Search Results

< Back to all projects COLUMBIA UNIVERSITY LOCATION: New York, NY STUDY DATE: April 2011 TECHNOLOGY: 11 MW 80,000 lb/hr Solar Mars Gas Turbine FIRM ROLE: Feasibility Study and Detailed Design Columbia University retained Waldron Engineering & Construction, Inc. to study the opportunity for Combined Heat and Power (CHP) at its Morningside Campus. The CHP will include on-site electric generation and recovery of waste heat in the generation of electricity to heat and cool campus buildings. The single most important driver for the study, other than its economic feasibility, was to determine if CHP offers a cost effective and reliable means to significantly reduce the University’s GHG emissions thru the recovery of waste heat and reduction of fossil fuel burning, in indirect purchased electricity and onsite usage, to meet the Morningside Campus’s energy needs. The project team considered a wide range of CHP technologies and configurations to be sited at the existing steam & chiller plants below the Center for Engineering and Physical Science Research (CEPSR). The CHP technologies investigated included: combustion turbines, fuel cells, reciprocating engines, and steam turbines in configurations sized up to about 14.5 MW. Waldron was selected to execute the detailed design for the project.

ANALYTICS Energy projects today face the unprecedented challenge of balancing economic, functional, and environmental outcomes in the face of rapidly evolving regulatory and market conditions. Waldron’s industry-leading analytics provide the strategic insights necessary to make efficient investment decisions, track program performance over time, assess risk and track the key metrics most important to your organization. DATA-DRIVEN RESULTS ENERGY MODELING TOOLS The cornerstone of Waldron’s analytical services is a proprietary, internally-developed software platform capable of performing integrated electrical, thermal, economic, and greenhouse gas emissions calculations for complex microgrid systems. Some basic features of the platform are the following: Utilizes equipment performance curve library enables accurate prediction of part-load performance of major electrical and thermal generation equipment. Incorporates electrical generation, solar PV, heat recovery, energy storage systems, centrifugal and absorption chilling, heat recovery chilling, heat pump technologies and other principal utility generation assets. Manages a portfolio of individual building loads that vary in time due to construction, demolition, energy efficiency retrofits, and demand-side management programs. Modifies the condition or performance of microgrid assets over time, such as time-varying fuel cell plant performance, combustion turbine degradation between overhauls, etc. Dispatches electric and thermal generation assets to concurrently meet electrical, steam, hot water and chilled water loads. Integrates multiple commodity supply cost futures, utility tariffs, and procurement strategies. Incorporates scheduled and unscheduled (randomly selected) maintenance periods and equipment availability profiles. Performs internal auxiliary load calculations for central energy plant and microgrid parasitic loads. Capable of incorporating and simultaneously dispatching multiple facilities on a common microgrid. STRATEGIC INSIGHTS Our array of in-house tools coupled with our experience in the design, construction and commissioning of energy generation and delivery systems enables us to offer true investment grade analysis. Our flexible tools allow rapid assessment of changes to market, regulatory or supply/demand conditions, so that existing assets are deployed optimally throughout their operating lifetimes. Determine optimal microgrid equipment configurations Efficiently identify key project drivers, sensitivities, and risks Track asset performance year-over-year compared to benchmark models Evaluate the true impact of Energy Conservation Measures (ECM’s) in a microgrid environment Identify the most cost-effective and environmentally sound dispatching strategies Determine the true cost of outages and equipment downtime Develop and/or analyze microgrid rate structures based upon calibrated system models Optimize returns on demand-side investments

