v004t10a013-98-gt-307

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THE AMERICAN SOCIETY OF MECHANICAL ENGINEERS 345 E. 47th St., New York, N.Y. 10017 98 -GT-307 The Society shall not be responsible for statements or opinions advanced in papers or discussion at meetings of the Society or of its Divisions or Sections, or printed in its publications. Discussion is printed only if the paper is published in an ASME Journal. Authorization to photocopy for internal or personal use is granted to libraries and other users registered with the Copyright Clearance Center (CCC) provided $3/article or a4/page is paid to CCC, 222 Rosewood Dr., Danvers, MA 01923. Requests for special permission or bulk reproduction should be addressed to the ASME Technical Publishing Department. Copyright 0 1998 by ASME All Rights Reserved Printed in U.SA CONSTRUCTION, STARTUP, COMMISSIONING AND TESTING OF A 240 MW GAS TURBINE SPINNING RESERVE POWER PLANT, CAMBALACHE, PUERTO RICO Neil M. Parece ABB Power Generation Inc., Richmond, Virginia Septimus van der Linden ABB Power Generation Inc., Richmond, Virginia Ismael Brito Diaz Autoridad de Energia de Puerto Rico, San Juan, Puerto Rico ABSTRACT The Cambalache Power Station, engineered from 1993 to 1995, and constructed from 1996 to 1997, provides the island grid of Puerto Rico with 240 MW of flexible gas turbine power. The plant, now in commercial operation, has demonstrated the capability of a steam enhanced gas turbine to provide highly efficient simple cycle base load power and spinning reserve power to an island network which cannot rely on outside power generators to supplement demand in the event of forced outages and emergencies in other power stations. The plant also demonstrates the first application of a high temperature selective catalytic reactor for NOx reduction to less than 10 ppm (No. 2 fuel oil) on a volume basis corrected to 15% 02. Finally, the installation demonstrated the benefits to the owner, the Puerto Rico Electric Power Authority (PREPA), of a turnkey contract with the entire plant, including offsite oil barge delivery facilities, water wells, and 230 kV substation, designed, supplied and installed by one contractor. The power station was engineered, constructed and started by a limited partnership led' by ABB Power Generation Inc. with Metric Constructors. Civil, structural and balance of plant engineering was performed by Lockwood Greene Scott and Associates., Cambalache Limited Partnership (CLP). Prime Movers 3 GTI IN1, steam injected 83 MW ISO Emissions control 3 Steam injection + High temp SCR 10 ppmvd NOx GT Control System 3 MOD300 Egatrol Standalone GT control Plant control system 1 MOD300 DCS Emissions monitoring 3 CEM system (1 per turbine) Switchyard 1 230 kV switchyard (3 infeeds) Fuel Storage 3 Above ground steel tanks, Not Distillate 4.2 MM US Gal each Demineralized water I Above ground steel, lined tank 2.2 MM US Gal Raw Water 1 Above ground steel tank 1.2 MM US Gal Demineralizing plant l Filtration/Cation/Anion/Mixed Bed 750 gpm throughput Black Start Engines 2 Diesel reciprocating engines 1500 kW each/paralleled Fuel unloading 3 Barge uploading pump facility 1150 gpm ea Raw water wells 4 Well pumps 450 gpm ea Waste water neutralizing 1 Neutralizing tank and acid/caustic pumps 150,000 US Gal Table 1 Main Equipment Presented at the International Gas Turbine & Aeroengine Congress & Exhibition Stockholm, Sweden — June 2—June 5, 1998 Downloaded From: http://proceedings.asmedigitalcollection.asme.org/ on 01/14/2015 Terms of Use: http://asme.org/terms

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Page 1: V004T10A013-98-GT-307

THE AMERICAN SOCIETY OF MECHANICAL ENGINEERS345 E. 47th St., New York, N.Y. 10017 98 -GT-307

The Society shall not be responsible for statements or opinions advanced in papers or discussion at meetings of the Society or of its Divisions orSections, or printed in its publications. Discussion is printed only if the paper is published in an ASME Journal. Authorization to photocopyfor internal or personal use is granted to libraries and other users registered with the Copyright Clearance Center (CCC) provided$3/article or a4/page is paid to CCC, 222 Rosewood Dr., Danvers, MA 01923. Requests for special permission or bulk reproductionshould be addressed to the ASME Technical Publishing Department.

