JWPCP
Steam System
Startup and Commissioning
February 27, 2014
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
HRSG’s
Steam Turbine
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 (after)
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
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
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.)
Steam Turbine Overspeed Event
● April 3, 2008
● Board authorizes emergency repairs for $2.5
million
Steam Turbine
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
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
Construction
Phase I
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Begins August, 2009
Ends ~April, 2010
Demolish steam turbine and HRSG’s
Install new steam turbine and HRSG’s
Mechanical installation only
HRSG’s
Steam Turbine
Construction (cont.)
Phase II
●
●
●
●
●
Begins May, 2010
Estimated completion March, 2011
Balance-of-plant equipment
Electrical and instrumentation
Startup and commissioning
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.)
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
Negotiations
Engineer
Systems Integrator
Engineering Design
S&C Contractor
Field Engineering
Phase II Contractor
JWPCP
Negotiations (cont.)
Topics
●
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●
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●
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Functional descriptions
Functional test plan
Functional testing
Control descriptions
Logic diagrams
O&M manuals
Training manuals
Training
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.)
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
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
Proposal (cont.)
Proposal Deliverables
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●
●
●
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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 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 & Commissioning
Divided into Three Stages
1. Document review
2. Document development
3. Startup and commissioning
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
Startup & Commissioning
(cont.)
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

Completed in March, 2013
One month behind schedule
Fifty-two recommendations
Most implemented
Approximately $85,000 in extra work
Implementing recommendations
Power Production
Steam Turbine
HRSG’s
Lessons Learned


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Limit involved parties
Avoid advance purchased equipment
Tighten startup and commissioning
language in specifications
Purchase all equipment under same
contract
Questions