Xi?

i?E??.ICE?ACIS:I A:1D BOILER PLANT
TSTAL E!TERGY PWIT FOR KINGS PLAZA
SHC?PI:iG CE:ITZ?. X:ID WAXINA
In or5e: ro g e t f u l l use of t h e heat reco.~ered
f r m the ?over ?:ant engines, one A b s o n t i o n ?.efrige r a r i o n !4ac?.ize has been provided. There a r e a l s o
t h r e e engine "r--1en c e n t r i f u g a l r e f r i g e r a t i o n com? r s s s o r s , srizk a c a p a c i t y of 880 tons each.
The er5:nes a r e o f the Spar!<-Iqni=ion ;as zype,
oser3c:zq 2: a;sr3xirnacel-( 1,200 .%?!.I. The cooling
s:!sren E3r c . 3 . ~ engines ?roy1ides f o r 25OC? jacker
.daze: ($S':llr?r.= cooling) and Heac ?.ecoy~er];'nits.
. . .
--..- ". g s z e ~ zs e~p a r a t o r s with exhaust recover]
-.-..?ricers.
-, .
f?e steam a t 15 p s i g thus generated i s
-..:-',A- ~ n z o3 zsrmon header with t h e 30wer Planc S t e m .
,.---.
Kings l l a z a Shopping Center and Marina i s a new
csmplex of s t o r e s and s e r v i c e s on a 23 a c r e s i t e i n
southern Brooklyn, New York, This Shopping Center i s
Xew York Cit.yls f i r s t completely enclosed and c l i -te
c o n t r o l l e d r e g i o n a l shopping c e n t e r . The
c e n t e r is groviding employment f o r over 2,500 people
s i n c e i t o ~ e n e di n the Summer of 1970.
The p r i n c i a a l occupants of t h e Center a r e
Alexander's m d :.Iacy*s, each xi-A a f o u r s t o r y s t o r e
3 5 323,000 square f e e t . Approximately 100 o t h e r
s t o r e s and f a c i l i r i e s occupy 410,000 square f e e t .
A 3500 c a r garage provides ample parking
f a c i l i t i e s f o r shoppers. The >farina, occupying
another 100,000 square f e e t , provides "parking"
l o r b o a t and o t h e r conveniences f o r b o a t owners.
The Shopping Center, which i s completely enclosed and c l i m a t e - c o n t r o l l e d , is provided with a
C e n t r a l Mall, with two l e v e l s connected by escal a t o r s ; access t o a l l s t o r e s i s through t h e B a l l ,
sxcept f o r Alexander's and i l a c y * ~ ,which a l s o have
d i r e c t s t r e e t access.
T0T.L; ENERGY PmXT
A f t e r a thorough a n a l y s i s based on economic
c o n d i t i o n s , it was decided t o provided t h e Center
ri::? energy f o r a l l t h e needs o f t h e Shopping Complex.
This p l a n t i s conbined with a i l e f r i g e r a t i o n and
3 o i l e r P l a n t , t o meet t h e c o o l i n g and h e a t i n g r e ouirements a l l year around.
The computations i n d i c a t e d a peak demand of
= p r o x i m a t e l y 8,000KW f o r t h e C e n t e r ' s l i g h t i n g and
?ewer requirements and a r e f r i g e r a t i o n load o f
agaroximately 3,600 tons f o r t h e A i r Conditioning
i:JStem.
The Power P l a n t c o n s i s t s o f 5 Nordberg four-cycle
-.
-Lboc:?aryed "Supairthermal" d u a l f u e l e n g i n e s , with
..
-
z y l i x d e r s , 11%" bore and 1&" s t r o k e . Engine
-a-<
- ~ . . gi s 3078 Xi?, with C?e g e n e r a t o r r a t e d a t
2,200 :Cri, 4,160 v o l t s , 3 phase, 50 c y c l e . Engine
-; -6
.--.-on
speed is 1,113 f e e t i n i n u t e , with 515 RPX. The
;enerator i s by I d e a l E l e c t r i c and Manufacturing
2acan.1..
j
?our Engine g e n e r a t o r s s a t i s f y t h e e n t e r ' s detqd t h e f i f t h u n i t i s f o r stand-by duty. The
'="er 7 l a n t layout a l s o provides space f o r a s i x t h
i----r
f o r f u t u r e expansion.