Copyright 0 1998 by ASME

All Rights Reserved

Printed in U.SA

CONSTRUCTION, STARTUP, COMMISSIONING AND TESTING OF A 240 MW GASTURBINE SPINNING RESERVE POWER PLANT, CAMBALACHE, PUERTO RICO

Neil M. PareceABB Power Generation Inc., Richmond, Virginia

Septimus van der LindenABB Power Generation Inc., Richmond, Virginia

Ismael Brito DiazAutoridad de Energia de Puerto Rico, San Juan, Puerto Rico

ABSTRACT

The Cambalache Power Station, engineered from1993 to 1995, and constructed from 1996 to 1997,provides the island grid of Puerto Rico with 240 MWof flexible gas turbine power. The plant, now incommercial operation, has demonstrated the capabilityof a steam enhanced gas turbine to provide highlyefficient simple cycle base load power and spinningreserve power to an island network which cannot relyon outside power generators to supplement demand inthe event of forced outages and emergencies in otherpower stations. The plant also demonstrates the firstapplication of a high temperature selective catalytic

reactor for NOx reduction to less than 10 ppm (No. 2fuel oil) on a volume basis corrected to 15% 02.Finally, the installation demonstrated the benefits tothe owner, the Puerto Rico Electric Power Authority(PREPA), of a turnkey contract with the entire plant,including offsite oil barge delivery facilities, waterwells, and 230 kV substation, designed, supplied andinstalled by one contractor. The power station wasengineered, constructed and started by a limitedpartnership led' by ABB Power Generation Inc. withMetric Constructors. Civil, structural and balance ofplant engineering was performed by LockwoodGreene Scott and Associates., Cambalache LimitedPartnership (CLP).

Prime Movers 3 GTI IN1, steam injected 83 MW ISOEmissions control 3 Steam injection + High temp SCR 10 ppmvd NOxGT Control System 3 MOD300 Egatrol Standalone GT controlPlant control system 1 MOD300 DCSEmissions monitoring 3 CEM system (1 per turbine)Switchyard 1 230 kV switchyard (3 infeeds)Fuel Storage 3 Above ground steel tanks, Not Distillate 4.2 MM US Gal eachDemineralized water I Above ground steel, lined tank 2.2 MM US GalRaw Water 1 Above ground steel tank 1.2 MM US GalDemineralizing plant l Filtration/Cation/Anion/Mixed Bed 750 gpm throughputBlack Start Engines 2 Diesel reciprocating engines 1500 kW each/paralleledFuel unloading 3 Barge uploading pump facility 1150 gpm eaRaw water wells 4 Well pumps 450 gpm eaWaste water neutralizing 1 Neutralizing tank and acid/caustic pumps 150,000 US Gal

Table 1Main Equipment

Presented at the International Gas Turbine & Aeroengine Congress & ExhibitionStockholm, Sweden — June 2—June 5, 1998

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Rte.u, Wftwcy(%vsrid v.La.dI%cl,b.skwnM;.ctionr,a' W

wat %J

Figure 1 - Relative unit efficiency (%) vs. Relative Load (%)for Steam and Water Injection GT1IN1

Steam does not undergo a phase change as water doesin the combustion process, therefore higher rates ofsteam flow are required to achieve the same emissionsreductions. Because steam injection rates are higherthan with water to achieve NO x reduction, powerenhancement is a natural byproduct. The gas turbineunits at Cambalache produce 83 MW nominally with85°F (30°C) ambient air temperature vs. ISO rating of83 MWnu, 59°F (15°C).

The feedwater supply system design is unique.As only piping losses had to be considered, OTSGfeedwater pumps were located adjacent to thedemineralized water storage tank, instead of usingforwarding pumps. The pump size was not affectedby the additional piping losses.

