Air Force Center for
Engineering and the
Environment
Massachusetts Military
Reservation
Federal Government and Military
Projects: Success Story, Current
Trends & Best Practices
Rose H. Forbes, P.E.
AFCEE/MMR
28 Mar 2012
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Primarily PCE, TCE, and EDB
Concentrations generally < 1 mg/L
Plumes are typically deep (>100 ft)
and thick (>100 ft)
9 treatment plants treating 12 MGD
(down from 17.8 MGD)
> 27 miles of pipeline
> 100 EWs and RWs
> 3,000 MWs
Sustainability Evaluation
• Fuhrlaender 1.5 MW, 80 m hub, 77 m rotor
Wind I
• Five year project; date of operation 2 Dec 09
• Expected to produce ~ 3,810 MWh annually
based on 29% capacity factor (P50); ~ 3,377
MWh annually based on 25.7% (P90)
• Expected to generate 25-30% of AFCEE’s
total electrical requirement (>$2M in 2009;
$1.7 M in 2011)
•Actual production: see chart on next slide;
capacity factor @17% for Year 1, 24% Year 2,
28% Year 3 (to date)
• Comparison of energy production to energy
use: see chart on next slide
• Expected to reduce ~25-30% air emissions
• Payback originally anticipated in 6-8 years
(RECs/O&M); latest ROI/SROI showing ~10
years
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Insert Use vs Production Chart
• will insert when the chart is ready
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25 Jan – 23 Feb 2011
$689,432: 02 Dec 2009-26 Dec 2011
(+ $60,000 availability guarantee for first year and meter problem)
Wind II
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• Two GE 1.5 MW, 80 m hub, 77 m rotor
Wind II
• Two year project; date of operation 8
Nov 11
• Expected to produce ~ 7,620 MWh
annually based on 29% capacity factor
(P50)
• Expected to generate 50-60% of
AFCEE’s total electrical requirement
(>$2M in 2009; $1.7 M in 2011)
• Actual production: 3250.25 MWh to
date; capacity factor @35.5%
• Expected to reduce ~25-30% air
emissions
• ROI/SROI showing ~10 years
10
Details
Wind I
Wind II
Machines
One Fuhrlaender 1.5 MW
Two GE 1.5 MW
Hub height/rotor diameter
80 m/77 m
80 m/77 m
Total height
~390 ft
~390 ft
Startup Date (witness test)
2 Dec 2009
8 Nov 2011
Project Timeframe
~5 years
~2 years
Distance from homes
1140 ft (on base residents)
3000 ft (off base residents)
Foundation
Spread form – 57’ diameter, 600 yds 5000 psi
concrete
Spread form – 47’ diameter, 470 yds 5000 psi concrete
Blades
ND: 122 ft, 13,600
TX: 121.4 ft, 13,900 lbs
Tower Sections
MN: 4; 41’-79’; 65,000-106,000 lbs
IA: 3; 72’-97’ long; 62,700-114,000 lbs
Machine Head
GE: 12.8’ high, 26.6’ long, 143,200 lbs
FL: 12.5’ high, 29’ long, 126,000 lbs
Crane
Manitowoc 16000; 440 ton; 315’ mast
Manitowoc 16000; 440 ton; 315’ mast
Funding Type
Environmental Restoration Account
Environmental Restoration Account
Constructability Assessment
$400,000
$462,284
Construction
$4.87M (plus two years O&M)
$9.43 (plus substation and one year O&M)
Utility Interconnection
$53,858 (to existing 23 kV distribution)
Title II Oversight
$150,000
$272,000 (to new 23 kV distribution line through new
substation and then to existing 115 kV transmission line)
$341,000 (and environmental surveys)
Energy Production (startup to date)
6145 MWhr (02 Dec 09 - 14 Mar 12)
3250 MWhrs (8 Nov 11 - 14 Mar 12)
Capacity Factor
Ranged from 17% in first year to 24% in second
year; 28.5% third year to date
9-10 years
35.5% to date
ROI
9-10 years
Notable Issues/Lessons Learned
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Communicate early and often with stakeholders
Understand net-metering, RECs, and state rules
Utility Interconnection – build in time and plan for costs
Logistics - room to haul and build (bridges, road width,
corners, permits, bad drivers, Military Cargo Preference Act
of 1904, etc)
Explore additional grants – can AF/DoD accept them?
Inspect the manufacturing facilities if possible
Make sure the turbine components suppliers and
transportation companies are insured.
Evaluate modes of transportation (roadway, rail, barge)
Contracting: Firm Fixed Price or Cost (Best Value or Lowest
Price)
Notable Issues/Lessons Learned
• Do spare parts come with the wind turbine purchase?
• Just because spare parts are new doesn’t necessarily mean
they will work
• Plan for technical and safety training – involve local
emergency response personnel
• An FAA ruling of presumed hazard is not the end of a project,
it’s the beginning of negotiations
• Ensure manufacturers are reputable and there are working
wind turbine models in the US for several years
• Select contractors who have experience with wind turbine
planning and construction projects
• Are anchor bolts sized correctly? Metric vs english conversions
can cause problems
• Provide site signage/directions to transportation companies
and police details
Notable Issues/Lessons Learned
• Construct foundation in cool weather and allow time to achieve
strength
• Long lead time on turbines - explore interest from manufacturers
(important on Wind I, not so much on Wind II)
• Plan on a schedule and hold contractors to it – include liquidated
damages in contracts
• Use existing wind resource data and other studies if available and
applicable
• Evaluate warranties and O&M/service contracts in advance; build
in availability guarantee
• Consult experts (i.e. DOE, AFCESA) on funding mechanisms
(DERA, ECIP, EULs, ESPCs, tax credits)
• Don’t plan a ribbon cutting ceremony until the turbine is up and
operational
• Long Haul Project – need a dedicated champion
• What about O&M????
