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Strength in numbers: executing a large and complex complex boiler decentralization mission with an aggressive timetable and ongoing critical activities is fraught with engineering versions of land mines, pitfalls, and friendly fire. What better facility to undertake this mission than a U.S. Marine Corps training site? See how solid planning and team performance hurdled multiple obstacles to improve economy and service for 125 buildings.

Article Excerpt
Beginning in 2001 James Naylor P.E., special projects manager at Marine Corps Base (MCB) Quantico, led the charge to modernize the base's ailing infrastructure with efficient, decentralized heating plants. The poor condition of the steam and condensate piping resulted in substantial energy loss, building damage, and a mounting deferred-maintenance liability.

Naylor opted for an energy savings performance contract (ESPC) strategy and designated the energy services company (ESCO) Select Energy Services, Inc. (SESI), to implement a program for installation and maintenance of new boilers and other heating equipment within various buildings.

Within three years, new heating plants serving 125 buildings (3.5 million sq ft) had been installed and placed in operation. The central steam system was decommissioned, and measurement and verification (M&V) confirms that the project saves more than $3.9 million/yr in costs for utilities and O&M. Taking utility cost escalation into account, the total savings over the life of the project will exceed $120 million.

The total ESPC cost, which MCB Quantico repays out of its utility budget as annual savings, is $31.5 million and includes construction as well as O&M over the 23-year contract term.

PRE-IMPLEMENTATION FACILITY CONDITIONS

As the USMC's premier enlisted- and officer-training academy in the Northeast, MCB Quantico occupies a 60,000-acre site in Quantico, VA that reaches three countries. It hosts a number of facilities including Officer Candidates School, Marine Corps University, Marine Corps Air Facility, target ranges, and recreational areas. Buildings date back as far as 1919, with many listed as historically significant. Among the various building uses are housing, administration, education, multipurpose, library, dining, recreation, storage, maintenance, and medical care.

The existing central steam plant originally burned coal but was later converted to use natural gas, with No. 2 fuel oil for backup. It was capable of producing 260,000 lbs/hr of steam at its distribution pressure of 125 psig.

The aging steam and condensate site-distribution piping developed significant leakage through connections, steam traps, and breaks, resulting in less than 20% of the supplied steam returning to the central plant as condensate. Many of these losses were evidenced by heavy steam plumes discharging continuously from manholes and vents. Conduction heat losses, inherent in any site steam-distribution system, worsened from damage, deterioration, and waterlogged pipe insulation.

The central plant used an annual average of 500,000 MBtu of natural gas and fuel oil, at a cost of $2.25 million. The steam and condensate losses resulted in a high makeup rate for water and associated costs for chemical treatment. In addition, the leaking steam and condensate also raised issues over environmental liability.

The steam systems inside the various buildings had deteriorated as well due to poor...