Additional Environmental Considerations

Hi-Temp SCR Application

Despite the incorporation of maximum steaminjection, and PREPA's commitment to use low sulfurand low nitrogen content fuel, it was determinedduring the air permitting process, that a furtherreduction in exhaust gas NOx was required to meetthe latest BACT (Best Available Control Technology)standards .2 PREPA was required to achieve anemission level of 10 ppmvd while burning No.2distillate. This resulted in a lengthy evaluationprocess of the possible design solutions. SelectiveCatalytic Reactors (SCRs) were considered the logicalchoice to accomplish the further emission reductions.Due to the maturity of the design, however, standardSCR technology which operates optimally in therange of 650°F (343°C) exhaust temperatures couldnot be readily applied. The exhaust temperaturesupstream of the OTSG's is full turbine exhausttemperature, for the GTI INI this is approximately960°F (515°C). Downstream of the OTSG,temperatures are still normally between 750 - 800 °F(400°C-426°C); too high for traditional SCRapplication.

PLANT DESIGN

The power station's major equipment and featureswere selected based on the following systemrequirements. (Table 1)

Spinning Reserve Capability

As an island grid, the Puerto Rico electric systemis highly susceptible to load rejection when one of itspower generating stations is off line due to unplannedoutages or failures. In order to limit the impact ofsuch failures by adding to grid stability, and plan for asteadily increasing base load demand, PREPA decidedto install a power station with a nominal capacity of240 MW, with the ability to rapidly respond to gridfrequency fluctuations. Frequency drops because ofthe loss of power supply on the grid. With a quickenough recovery by other generators, or bydisconnecting load, the grid can be stabilized withouta serious blackout. Gas turbines were the logicalchoice for a power station which could start and stopdaily, operating only when system demand required,and which could be available to rapidly introducepower to the grid on demand. During contract testing,it was demonstrated that each gas turbine could rampfrom 60% relative load (approximately 48 MW at siteconditions) to base load (approximately 83 MW at siteconditions) in one second or less. The subject of theCambalache Power Station's Rapid Spinning Reserve(RSR) design will be presented in further detail inanother ASME paper.

Steam Enhanced Power

PREPA operates the power station daily tosupport its goal of rapid spinning reserve, thereforeefficiency was an important design goal. While acombined cycle plant offers the best efficiency, itcould not offer as quick startups or ease of operationas a simple cycle plant. As an innovative approach,ABB offered PREPA a steam enhanced simple cycle,utilizing heat recovery steam generators of the oncethrough design. This approach was described asSteam Enhanced Power (SEP), and was conceptuallydescribed in ASME paper 95-CTP-20 presented inVienna, Austria.' Supplied by Innovative SteamTechnologies, of Ontario, Canada, the once throughsteam generators (OTSG) provide up to 145,000 pph(65,772 kg/hour) of 325 psig [22.5 bar], 750°F(400°C) steam for injection in the combustion process.Steam enhancement provides NO x reduction to 50ppmvd and power augmentation, while allowing thegas turbines to operate at a proven heat rate of lessthan 10.500 Btu/kWh at base load. This comparesfavorably with the traditional No control injection ofwater into the combustion process. Fig I

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To keep the project on track, and meetenvironmental requirements, a relatively newtechnology was evaluated, and ultimately applied.The technology is so-called high temperaturecatalysts. The catalyst chosen was designed andsupplied by Engelhard Corporation, using theirproprietary ZNX catalyst technology. 3 This catalystis designed to operate in exhaust gas streams up to1000°F(538°C), and ideally in the 850-950°F (454°C-510°C) range. The ZNX solution is otherwise verysimilar to traditional SCRs, using ammonia injectionto react with NOx in a reduction process across thecatalyst bed. Contract and regulatory testsdemonstrated the catalyst application achieved thegoal of <10 ppmvd NO in the stack gas. A threeyear catalyst warranty is intended to support long termdemonstration of the suitability of the technologyapplication. To the authors' knowledge, theCambalache Power Station is the first application ofhigh temperature catalyst technology on a large framesize engine, for No. 2 Distillate.

