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