-:
..-=
3 -..-- -..- : e n t e r ' s
h e a t requirements a r e not
f-LL:? met 5:/ =he reclaimed steam a x ? hot r a t e r , two
a e i i c i o n a l lssr p r e s s u r e steam b o i l e r s have been proviZed. 3 e s s b o i l e r s o p e r a t e o n l y a t times of pea:<
denand. 2ce
the s u b s t a n t i a l h e a t recover], the
s i z e and z'z:h+r of t h e b o i l e r s h a s beer? markecly re*..
:-ced, :?as ==r.criSusing t o t h e o v e r a l i savings.
==
The T o t a l %erg-1 F2.zr.t i s l o c c t e d on t h e roof o f
Sl:op_ci:g :enter.
To p r e v e n t v i b r a t i o n and shock
. .
rrmsmlss:c;n, =he u n i t s a r e mounted on j r i n g t y s e
-1L5ratio: Lscla=ors. Yordberg Banufacturing Company
f.13isteC t?a issemjly wit:? a s t r u c t u r a l s t e e l base
p i a t e , havizg s u f f i c i e n t s t r e n g t h and r i g i d i t y t o
n a i n t a i n e-T&:ent
alignment o f t h e engine and generat o r . This a r r m g e x e n t has been chosen, f o r an
e f f e c t i v e c o r c r e t e i n e r t i a block would have added
s , > s t a n t i a l v e i g h t t o t h e equipment.
--:.a-
;icodiiart e l e c t r i c load s e n s i n g ty2e governors
capable of m n t r o l l i n g t h e enq i z e speee f r c n 9 t o 34 of t h e r a t e d f u l l load
s z e e l , xpcn ;radual load changes from no l o a d t o f u l l
:=ad.
?,a-,-~ Seen ins=al;e2,
C o n s t a t steady s t a t e frequency i s maintained by
the governor :o an accuracy o f
0.25% of r a t e d
speed.
+
3uring g e z e r a t o r p a r a l l e l o p e r a t i o n ,
nor accomplis:1es r e a l load d i v i s i o n t o a
rated
lczd.
t h e gover-
5 59 of
2ach ezgine has i t s own c o n t r o l m e l , e ~ c i g p e d
v i 5 a l l the zecessary ala-ms, gauges, c o n t r o l s , e t c .
I n d i c a t i n ~p r e s s u r e Sauges a r e provided f o r lube
o i l , jacket s-azer, f u e l o i l , s t a r t i n g air manifold
b-.E t r a ? s h c e r o u t p u t , t h r o t t l e valve a i r , f u e l gas
ar.8 a c t c a t o r o i l . Control devices permit inannal
engine shutecx~.on engine overspeed, high j a c k e t
water tez!cerature, low l.l;?e o i l p r e s s u r e , lockout
s i v . a l from suizchgear p r o t e c t i v e d e v i c e s , e t c .
'uel c:l&:geover equigment from o i l t o gas operati-n and vice-versa, is i n c o r p o r a t e d i n t h e panel.
The chanseover c o n t r o l s permit s t a r t i n g on o i l f u e l
or.1:~ and allow changeover t o gas o p e r a t i o n t o proceed when c c r d i = i o n s t h a t allow s t a b l e gas operation
a r e met.
AUTOMATIC ENGINE SEQUENCE
S t a r t and s t o p of Units i s accomplished by system
switchgear, through closure of s i g n a l i n g contacts.
Automatic engine s t a r t includes check of pres t a r t conditions and lockouts. I f a l l s a f e t y cond i t i o n s a r e met, motor driven a u x i l i a r i e s w i l l be
s t a r t e d i n timed sequence. Before an engine s t a r t
w i l l be allowed, t h e a u x i l i a r i e s w i l l be proved by
system output.
SWITCHGEAR
S t a t i o n a r y , indoor, metal c l a d type, 5,000 V ,
250 MVA, manufactured by t h e I d e a l E l e c t r i c and
Manufacturing Company.
f o r the preparation of domestic hot water and preheating of b o i l e r feed water.
