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
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(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
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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
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Questions?
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