HomeMy WebLinkAbout06.a.1 (Handout) re Cogeneration System RecommissioningCOGENERATION SYSTEM RECOMMISSIONING Board of Director's Meeting September 6, 2012 Craig Mizutani Senior Engineer Central Contra Costa Sanitary District Cogeneration System Failure Investigation • Investigation Continues by District's Insurance Co. technical consultant, Engineering Design and Testing (ED &T) - Met August 27, 2012 - 3 Contributing Factors • Mechanical • Controls • Human Factors - Main Reason for Explosion: Uncombusted or partially combusted fuel in turbine 6A. /) (9-qndoa�) 1 Cogeneration System Failure Investigation • Mechanical - Fuel valve actuator considered bad, but not tested yet. - Orifice found missing from bottom injector - LEADING CAUSE (poor fuel distribution) - All other mechanical causes ruled out Mechanical Orifice & Fuel Actuator Cogeneration System Failure Investigation • Controls - ED &T has used CCCSD provided information on the control system - Several items that could be have contributed - No previous start issues - All "suspect" logic being reviewed by Solar Turbines & CCCSD - ED &T has determined that controls not an issue Cogeneration System Failure Investigation • Human Factors - ED &T believes human decisions were a factor • Fuel Actuator - lack of proper troubleshooting • Decision to try to manually adjust fuel at startup • Mechanical and Controls factors were contributory to human factors • No human factor attributable to Solar Turbines or CCCSD 3 Cogeneration System Failure Investigation • ED &T Summary for Startup - Mechanical Issues have all been addressed • Only remaining causes: orifice and fuel actuator have been addressed. • Other components that are suspect have been replaced. - Controls issues have been investigated and mitigated • Startup algorithm reviewed by Solar Turbines • Purge sequence being reviewed by Solar Turbines - Human Elements • Solar Turbines and CCCSD taking proper steps Cogeneration Repair Repairs Complete - R.F. MacDonald: Economizer, Ducting, Structural Supports, Expansion Joints, Diverter Valve. - CCCSD: New HRSG PLC, Enclosure panels, exhaust components - Aztec: Concrete work /Grout - Solar Turbines: Turbine exhaust parts, fuel system components, misc. parts - Boiler Permit Inspection 4 Cogeneration 7. Solar Turbines • New Fuel Train Components • New Exhaust Parts • New Miscellaneous Parts • Control System Review F r •I .. �.%k t BCD 5 Next Steps • Still Waiting on Critical Path Parts - Loader Valves (expected 9/21) - Fuel actuator • Miscellaneous (Insulation, Instruments, etc.) • Solar Turbine Work - Install loader valves - Install fuel actuator - Calibrate all instruments - Perform End -to -End test - Controls changes • Startup week of 9/24 -XL Next Steps • Insurance - Insurance will cover equipment rebuild costs (less $250,000 deductible) - Per ED &T, Insurance can allow 100% reimbursement of additional power costs if current schedule held - ED &T working on additional power cost verification a Questions? „,ter ��CCD-