< Back to all projects UNIVERSITY OF MASSACHUSETTS MEDICAL SCHOOL LOCATION: Worcester, MA DESIGN START: Winter 2010 DESIGN COMPLETION: Winter 2011 SIZE & TECHNOLOGY: 7.5 MW Electric, 60,000 lb/hr Steam, 4,000 ton Electric Chiller, Dual Fuel Combustion Turbine FIRM ROLE: Engineering, Construction Management, Technical Support and Commissioning The University of Massachusetts Medical School (UMMS) in Worcester is a large medical hospital, research center, and medical school campus. Due to continuing campus expansion, their existing cogeneration facility could not meet capacity. Energy efficiency and reliability were key concerns in developing plant options. Waldron Engineering was selected to do the engineering and design of the UMMS cogeneration plant expansion. The cogeneration plant expansion included a 7.5 MW dual fuel combustion turbine, a fired HRSG rated at 60,000 lb/hr, 1100 psig and 850ºF, a new natural gas compressor, a new 4000 TR electrical chiller and a new plant master electrical control system with intelligent load shedding scheme that greatly enhanced the overall electrical system reliability. The new cogeneration system boosted the overall efficiency from 55% to over 70%, exceeding expectations. The project scope included: building structural design electrical design—included interconnection between the existing generators and the new electrical system to shape a complete load shedding scheme mechanical design— included high pressure steam system connecting with the existing steam system new HP natural gas system modified an existing 80,000 gal no. 6 fuel oil system to no.2 fuel oil system.

< Back to all projects LYONDELL BASELL MICROGRID LOCATION: Lake Charles, LA DESIGN START/COMPLETION: Fall 2007 – Fall 2008 SIZE & TECHNOLOGY: 30 MW Electric 160,000 lb/hr steam gas turbine / HRSG, reciprocating engine / HRSG IN-SERVICE: Spring 2009 FIRM ROLE: EPC (Engineering, Procure, Construct), Commissioning LyondellBasell is one of the world’s largest plastics, chemical, and refining companies with 55 manufacturing sites in 18 countries. Their Lake Charles, LA facility manufactures Polyolefins, a common product found in many household items. It continually ranked in the lowest quarter for energy costs for the LyondellBasell facilities. Waldron, as the EPCC contractor, engineered the systems, procured the equipment, managed the construction and commissioned the new 30 MW stand-alone CHP facility. It included a Solar Titan 130 gas turbine, two Rolls Royce reciprocating gas fired engines, two package boilers and a complete balance of plant system including a remote monitoring system. The design included a site-wide electrical infrastructure upgrade and a fuel-blending station that allowed the CHP equipment to utilize waste gas from the primary on-site processes.

< Back to all projects NEWINGTON ENERGY LOCATION: Newington, NH IN-SERVICE: May 2004 SIZE & TECHNOLOGY: 2x-GE 7FA Combustion Turbines with dry, low NOx Combustors FIRM ROLE: Owner’s Engineer, Design Engineer, Commissioning Waldron Engineering was engaged to act as the Independent Engineer on behalf of the owner, Con Edison Development. The installed facility generates 535 MW of electricity using natural gas or No. 2 Fuel Oil. Emissions is controlled by using a combination of low NOx combustion and SCR in the HRSG. Waldron had a full-time presence on-site to supervise the design, construction, commissioning and testing of the plant on the owner’s behalf.

Services Waldron delivers custom-tailored, full-service energy solutions for our clients. Our unique blend of talent, expertise and innovation drives every service we offer. Multi-Discipline With structural, electrical, controls, and mechanical engineering in-house, Waldron delivers integrated, fully-coordinated designs that capture all key project elements. Vertically-Integrated Waldron’s experience is informed by active participation in every phase of an energy project’s life cycle, from initial development through construction to start-up and commissioning, including delivery of turnkey projects. Utility Grade Waldron’s design packages are detailed, coordinated, and comprehensive. We deliver a “utility grade” standard of care by conveying fully engineered system designs with the essential details required to construct your facility. Energy-Focused Energy generation, storage, and distribution projects are what we do. Because of this, each and every day on the job expands our market-leading expertise. Customer-Centric Waldron emphasizes pragmatic, proactive problem-solving on behalf of our clients. Flexibility, responsiveness, and transparent communications are hallmarks of our approach. Performance Guaranteed Given the opportunity, Waldron will deliver turnkey energy generation and distribution projects backed by performance guarantees. ANALYTICS Waldron’s suite of analytical tools has been developed specifically to explore the complex interactions of microgrid systems. We are adept at mapping the technological, financial, regulatory and environmental parameters that shape an energy project, and delivering the insights required to manage your future with confidence. LEARN MORE ENGINEERING Waldron has extensive experience in the engineering and design of energy generation and distribution systems. We excel at developing fully integrated design packages tailored to your needs, and steering them through construction. LEARN MORE CONSTRUCTION MANAGEMENT Waldron’s construction management team is focused solely on the construction of central energy facilities and utility distribution systems. We can provide the program management, pre-construction Services and construction management required to ensure your project is delivered on time and on budget. LEARN MORE COMMISSIONING Waldron’s startup, commissioning and performance testing expertise provides the bridge between construction and commercial operation. We have a proven track record in the development and successful execution of detailed commissioning plans for plants ranging from institutional central heating and cooling facilities to full-scale utility power stations. LEARN MORE