The exhaust gases a r e piped through Engineering
Controls Co. Heat Recovery Silencer and dry and satur a t e d steam a t 15 p s i g is generated. A t f u l l load,
each Heat Recovery S i l e n c e r w i l l provide 2,340 l b s .
steam/hour.
This steam is used i n summer f o r cooling
and i n winter f o r heating the Center. Exhaust e x i t
temperature from Silencer w i l l be maximum 325OP.
The above described heat reclamation arrangement
provides f o r maximum usage of a l l a v a i l a b l e thermal
energy.
A sequence timer locks o u t t h e u n i t , i f the
equipment is not synchronized w i t h i n a predetermined
time, a f t e r t h e engine s t a r t i n g s i g n a l has been given.
In o r d e r t o a s s u r e proper functioning of t h e
Total Energy P l a n t , Load Balancing Condensors have
a l s o been provided; thus, when there i s no demand f o r
steam o r hot water, t h e heat i s r e j e c t e d t o t h e
cooling tower. I t i s i n t e r e s t i n g t o note, t h a t t h e
Cooling Tower capacity need not be increased above
b a s i c r e f r i g e r a t i o n requirements whenever a Total
Energy P l a n t i s connected with a cooling p l a n t , because t h e r e i s no need t o condense steam when ref r i g e r a t i o n i s required. The cooling tower sized f o r
t h e r e f r i g e r a t i o n equipment ( a t l e a s t one absorption
u n i t when T o t a l Energy i s designed) has ample capacity
t o r e j e c t engine h e a t i n the intermediate seasons
and c e r t a i n l y i n winter. Obviously, one c e l l of t h e
tower must be winterized.
AUTOMATIC PLANT OPERATION
FUELS
With t h e "lead" u n i t running and'on t h e l i n e ,
t h e second u n i t w i l l be automatically s t a r t e d up, synchronized and p u t on t h e l i n e when t h e demand has
increased t o a p r e s e t percentage o f t h e capacity of
the "lead" u n i t . I n sequence, t h e t h i r d and fourth
unitd w i l l be put on t h e l i n e i f t h e demand continues
t o b u i l d up beyond p r e s e t percentages of t h e capac i t i e s of the u n i t s already on t h e l i n e .
I n t e r r u p t i b l e n a t u r a l gas @ $2.30 p e r 1,000 f t ?
i s a v a i l a b l e from t h e Brooklyn Union Gas Company. Past
Each generating u n i t has been provided with one
c i r c u i t breaker compartment and one a u x i l i a r y compartment.
The generator a u x i l i a r y compartment i s equipped
with load demand c o n t r o l r e l a y s f o r automatically
s t a r t i n g up and stopping t h e engine generator u n i t s .
The e l e c t r i c load sensing and s h a r i n g governors
w i l l a t a l l times equally d i v i d e t h e load among the
engine generator u n i t s .
On a decrease i n demand, t h e above described sequence i s reversed.
Should t h e "lead" u n i t t r i p o u t while it i s running alone, t h e sequencing c o n t r o l s w i l l s t a r t up t h e
next u n i t i n l i n e and power w i l l be reestablished.
In order t o equalize engine running time, stop
engines f o r r e p a i r , o r b r i n g u n i t s i n t o proper operat i n g sequence a f t e r shutdown, t h e sequencing can be
rearranged with engines on t h e l i n e .
Load-dump relaying equipment has been provided
t o t r i p open load c i r c u i t breakers should enginegenerator overload occur. Tripped load breakers
w i l l automatically r e c l o s e when t h e replacement u n i t
comes on t h e l i n e .
HEAT RECOVERY
The h e a t recovery was designed f o r a dual c i r c u i t ; hot water and steam. Engine jacket water a t
17s0 i s pumped through a h e a t exchanger, and
t o t h e engine a t 163O F. thus h e a t i n g water from
150° t o 1 6 0 ~ ~This
.
water i s piped i n a s e r i e s i n t o
a "booster" heat exchanger, where i t s temperature is
r a i s e d t o 1900F. whenever t h e h e a t i n g system c a l l s f o ,
higher temperature water. During t h e intermediate and
sununer seasons, the jacket water r e j e c t e d heat is used
records have i n d i c a t e d i n t e r r u p t i o n s i n supply of
l e s s than 5 days p e r year,thus t h e a v a i l a b i l i t y of
t h i s f u e l keeps c o s t s a t a minimum.
