phase 1 Page 95 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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 Final Report - Phase 1 Page 96 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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. Final Report - Phase 1 Page 97 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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. Final Report - Phase 1 Page 98 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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 Final Report - Phase 1 Page 99 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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) Page 100 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations Bl072 6/23/06 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 Final Report - Phase 1 Page 101 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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 Final Report - Phase 1 Page 102 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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 Final Report - Phase 1 Page 103 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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 Final Report - Phase 1 Page 104 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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 Final Report - Phase 1 Page 105 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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. Final Report - Phase 1 Page 106 National Science Foundation 2006 Report on South Pole Energy Issues & Recommendations 6/23/06 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. Final Report - Phase 1 Page 107