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Franklin Heating Station

11.75 MW CHP Application


Project Profile
In Partnership with the US DOE

Quick Facts
Location: Rochester, Minnesota Began Operation: 1928 (recent upgrade in 1999) Maximum CHP Generating Capacity: 11.75 Megawatts Maximum Boiler Capacity: 390,000 lbs/hr Max. CHP Chilled Water Capacity: 12,200 tons (steam turbine driven centrifugal chillers) Fuel: Natural Gas, #2 and #6 Fuel Oil Number of Buildings Served: 23 Buildings Floor Space of Buildings Served: 8,037,000 Square Feet

Project Overview
The Franklin Heating Station (FHS) provides chilled water, soft tempered water, low and high pressure steam and electricity to 25 downtown buildings in Rochester, Minnesota. Totaling over 8,000,000 square feet of floor space, the downtown properties include the Mayo Clinic, Rochester Methodist Hospital, Charter House and the Sunstone Corporation Hotel Properties. The FHS, in operation since 1928, is owned in partnership between the Mayo Clinic and Rochester Methodist Hospital and has a Combined Heat and Power (CHP) electric .generating capacity of 11.75 MW. Since 1928, the plant has been constantly expanded and modernized over its life to increase capacity, improve reliability and efficiency and serve the needs of its customers.

CHP Overview
The system utilizes two dual fuel high pressure steam boilers producing up to 240,000 lbs/hr steam at 850 psig. The 850 psig steam is fed through a single steam turbine producing 6.75 MW of electric power. Steam is extracted from the 6.75MW turbine at 400 psig and combined with the output steam from two additional dual fuel high pressure boilers with a total capacity of 150,000 lbs/hr steam at 400 psig. The 400 psig steam is run through two steam turbines producing a total of 5MW of electric power. A portion of the 400 psig steam is also utilized to operate four steam turbine driven centrifugal chillers producing a total of 8,600 tons of chilled water. The remaining 400 psig steam is reduced through a pressure reduction valve to 125 psig steam provided for customer use. The two steam turbines that produce a total of 5 MW of electric power also provide a stream of 10 psig steam that is utilized in part to produce an additional 3,600 tons of chilled water through a steam turbine driven centrifugal chiller. Part of the 10 psig steam is also provided for customer use.

FRANKLIN HEATING STATION ROCHESTER, MN


400 PSIG BOILER NO. 70 400 PSIG BOILER NO. 80 850 PSIG BOILER N0. 120 POE W M ER ER BUGE SS NC ENGINE/GENERATOR NO. 4 2500 KW ENGINE/GENERATOR NO. 5 2500 KW EMERG. PWR TO CUSTOMERS NORM AL POWE R BUSSE RPU PURCHASED ELECTRICITY TO CUSTOMERS 10 PSIG STEAM TO CUSTOMERS

850 PSIG BOILER NO. 120

400 PSIG

850 PSIG

TURBINE NO. 1 70 KPPH SC

GEN. NO. 1 2500 KW

28% of the electricity used in the system is produced by CHP

TURBINE NO. 3 240 KPPH

GEN. NO. 3 6800 KW

10 PSIG

TURBINE NO. 2 70 KPPH S C

GEN. N0. 2 2500 KW

STEA TURBINE S

CHLR NO. 2 3500

CHLR NO. 1 2700

ELEC. MOTOR

CHILLED WATER TO CUSTOMERS

STEAM TURBINE SC

CHLR NO. 3 1000 TONS

STEAM TURBINE S

CHLR NO. 5 3000

STEAM TURBINE S

CHLR NO. 6 3600

CHLR NO. 4 2000 125 PSIG

ELEC. MOTOR 125 PSIG STEAM TO CUSTOMERS

90% of the 10 psig heating steam is produced by CHP turbines

400 PSIG

WATER SOFTENERS COOLING TOWER MAKEUP AND SEWER

TEMP. SOFT WATER TO CUSTOMERS

Financial Overview Energy Flow Overview


The diagram above shows the steam flows within the Franklin Heating Station facility. The tables list the major equipment involved. In 1928, the plant incurred expenses of $22,000 with a work force of 15 employees and servicing 11 buildings. Today, the expenses total over $22,000,000 with the work force reaching 36 employees and servicing 25 buildings. The operating revenue for the Franklin Heating Station is recovered from rates charged for products metered at each building served, while the capital costs for new equipment are reimbursed by the partners based upon the percentage of their system demand.

STEAM PRODUCT EQUIPMENT


UNIT NO. BLR. 1 BLR. 2 BLR. 3 BLR. 4 MANUFACTURER Riley Stoker (1952) Riley Stoker (1950) Combustion Engineering (1968) Combustion Engineering (1968) PRESS. 400 psig 400 psig 850 psig 850 psig CAPACITY 70,000 pph 80,000 pph 120,000 pph 120,000 pph FUEL N. Gas/#6 Fuel Oil N. Gas/#2 Fuel Oil N. Gas/#6 Fuel Oil N. Gas/#6 Fuel Oil

88% of the condensate from the heating steam is recovered for reuse

ELECTRICAL GENERATION EQUIPMENT


UNIT NO. 1 2 3 4 5 MANUFACTURER G. E. (1952) G. E. (1952) Worthington (1968) Fairbanks Morse (1982) Fairbanks Morse (1982) TYPE Steam Turbine Steam Turbine Steam Turbine Duel Fuel Engine Duel Fuel Engine SIZE 2,500 kW 2,500 kW 6,750 kW 2,500 kW 2,500 kW INLET PRESS. 400 psig 400 psig 850 psig EXTR. PRESS. 10 psig 10 psig 400 psig

CHILLED WATER EQUIPMENT


UNIT NO. MANUFACTURER 1 2 3 4 5 6 Carrier (1985) Carrier (1988) York (1999) York (1997) Carrier (1966) Carrier (1974) TYPE Open Drive Centrifugal Open Drive Centrifugal Open Drive Centrifugal Open Drive Centrifugal Open Drive Centrifugal Open Drive Centrifugal SIZE 2,700 tons 3,600 tons 2,000 tons 2,000 tons 3,000 tons 3,600 tons DRIVER 3000 HP Synchronous Motor 3500 HP 10 psig Steam Turbine 1989 HP 400 psig Steam Turbine 1825 HP Induction Motor 2750 HP 400 psig Steam Turbine 3500 HP 400 psig Steam Turbine

For further information, contact: Midwest CHP Application Center 851 S. Morgan Street Chicago, IL 60607-7054 Phone: (312) 413-3835 Fax: (312) 996-5620 www.CHPCenterMW.org