JWPCP Steam System
description
Transcript of JWPCP Steam System
![Page 1: JWPCP Steam System](https://reader033.fdocuments.net/reader033/viewer/2022061517/56814930550346895db670b8/html5/thumbnails/1.jpg)
JWPCPJWPCP Steam System Steam System
Startup and Commissioning
February 27, 2014
![Page 2: JWPCP Steam System](https://reader033.fdocuments.net/reader033/viewer/2022061517/56814930550346895db670b8/html5/thumbnails/2.jpg)
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
![Page 3: JWPCP Steam System](https://reader033.fdocuments.net/reader033/viewer/2022061517/56814930550346895db670b8/html5/thumbnails/3.jpg)
HRSG’sHRSG’s
![Page 4: JWPCP Steam System](https://reader033.fdocuments.net/reader033/viewer/2022061517/56814930550346895db670b8/html5/thumbnails/4.jpg)
Steam TurbineSteam Turbine
![Page 5: JWPCP Steam System](https://reader033.fdocuments.net/reader033/viewer/2022061517/56814930550346895db670b8/html5/thumbnails/5.jpg)
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
![Page 6: JWPCP Steam System](https://reader033.fdocuments.net/reader033/viewer/2022061517/56814930550346895db670b8/html5/thumbnails/6.jpg)
JWPCP (before)JWPCP (before)
![Page 7: JWPCP Steam System](https://reader033.fdocuments.net/reader033/viewer/2022061517/56814930550346895db670b8/html5/thumbnails/7.jpg)
JWPCP (after) JWPCP (after)
![Page 8: JWPCP Steam System](https://reader033.fdocuments.net/reader033/viewer/2022061517/56814930550346895db670b8/html5/thumbnails/8.jpg)
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
![Page 9: JWPCP Steam System](https://reader033.fdocuments.net/reader033/viewer/2022061517/56814930550346895db670b8/html5/thumbnails/9.jpg)
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
![Page 10: JWPCP Steam System](https://reader033.fdocuments.net/reader033/viewer/2022061517/56814930550346895db670b8/html5/thumbnails/10.jpg)
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
![Page 11: JWPCP Steam System](https://reader033.fdocuments.net/reader033/viewer/2022061517/56814930550346895db670b8/html5/thumbnails/11.jpg)
Chronology (cont.)Chronology (cont.)
Steam Turbine Overspeed Event● April 3, 2008
● Board authorizes emergency repairs for $2.5 million
![Page 12: JWPCP Steam System](https://reader033.fdocuments.net/reader033/viewer/2022061517/56814930550346895db670b8/html5/thumbnails/12.jpg)
Steam TurbineSteam Turbine
![Page 13: JWPCP Steam System](https://reader033.fdocuments.net/reader033/viewer/2022061517/56814930550346895db670b8/html5/thumbnails/13.jpg)
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
![Page 14: JWPCP Steam System](https://reader033.fdocuments.net/reader033/viewer/2022061517/56814930550346895db670b8/html5/thumbnails/14.jpg)
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
![Page 15: JWPCP Steam System](https://reader033.fdocuments.net/reader033/viewer/2022061517/56814930550346895db670b8/html5/thumbnails/15.jpg)
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
![Page 16: JWPCP Steam System](https://reader033.fdocuments.net/reader033/viewer/2022061517/56814930550346895db670b8/html5/thumbnails/16.jpg)
HRSG’sHRSG’s
![Page 17: JWPCP Steam System](https://reader033.fdocuments.net/reader033/viewer/2022061517/56814930550346895db670b8/html5/thumbnails/17.jpg)
Steam TurbineSteam Turbine
![Page 18: JWPCP Steam System](https://reader033.fdocuments.net/reader033/viewer/2022061517/56814930550346895db670b8/html5/thumbnails/18.jpg)
Construction (cont.)Construction (cont.)