< Back to all projects FRASER PAPER MILL/NEXFOR LOCATION: Edmundston, New Brunswick DESIGN START: 1995 DESIGN COMPLETION: 1998 IN-SERVICE: Commercial Operation beginning early 1998 SIZE & TECHNOLOGY: 45 MW net, Hydrograte Stoker, Biomass-Fired Boiler FIRM ROLE: Owner’s Engineer, Engineering, Construction Management and Commissioning Waldron Engineering was engaged to act as the owner’s engineering group during the development of a biomass fueled cogeneration facility for a 1300 ton per day paper mill in Edmundston. The installed facility generated 45 MW of electricity and an equivalent thermal load of 60 MW. Waldron developed the plant’s conceptual design. Additionally, Waldron dealt with boiler efficiency analysis, thermodynamic cycle design, and conceptual layout, technical and economic optimization of design. Finally, Waldron developed and evaluated the EPC contract bids. This project successfully meets all thermal output designed at concept. As of 1998 the Fraser Cogeneration Power Plant was the largest biomass-fueled boiler in North America.

< Back to all projects JAMAICA BROILERS LOCATION: Spring Garden, Jamaica IN-SERVICE: 2002 SIZE & TECHNOLOGY: 15 MW Heavy Oiled Fired Reciprocating Engine FIRM ROLE: Owner’s Engineer Waldron Engineering was engaged to develop a design concept for a cogeneration plant at a food processing facility. The plant size was 15,300 KW with 50,000 lbs/hr of steam generation. The prime movers for this project are multiple #6 oil fired Wartsilla reciprocating engines exhausting into a single heat recovery steam generator, a dual fuel package boiler and a hot water absorption chiller. Waldron Engineering oversaw the letting of the EPC contract and the commissioning of the plant systems as the Owner’s Independent Engineer.

ENGINEERING Waldron’s detailed engineering packages are fully-coordinated, comprehensive, and informed by the client’s needs. The key is to understand the stakeholder’s goals, and structure a set of plans and specifications that clearly communicate these goals to the contractors. In turn, the result is a well-defined, successful project. OUR PROCESS Important steps in the engineering and design services process include: PROJECT DEVELOPMENT The project development process can be a tortuous path through a maze of regulatory, contractual and financial barriers. Navigating this gauntlet successfully requires knowledge of the ways in which facility performance, technical constraints, and regulatory obligations coincide. Our direct experience bringing energy facilities from concept to operation enables us to optimize the path for you without sacrificing key outcomes. DETAILED ENGINEERING & DESIGN Waldron’s detailed engineering and design process is an orchestrated flow of information that proceeds from a comprehensive understanding of stakeholder goals to a set of plans and specifications that is specific to the project’s needs. We take a “no more and no less than is needed” approach: our multi-discipline in-house coordination process emphasizes comprehensive drawing sets with little to no delegated design, while our specifications are pared down to those requirements both specific to and essential to the project. The result is a design package truly ready for bidding and construction, which minimizes change orders and project delays by providing the clear direction that is required for an efficient construction process. CONSTRUCTION ADMINISTRATION Every construction project presents unique challenges. The key to success is working proactively with the vendors and trade subcontractors to navigate those challenges in a timely and cost-effective manner on behalf of the Owner. Waldron emphasizes productive relationships with all stakeholders, and adopts a responsive, flexible approach to overcoming obstacles and keeping the project on track. Because the starting point is a comprehensive, fully-coordinated design, our teams have the ability to quickly identify the impacts of design decisions on all project disciplines and resolve field challenges practically and efficiently.