Examples of Other Projects - MMR
• PAVE PAWS wind turbines – ECIP funds, own &
operate
• 102 IW (ANG – Otis) – solar PV on landfill (DLA –
developer based PPA)
• The VA cemetery installed a smaller wind turbine (50
kW) on their property
• USCG uses a geothermal heating/cooling system at
one of its hangars and is incorporating geothermal in
a new hangar construction project
Examples of Other Projects
• USACE-Kansas City wind turbine project
• FE Warren – Cheyenne WY wind turbines
• See AFCESA website for additional projects at
AF/ANG bases
• Town of Plymouth wind turbines; land lease
developer based PPA
• Town of Plymouth solar PV on landfill – land lease,
developer based PPA
Issues for Wind Developers
• Land lease on federal property can be
complicated
• Price of solar << than wind turbine in a power
purchase agreement (especially in MA)
• Utility interconnection
• AFCESA, AFCEE, USACE, DLA, GSA – get to
know your toolbox of selected contractors
• Central Contractor Registration (register)
• Federal Business Opportunities
Issues for Wind Developers
• Engineering Technical Letter (ETL) 11-1 (dated
30 Mar 2011): Civil Engineer Industrial Control
System Information Assurance Compliance
• Contact agencies and toolbox contractors and
provide company information
• DoD getting familiar with wind projects but
not quite there yet
Agencies/Contacts
• Air Force Civil Engineering Support Agency (AFCESA) AFCESAReachBackCenter@tyndall.af.mil
• Air Force Center for Engineering and the
Environment (AFCEE)
http://www.afcee.lackland.af.mil/contracting/contr
acts.asp
• Air Force Real Property Agency (AFRPA)
http://www.safie.hq.af.mil/afrpa/index.asp
• Defense Logistics Agency
http://www.dla.mil/Pages/default.aspx
Agencies/Contacts
• US Army Corps of Engineers
• Federal Business Opportunities:
https://www.fbo.gov/
• Central Contractor Registration:
https://www.bpn.gov/ccr/default.aspx
QUESTIONS/COMMENTS?
rose.forbes@us.af.mil
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Energy Optimization
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Wellfield optimization
Use of passive diffusion bag sampling
Use of direct push rig vs larger sonic/auger rig
On site O&M/well maintenance
Installation of VFDs and premium efficiency
motors
Elimination of booster pumps and pump
motor downsizing
Replaced sodium vapor overhead lighting
Use of bio-diesel, soy based hydraulic fluid
Reduction in propane use
Installation of low-wattage heaters
Misc energy (motion sensors, lighting
replacement, programmable thermostats,
LED exit lighting, new windows, etc.)
Signed up with the load reduction program
(demand response program)
Evaluated utility rate structures
Distance from
turbine to base
housing ~ 1140 ft
Activities
• Completed Constructability Assessment [Basis of Design, Economic
Analyses, Environmental Assessment (EA)]
• EA Public Comment Period; FONSI signed in Nov 2010
• Submitted Interconnection application to NSTAR
• FAA studies approved
• PAVE PAWS evaluation approved
• Coordination with other agencies and community completed
– EMC/SAC/CAC, USFWS , MA NHESP, MHC/BHC, THPO, MA FWS, MMRCT/SMB, news
releases
• Awarded construction project in Sep 2010 to ECC ($9.4M)
• Initial clearing of two turbine sites in Oct/Nov 2010, included turtle
surveys and baseline invasive species survey
• Grubbing, cut/fill and substation clearing in March/April 2011 , included
Eastern Box turtle surveys
• Pre- and post-construction bird/bat surveys started/continuing
Foundations
~470 yds 5000 psi concrete
47’ diameter
Spread form design
Completed in May 2011
Blades - Texas
• Insert photo
Length = 121.4 ft
Weight = 13,900 lbs
Fiberglass construction
Arrived 7 Jun 2011
Tower Sections - Iowa
Steel construction
Arrived June/July 2011
Base: 111,400 lbs; 72 ft long; 15 ft diameter at base
Mid: 80,700 lbs; 85 ft long;
14 ft diameter at base
Top: 62,700 lbs; 97 ft long; 11 ft diameter at base
Tower Sections (cont)
Mid section hit an overpass in
Indiana on 22 Jun 2011
Driver varied from permitted route
Damage was cosmetic;
tests/repairs conducted on site
Machine Head - Florida
126,000 lbs
12.5 ft high
29 ft long
Under Construction
• Both wind turbines installed late June through mid July 2011
View from Scenic Highway
(across the canal)
Both turbines produced a
combined total of 2173
MWhr from 04 Nov 2011 –
31 Jan 2012
View from Sagamore Bridge
Ribbon Cutting