Phase II● Begins May, 2010
● Estimated completion March, 2011
● Balance-of-plant equipment
● Electrical and instrumentation
● Startup and commissioning
![Page 19: JWPCP Steam System](https://reader033.fdocuments.net/reader033/viewer/2022061517/56814930550346895db670b8/html5/thumbnails/19.jpg)
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
![Page 20: JWPCP Steam System](https://reader033.fdocuments.net/reader033/viewer/2022061517/56814930550346895db670b8/html5/thumbnails/20.jpg)
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
![Page 21: JWPCP Steam System](https://reader033.fdocuments.net/reader033/viewer/2022061517/56814930550346895db670b8/html5/thumbnails/21.jpg)
NegotiationsNegotiations
JWPCP
EngineerSystems IntegratorEngineering Design
S&C ContractorField Engineering
Phase II Contractor
![Page 22: JWPCP Steam System](https://reader033.fdocuments.net/reader033/viewer/2022061517/56814930550346895db670b8/html5/thumbnails/22.jpg)
Negotiations (cont.)Negotiations (cont.)
Topics● Functional descriptions
● Functional test plan
● Functional testing
● Control descriptions
● Logic diagrams
● O&M manuals
● Training manuals
● Training
![Page 23: JWPCP Steam System](https://reader033.fdocuments.net/reader033/viewer/2022061517/56814930550346895db670b8/html5/thumbnails/23.jpg)
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
![Page 24: JWPCP Steam System](https://reader033.fdocuments.net/reader033/viewer/2022061517/56814930550346895db670b8/html5/thumbnails/24.jpg)
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
![Page 25: JWPCP Steam System](https://reader033.fdocuments.net/reader033/viewer/2022061517/56814930550346895db670b8/html5/thumbnails/25.jpg)
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
![Page 26: JWPCP Steam System](https://reader033.fdocuments.net/reader033/viewer/2022061517/56814930550346895db670b8/html5/thumbnails/26.jpg)
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
![Page 27: JWPCP Steam System](https://reader033.fdocuments.net/reader033/viewer/2022061517/56814930550346895db670b8/html5/thumbnails/27.jpg)
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
![Page 28: JWPCP Steam System](https://reader033.fdocuments.net/reader033/viewer/2022061517/56814930550346895db670b8/html5/thumbnails/28.jpg)
Startup & CommissioningStartup & Commissioning
Divided into Three Stages1. Document review
2. Document development
3. Startup and commissioning
![Page 29: JWPCP Steam System](https://reader033.fdocuments.net/reader033/viewer/2022061517/56814930550346895db670b8/html5/thumbnails/29.jpg)
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
![Page 30: JWPCP Steam System](https://reader033.fdocuments.net/reader033/viewer/2022061517/56814930550346895db670b8/html5/thumbnails/30.jpg)
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
![Page 31: JWPCP Steam System](https://reader033.fdocuments.net/reader033/viewer/2022061517/56814930550346895db670b8/html5/thumbnails/31.jpg)
Power ProductionPower Production
![Page 32: JWPCP Steam System](https://reader033.fdocuments.net/reader033/viewer/2022061517/56814930550346895db670b8/html5/thumbnails/32.jpg)
Steam TurbineSteam Turbine
![Page 33: JWPCP Steam System](https://reader033.fdocuments.net/reader033/viewer/2022061517/56814930550346895db670b8/html5/thumbnails/33.jpg)
HRSG’sHRSG’s
![Page 34: JWPCP Steam System](https://reader033.fdocuments.net/reader033/viewer/2022061517/56814930550346895db670b8/html5/thumbnails/34.jpg)
Lessons LearnedLessons Learned
Limit involved partiesAvoid advance purchased equipmentTighten startup and commissioning
language in specificationsPurchase all equipment under same
contract
![Page 35: JWPCP Steam System](https://reader033.fdocuments.net/reader033/viewer/2022061517/56814930550346895db670b8/html5/thumbnails/35.jpg)
QuestionsQuestions