Another design challenge associated with theapplication of the high temperature SCR was itsplacement directly downstream of the turbine exhaustwhere gas flow is turbulent and velocities are non-uniform Fig 2 & 3

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Side to Side Velocity Distribution Entering Cavity

SCR manufacturers typically require flow velocities tobe uniform within ± 15% across the entire catalystsurface. In typical applications, where the SCR isinstalled between heat transfer surfaces in a heatrecovery steam generator, this is not unreasonable, asthe HRSG tubing provides significant flowstraightening and distribution. Also, some flowstraightening is often incorporated upstream of theHRSG to improve heat transfer performance or toaccommodate supplemental firing. In the applicationat Cambalache, significant modeling and analyticalstudy was performed to achieve a flow correctiondesign that would achieve the required level of flowuniformity. Fig. 4

In the end the SCR manufacturer tookresponsibility to design the upstream ductwork, withflow straightening devices. Site testing and catalystinspections demonstrated that acceptable flowdistribution was achieved.

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Cambolacbe Unit Pte. Now Model

Normalized Normal Velocity SCR Inlet now

-NAPA wC obJ 2 1 4 5 4 7 dR A^ara^e

1 -0.04 •036 -0.71 -0.37 -105 -0.01 -0L0 0.13 -O.5l92 •Oi? -OAI 022 1.13 1.11 .40 •0.?0 .0.79 .0.1*3 41,51 -0.ZZ 1.11 1.16 1.15 0.95 -0.17 0.74 0,3614 1.09 0.01 1.75 3.17 2.89 2.11 0.94 -L3& UMS3 -1..Z,7 0.80 2.75 4.44 4.33 1.94 0.) 1.83 1.5394 -1.71 0.I1 2.69 6.65 6.66 2.11 0.48 -3.11 1.7407 -1.75 .4}# 3.47 0.?: 6. 1$ 1.65 0.17 •2.24 2.0148 -134 .1.84 2.97 5.90 5.84 1.85 -1.34 -2.66 L083

Aresna •I.It16 -0336 1.7$S 340 3.395 IM* -44065 .1.681 1.000Sinew 344.71%

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Avarsge 1.0$ 1.007 0.973 14)09 0.993 0.995 0.967 14M 0.995Sella+ 7.04%

Fig. 4. Gas Distribution at SCR Surface (Plane 1)

Plant Location

The plant is located on the northwestern coast ofPuerto Rico. The selection of this area was the resultof network and capacity planning during the 1980sand early 1990s. The owner, Puerto Rico Electric

Power Authority (PREPA) intends the plant toenhance voltage stability to the western side of thePuerto Rico electrical grid. The majority of othergenerating stations are located on the eastern half ofthe island, nearer to the larger population centers.With expansion of residential and commercial

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property in the west, additional generating capacitywas needed.

Wetlands Consideration

The plant is located in the Arecibo River valley, ongovernment controlled land with occasionalagricultural use. The land adjacent to the plantproperty was known to contain certain plant specieswhich are indigenous to Puerto Rico wetlands.During the plant design and permitting phase in late1994, the US Army Corps of Engineers (USACOE)surveyed the site and surrounding land to determinethe extent to which wetlands might be affected by thepower station. USACOE's determination radicallychanged the expectations of PREPA and ABB.PREPA was faced with a potentially lengthy reviewprocess if the original plant layout was to bemaintained. Instead, a complete redesign of the plantarrangement was undertaken Fig. 5a&b, [Next Pages]

This action allowed the plant design to continuetoward completion, and avoided disturbing wetlandareas. The plant area designated for the gas turbineswas fortunately not affected, as any relocation of theexhaust stacks would have resulted in significant airpermit delays.

