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JWPCP Steam System. Startup and Commissioning. February 27, 2014. History. Total E nergy Facility ● Placed into operation in 1986 Combined cycle power plant Three gas turbines (7.2 MW each) One steam turbine (5.5 MW) Generates ~14 MW ● Capital cost of ~$45 million. HRSG’s. - PowerPoint PPT Presentation
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JWPCPJWPCP Steam System Steam System
Startup and Commissioning
February 27, 2014
HistoryHistory
Total Energy Facility● Placed into operation in 1986
Combined cycle power plant
Three gas turbines (7.2 MW each)
One steam turbine (5.5 MW)
Generates ~14 MW
● Capital cost of ~$45 million
HRSG’sHRSG’s
Steam TurbineSteam Turbine
History (cont.)History (cont.)
1994 Consent Decree
● Federal and state governments, NRDC and Heal the Bay
● Full secondary by December 31, 2002
Four new Reactor/clarifier trains
New cryogenic oxygen plant
Seven new digesters
● Higher electricity/steam demand
● Higher digester gas production
JWPCP (before)JWPCP (before)
JWPCP (after) JWPCP (after)
History (cont.)History (cont.)
TEF Modifications
● Conduct in two stages
1. Replace gas turbines
7.2 MW to 9.9 MW
Completed in 2001
2. Replace steam system
5.5 MW to 8.7 MW
New HRSG’s
ChronologyChronology
Equipment Procurement
● Steam Turbine
Purchased in 2005 for $2.4 million
Placed in storage in 2005
● HRSG’s
Purchased in 2005 for $3.3 million
Stored outside, beginning 2005
Chronology (cont.)Chronology (cont.)
2007 Advertisement● Advertise for Engineering, Procurement and
Construction (EPC) contractor
● No takers
Contractors unable to locate consultants to complete engineering design
● Advertisement terminated
● Negotiate with Engineer to complete design
● Anticipate construction completion in April 2011
Chronology (cont.)Chronology (cont.)
Steam Turbine Overspeed Event● April 3, 2008
● Board authorizes emergency repairs for $2.5 million
Steam TurbineSteam Turbine
Chronology (cont.)Chronology (cont.)
Expedite ProjectSplit into two phases in summer 2008
● Phase I: mechanical installation of steam turbine and HRSG’s
● Phase II: balance-of-plant installation and startup & commissioning
Advance procure additional equipment
Anticipated construction completion in May 2010
The PlayersThe Players
Sanitation Districts
Engineering Design
Field Engineering
JWPCP Engineer (designer) Phase I Contractor Phase II Contractor Systems Integrator Startup & Commissioning (S&C) Contractor Equipment Suppliers
ConstructionConstruction
Phase I● Begins August, 2009
● Ends ~April, 2010
● Demolish steam turbine and HRSG’s
● Install new steam turbine and HRSG’s
Mechanical installation only
HRSG’sHRSG’s
Steam TurbineSteam Turbine
Construction (cont.)Construction (cont.)
Phase II● Begins May, 2010
● Estimated completion March, 2011
● Balance-of-plant equipment
● Electrical and instrumentation
● Startup and commissioning
Construction (cont.)Construction (cont.)
Phase II Construction Delays● Equipment approvals
● Equipment fabrication
● Equipment erection
Cooling towers
High-pressure gas pretreatment
● In part, due to the multitude of players
Construction (cont.)Construction (cont.)
Steam Blows● Conducted in October 2011
● Precedes startup and commissioning
● Startup & commissioning contractor needed detailed start up documents
● Startup and commissioning halted for safety reasons
NegotiationsNegotiations
JWPCP
EngineerSystems IntegratorEngineering Design
S&C ContractorField Engineering
Phase II Contractor
Negotiations (cont.)Negotiations (cont.)
Topics● Functional descriptions
● Functional test plan
● Functional testing
● Control descriptions
● Logic diagrams
● O&M manuals
● Training manuals
● Training
Negotiations (cont.)Negotiations (cont.)
Summary● S&C Contractor
Didn’t want to provide materials, or wasn’t going to provide materials unless paid more
● Engineer and Systems Integrator
Wanted more money; however, we were not confident they had the expertise to do it
Negotiations (cont.)Negotiations (cont.)
May 2012
● Districts parties agree
1. Remove startup and commissioning from Phase II contract
2. End Phase II contract
3. End contract with Engineer and Systems Integrator
4. Turnover startup and commissioning to JWPCP
5. Engineering Design to assist JWPCP
ProposalProposal
June 2012● JWPCP solicits proposals from four contractors
● Two proposals received
● Select contractor
Offers expert in steam systems
● On June 27, 2012, Board of Directors authorizes Purchase Order for $415,000
Proposal (cont.)Proposal (cont.)
Proposal Deliverables● Functional test plan
● Functional testing
● Logic diagrams
● Control descriptions
● O&M manuals
Including startup, shutdown, operating, troubleshooting and emergency procedures
● Training manuals
● Training
Proposal (cont.)Proposal (cont.)
Proposal Deliverables (cont.)● Schedule
Seven-month schedule, completing in February, 2013
● Programmer
Logic review
Make changes to programming (200 hours)
● Expertise
Make recommendations for improvements
● Project team dedicated to project
Startup & CommissioningStartup & Commissioning
Divided into Three Stages1. Document review
2. Document development
3. Startup and commissioning
Startup & Commissioning Startup & Commissioning (cont.)(cont.)
Issues● Steam turbine
In storage since 2005
● Steam blows
Conducted more than one year ago
● Chemical cleaning
Conducted more than one year ago
Startup & Commissioning Startup & Commissioning (cont.)(cont.)
Completed in March, 2013
One month behind scheduleFifty-two recommendations
Most implementedApproximately $85,000 in extra work
Implementing recommendations
Power ProductionPower Production
Steam TurbineSteam Turbine
HRSG’sHRSG’s
Lessons LearnedLessons Learned
Limit involved partiesAvoid advance purchased equipmentTighten startup and commissioning
language in specificationsPurchase all equipment under same
contract
QuestionsQuestions