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JWPCP Steam System

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.

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JWPCP Steam System

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  1. JWPCP Steam System Startup and Commissioning February 27, 2014

  2. History 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

  3. HRSG’s

  4. Steam Turbine

  5. 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

  6. JWPCP (before)

  7. JWPCP (after)

  8. 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

  9. Chronology 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

  10. 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

  11. Chronology (cont.) Steam Turbine Overspeed Event ● April 3, 2008 ● Board authorizes emergency repairs for $2.5 million

  12. Steam Turbine

  13. Chronology (cont.) Expedite Project Split 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

  14. The 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

  15. Construction Phase I ● Begins August, 2009 ● Ends ~April, 2010 ● Demolish steam turbine and HRSG’s ● Install new steam turbine and HRSG’s Mechanical installation only

  16. HRSG’s

  17. Steam Turbine

  18. Construction (cont.) Phase II ● Begins May, 2010 ● Estimated completion March, 2011 ● Balance-of-plant equipment ● Electrical and instrumentation ● Startup and commissioning

  19. 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

  20. 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

  21. Negotiations Engineer Systems Integrator Engineering Design JWPCP S&C Contractor Field Engineering Phase II Contractor

  22. Negotiations (cont.) Topics ● Functional descriptions ● Functional test plan ● Functional testing ● Control descriptions ● Logic diagrams ● O&M manuals ● Training manuals ● Training

  23. 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

  24. Negotiations (cont.) May 2012 ● Districts parties agree • Remove startup and commissioning from Phase II contract • End Phase II contract • End contract with Engineer and Systems Integrator • Turnover startup and commissioning to JWPCP • Engineering Design to assist JWPCP

  25. Proposal 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

  26. 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

  27. 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

  28. Startup & Commissioning Divided into Three Stages • Document review • Document development • Startup and commissioning

  29. Startup & Commissioning (cont.) Issues ● Steam turbine In storage since 2005 ● Steam blows Conducted more than one year ago ● Chemical cleaning Conducted more than one year ago

  30. Startup & Commissioning (cont.) • Completed in March, 2013 One month behind schedule • Fifty-two recommendations Most implemented • Approximately $85,000 in extra work Implementing recommendations

  31. Power Production

  32. Steam Turbine

  33. HRSG’s

  34. Lessons Learned • Limit involved parties • Avoid advance purchased equipment • Tighten startup and commissioning language in specifications • Purchase all equipment under same contract

  35. Questions

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