Soils & Site Preparation

The soils in the vicinity of the plant areinadequate to support heavy structures and rotatingequipment. The original design plans for theCambalache station envisioned a 6 month periodduring which the site would be surcharged withimported fill material, and allowed to settle, thuscompacting the soils to acceptable strengths. Thisconcept was costly both in the cost of construction.and in the waiting period imposed on PREPA andCLP. An alternative design solution was proposedand accepted by PREPA which resulted in significanttime savings. The solution was based on the use ofreinforced concrete piles to support major equipment,structures and foundations. This solution elegantlysolved a frustrating problem, using a patented piledesign indigenous to Puerto Rico, the Fuentes pile.75 kip strength per pile was achieved with 100-125feet (38-52m) pile depths. Piling was achieved inapproximately 4 months, during which parallelconstruction activities could take place around piledriving equipment. This significantly improved analready strained schedule.

A similar consequence of the poor soils in thearea was difficult with the traditional utility practiceof burying cable and piping in concrete duct banksand pipe chases. Initial design analyses indicated thatconcrete duct banks and pipe chases would requirepile supporting. This would have resulted insignificant cost impacts to the project, which wereunforeseen at the outset. With cooperation fromPREPA, the design team was able to use above

ground pipe racks, cable trays, in conjunction withmodular concrete cable trenches, thereby avoiding pilesupporting of these ancillary structures. Only mainroad crossings were provided with concrete pipetrenches, which were short enough in span to besupportable without piles. Access andmaintainability have been preserved in the design,avoiding the usual objection to above ground cableand pipe routing.

Power and control cables were selected towithstand the expected higher exposure to water fromrunoff during rainstorms. Experience in areas likePuerto Rico, which is subject to regular and heavyrain, as well as lightning, led to the use of fiber opticcommunication cable for the main plant controlsystem. This cable connects the gas turbinecontrollers and the field located input/output hardwareto the distributed control systems main controller.Other plants using traditional communication cabletypes, such as coaxial, have suffered control systemfailure during heavy lightning storms. Fiber opticcommunication has been shown to be less susceptibleto these failures.

Switchyard

The power station includes a 230/115 kVsubstation. The substation feeds 3 remote substations,one in Manati, one in Mayaguez, and one in Arecibo.The Arecibo substation, called Cambalache after theneighborhood in which it is situated, operates at 115kV. A 230kV/1 15 kV autotransformer is part of thepower station switchyard. The transformer stepsdown power station voltage to the local networkvoltage, and has sufficient capacity to carry the entireload of the plant. The switchyard utilizes a dual bus,breaker and a half scheme. This design providesoperational and maintenance flexibility, with theability to have one bus and associated circuit breakersand disconnect switches out of service in the event offailure, or required maintenance, withoutdisconnecting from the power station or the grid. Theswitchyard uses SF6 gas breaker technology withexposed copper bus and aluminum/steel cableconductors. Fig 6

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-`------ Fuel and Water

Figure 5BCambalache Site (Redesigned Plant Layout)

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Black Start Capability CONSTRUCTION SCHEDULE & CHALLENGES

A further design consideration for the plant wasblack starting capability. In the event of the loss ofnetwork power, the Cambalache plant is intended tobe a key contributor in re-establishing electrical powerto the grid. The plant design incorporates 3 MW ofblackstart diesel generators (2 x 1500 kW), withparalleling switchgear. The design allows thegenerators to be synchronized to any of the three gasturbines through a common plant 5 kV switchgear fortesting purposes, and has sufficient capacity to startone gas turbine in the event of blackout.Synchronizing logic and load capacity were provenduring routine plant startup testing.

Schedule

The project underwent significant schedulemodifications from the initial kickoff in 1992 virtuallyup to commercial operation in July 1997. Thesemodifications presented challenges to the entireproject team. In the end, the project was completedwithin 16 months of full construction release.

The original contract schedule Fig' envisioned anapproximate 18-month development and permittingphase for the project, followed by a 9-month period offilling the site with a soil surcharge, as describedabove. The main construction and startup activitieswere to follow, and were scheduled to take 16 months,including all civil, mechanical and electrical work.