CONSULTING At Waldron, commissioning is a thoroughly mapped, step-by-step approach designed to explore the entire operating envelope of a facility and demonstrate the project’s key outcomes have been met. Because of our focused expertise in energy system engineering, we are able to remain constructively engaged throughout the process of testing, troubleshooting, and optimizing a facility’s performance. STEP-BY-STEP GUIDANCE PROJECT DEFINITION In-depth commissioning requires a thorough understanding of project goals. As with all of our services, the starting point is a detailed understanding of the specific financial, environmental and functional criteria established at the project outset. This knowledge informs the planning process. PLANNING There are three levels of planning: project level sequencing of system energization and functional testing with a facility, detailed step-by-step commissioning procedures for each system that guide the start-up and testing processes, and daily plans convened by Waldron’s commissioning manager on-site to coordinate all parties associated with or affected by the work. Much of our work is accomplished in operating facilities and requires a thorough understanding of the impacts commissioning will have on existing systems, as well as the ability to develop contingency plans. TESTING AND RESPONDING Commissioning is not a straight line from A to B: a thorough commissioning process is a daily encounter with the unexpected. Waldron’s commissioning teams excel at providing leadership and technical guidance to clients, contractors and operations teams when troubleshooting is necessary, and are capable of efficiently realigning resources to keep the process moving forward. Given the opportunity, we are not passive observers, but active contributors to the resolution of difficulties encountered. DOCUMENTATION Waldron provides daily reports of commissioning activities, as well as annotated procedures that document the step-by-step outcomes realized during the commissioning process. The result is a wealth of information for the facility owners and operators. It is possible to understand exactly what was tested, what worked and what didn’t and why, and how the deficiencies were resolved. The result is a clear roadmap for future operations.

< Back to all projects TUFTS UNIVERSITY COMMISSIONING LOCATION: Medford, MA SIZE & TECHNOLOGY: 4 MW Gas-fired recip. engine. 800-ton electric chiller 600-tons of hot water absorption chiller and pumps IN SERVICE: Winter 2018 FIRM ROLE: Owner’s Engineer Services, Cx Waldron Engineering was contracted to perform the commissioning services for the new Tufts Central Energy Plant. The plant consisted of a 4 MW gas-fired reciprocating engine, with 200 horsepower waste heat recovery boiler and 3x800 horsepower firetube boilers. The facility also included an 800-ton electric chiller and 600-ton hot water absorption chiller. Waldron, as the commissioning agent and systems trainer, coordinated new boiler/chiller plant startup while the existing plant was in operation, provided supplemental design and engineering during construction and commissioning, worked with vendors to correct equipment design oversight, and developed commissioning test procedures. The challenge of getting the new systems operational against the backdrop of a working plant required careful coordination, precise planning, and smooth execution of our commissioning plan. Tufts was able to get its system online and derive an economic benefit from its new cogeneration systems.

< Back to all projects ONE BRYANT PARK MICROGRID LOCATION: New York, NY DESIGN START/COMPLETION: Spring 2006 – Spring 2007 SIZE & TECHNOLOGY: 4.5 MW Electric 50,000 lb/hr steam Gas Turbine / HRSG IN-SERVICE: Spring 2009 FIRM ROLE: Engineering, Construction Management, Technical Support The Durst Organization builds, owns, and operates some of the world’s most innovative and efficient buildings. In developing the One Bryant Park building (a.k.a The Bank of America Tower), The Durst Organization made a commitment to achieving the lowest environmental footprint. The building, which is located one block off Times Square on Sixth Avenue, is a 50-story structure that is predominately leased by Bank of America. The building is designed to conserve energy wherever possible. The energy that is consumed is supplied by a gas turbine-based CHP facility located on the 7th floor podium. Waldron designed the complete plant around the Solar Mercury 50 gas turbine that exhausts into a fired HRSG. The HRSG is sized to serve the complete needs of the building. The building set a new standard in sustainable commercial construction by utilizing the least amount of energy possible, and the energy consumed is generated in the most efficient manner possible. It is the first LEED Platinum high-rise office tower in North America and ranks among the most environmentally advanced skyscrapers in the world.