The f u e l consumption, guaranteed by Nordberg, a t
80% P.F, when operating on a minimum of 4.1% p i l o t
o i l and maximum ~ a t u r a lgas is 8,185 BTO/net KWH f o r
Gas and 350 BTU/net KWH f o r O i l . The f i g u r e s f o r gas
assumes Low Heat Value and t \ e f i g u r e s f o r o i l , High
Heat alue. Naturally, a t p a r t load conditions, t h e
f u e l consumption increases. No. 2 f u e l o i l i s prese n t l y purchased a t $9.35 p e r gallon.
CONCLUSIONS
This T o t a l Energy Plant was b u i l t 8 years ago.
when e l e c t r i c energy was s e l l i n g i n New York f o r 0.90
p e r KWH and t h e bulk r a t e f o r i n t e r r u p t i b l e n a t u r a l gas
was 450 p e r 1000 cubic f e e t . Today, e l e c t r i c energy
c o s t s a r e about 5C p e r KWH with a demand charge o f
about $10.00 p e r KWH. I n t e r r u p t i b l e n a t u r a l gas s e l l s
f o r $2.30/1000 cubic f e e t .
The owners of t h i s Shopping Center had decided
t o accept o u r recommendation. t o build t h i s Total
Energy P l a n t i n 1970, although l o c a l u t i l i t y
( e l e c t r i c ) company opposition was strong. The engineering -economic a n a l y s i s , however, proved t h a t
t h e Return on Investment was good and t h e operation
of t h e P l a n t would not put undue burdens on t h e
Center's management.
The o p e r a t i n g records f o r t h e l a s t e i g h t years
have proven t h a t o w assumptions and computations
were c o r r e c t . In f a c t , t h e f u e l p r i c e i n c r e a s e of
over 500% s i n c e t h e p l a n t was f i r s t s t a r t e d did not
harm t h e economics of t h i s f a c i l i t y , s i n c e the
e i c c t r i c energy c o s t has increased by more than 10
'2Je.Ss
6 u ~ q p x a d op m 'xoq3erquo3 4 x a m q a e ~ n w quamdrnbz
4raau~6us' r a w aqq uaaMqaq uo~qeradooa as013
ayq 07 s y u ~ y l' h o q s ssaa3ns e uaaq seq sryl~,
-quama6euern
6 u ~ a e x a d oquaTfa3xa sqt pue uoTTeTTe?suT xadozd
sq? 'quaurd~nba s s e p q s n 3 sqy 02 s y u e ~' ~ 0 y 3 6 a 3 ~ ~
s q m
~ o q s s a m n s paqdnxxaqurun U P uaaq seq q u e ~ dSTY&
OTensn CP
SsauTsnq bu~q3npuoz1SPM xaqua3 hurddoyg PZPTd S ~ U T ) :
aq? ' L L ~ T A ~ n ru~ X q ~ 33 x 0 ~MaN u~ qnoyDeTq z o t m aw
6 u ~ x n pqeyq.aqe?s 03 sssaTpaN *eaxe m o ur sqnowozq
snoxamu p m s q n o y ~ e ~~ qF T ~ X20P apnqTqTnur
~
a142
q ~ y mpaxe&ozI aq qsnm s r r ~ , * m o q 3 ~ e ye 30 q n o y ~ e f q
a~fju~
aU0
s Y q T M uo?qexado snonu~quo330 s m o q 0 0 0 6 ~
xano u? g ~ a s q ruanoxd seq q u e ~ dAbxau3 Te?oL stm J O
h ~ ~ ~ c l aqa
e ~' o~s l va l - 0 ~ UT
6 ~qso3 S ~ Tsamta
---
----_
_
TOTAL ENERGY SYSTEM
COOLlNO TOW@#Y A I C R
USED Fm n E r n l a C R A ~ 1
CONDLNCINO IND. WHCN
~ ~ O U I ~ C O . U I O I McCo a 8 n o
COOLING TOWER
COOLING W A l E R SUPPLY
EL STEAM BOILERS