ID Task Name Start j Finish

189704 O7 Q2 03 04

1994 1995 1998 1997 1998 1

01 02 03 04 01 OZ 03 Q4 01102103104 01102103104 Ot 02 03 04 01 1 02

1 i

• Planned CO

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3 Permitting Actual Sat &15592 Sun 1/1/95

4 Site fill and compaction Plan Sat 111/94 I Thu 9/8194

5 InstallatioNCommissbnirg Planned ; Fri 9/9/941 Thu 11/30195

$ Planned Commercial Operation Thu 11/30/951 Thu 11/30/95

7 Full Release delay Mon 1/2195 i Thu 2/22/95

i InstaSatkkVCommisaioning Actual Fri 2123/96 Thu 7/10/97

9 Actual Commercial Operation Thu 7/10/97 Thu 7/10197

Figure 7Cambalache Construction Schedule

The site permitting process, in fact, took 29months before a draft air permit was received, and anadditional 15 months elapsed before the project couldbe fully released. During this time, engineering andmanufacturing were released in phases as confidencegrew that the project would ultimately go ahead. Siteclearing and grading were allowed to proceed in April1995, but no permanent construction was allowed tocontinue until late February 1996.

As discussed earlier, a design change from soilsurcharging to piling allowed the project to improvethe overall time schedule. In fact, pile driving wasaccomplished in the 16 month window originallyenvisioned for construction and startup.

Installation

In general, installation proceeded as planned.During the 16-month period from February 1996 untilCommercial Operation in July 1997, Puerto Rico wassubject to three major hurricanes. However, the plantsite was spared any damage resulting from thesehurricanes, as they passed by to the north and south,with the heaviest weather missing the Arecibo area.

In this 16 month period, only 7 days of standstilldelay resulted from the weather.

PREPA intended to energize a 115 kV infeed tothe plant as the first connection to their system. Thiswas delayed when a lightning strike in October 1996destroyed the 230 kV/I 15 kV autotransfonner duringits installation (Fig 6). PREPA had to aggressivelyregroup to move forward the completion of a 230 kVconnection from Manati. A significant project delaywas avoided by the completion of this line in March1997. A replacement autotransformer was deliveredin August 1997, and the 115 kV system was energizedin November 1997. PREPA anticipates a significantimprovement in service to western customers as aresult.

Equipment delivery delays could have been aserious stumbling block for this project. Competentlocal representation is necessary to expedite criticaldeliveries, and a central control of all shippingactivities also proved essential. Most projects of thisnature suffer from extremely challengingmanufacturing schedules, with the constant threat ofsignificant delays due to equipment delivery. Sincemanufacturing had been released in phases, the projectwas able to stage equipment deliveries according the

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needs on site. What could have resulted in furtherproject delays, was thus avoided.

A great deal of planning and coordination wasstill required due to the island location. Because of itsclose affiliation with the United States, Puerto Rico isoften considered as close by, and not too difficult toaccess for delivery of material. In fact, for largeheavy equipment such as that for power plants. oceangoing barges are the standard. What can be deliveredon the mainland in 2 or 3 days by truck, requires 2 to3 weeks to be delivered to the jobsite in Puerto Rico.Goods must be delivered to certain ports of export,Jacksonville. Florida is one, to embark on a scheduledweekly barge. Once in Puerto Rico, goods are subjectto inspection and payment of excise taxes.Documentation and delivery processes are nearly asinvolved as importation through federal customsauthorities.

Start-up and Commissioning

Start-up of the power plant was achievedbetween January and July 1997. Fig. s

Figure 8Completed Cambalache Power Plant

Parallel commissioning of the balance of plant and thegas turbines was required. Each gas turbine wasassigned a dedicated team of engineers. supported bya team commissioning balance of plant systems. the230 kV switchyard. and equipment supplierrepresentatives.

First ignition for each turbine was achieved onFebruary 20. March 21. and May 23, 1997. for unitsI. 2 and 3 respectively. Steam injection, SCR andammonia control, full load, and rapid spinning reservetesting followed. The SEP system was initiallyhampered by fluctuations in the feedwater supplypressures, and a dead band phenomenon atapproximately 70% relative load. Root cause analysisled to a change in the feedwater control valve trim.which eliminated the fluctuations. The trim waschanged from an equal percentage design to a moretraditional linear design. While this design provides

slightly less turndown control, the stability in thenormal operating ranges was the determining factor.

Ammonia control was achieved using feedforward and feed back control. Feed forward controlwas based on relative turbine load, using a fieldestablished curve for ammonia vs. GT load, andfeedback control used stack NOx to trim ammoniaflow.

Performance testing was required to demonstrateguaranteed unit output, heat rate, and exhaustemissions. The output and heat rate tests wereconducted during an agreed on 2 hour periodaccording to a contract procedure. All units exceededperformance guarantees (Table 2)

TABLE 2Dimension Unit I Unit 2 Unit 3

Date 6/12/97 6/20/97 6/26/97Corrected kW 83,593 82,967 83,655OutputOutput kW 82,120 82,120 82,120GuaranteeCorrected BtuikWhr 10,148 10,160 10,149Heat RateHeat Rate Btu/kWhr 10,316 10,316 10,316Guarantee

Table 2:Performance Test Summary Of Results

Emissions Testing

Emissions testing was conducted according to anEPA approved test protocol. The test protocolrequired analysis of stack gases for volumetric flow,concentrations and mass flows of NOx, 02, CO, S02,SO3 and H2SO4, particulate matter < 10 microns(PM 10), opacity. and lead. Testing was conducted atspecified load conditions, and lasted approximatelysix days per unit. All units passed the requiredemissions tests. In addition, the CEMS were requiredto be tested for relative accuracy and calibration drift.The relative accuracy tests were conducted during theemissions testing, and all analyzers passed. The drifttesting requires unit operation over a period of 168hours. As the units are operated on an as neededbasis, the drift testing was not complete at the time ofwriting, however all analyzers are expected to meetthe drift requirements.

The unique feature of rapid spinning reserve(RSR) was also tested as part of the contractguarantees. The original contract required that eachgas turbine must respond to a drop in grid frequencyfast enough to ramp from 20% relative load to baseload in 5 seconds. Due to the air permit requirements,PREPA is only allowed to operate the units at 60%load and base load. Therefore the testingrequirements were modified to require that each

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turbine respond to a grid frequency drop by rampingfrom 60% relative load to base load in 3 seconds.The site testing showed that the gas turbines exceededthis guarantee. In a test run by PREPA, it wasdemonstrated that the gas turbines could ramp from60% relative load to base load in approximately 1second. Lifetime impacts were analyzed, andincorporated in the lifetime operating hour counters ofeach turbine. For a more detailed analysis of the RSRfeature demonstrated at the Cambalache PowerStation, the reader is referred to a further ASMEpaper.4

CONCLUSION

The Cambalache Power Station represents asignificant improvement to the reliability of the PuertoRico electric power system. The Steam EnhancedPower (SEP) plant demonstrated efficient, reliablepower, while also serving a spinning reserve powerfunction. At a nominal 248 MW plant output, theplant represents approximately 10% of the normalsystem load, and when operating in spinning reservemode, the plant offers approximately 100 MW ofinstantaneous load support. The plant offers thelowest fossil fueled emissions in Puerto Rico in itsclass, and demonstrates the achievement of over 5years of planning and execution, incorporating state ofthe art technologies enhancing proven powergeneration technology.

PREPA looks forward to future possibilities toconvert the Cambalache station to a full combinedcycle station, and to the possibility of alternative fueluse, such as liquefied natural gas which may becomeavailable in the coming years. The Cambalachestation has been designed to accommodate theseimprovements without major system or equipmentchanges.

ACKNOWLEDGMENTS

1 Rodriguez, van der Linden - Innovative Applications ofABB's GT1 IN! in a 248 MW Power Plant for SpinningReserve and Grid Stability on Island Generator System —Cambalache, Puerto Rico — ASME 95-CTP-20

2 Diaz Brito, Nymberg, "The Planning and ConstructionPermitting Requirements of a 248 MW GT Plant to MeetDemands and Growth of an island Generated system —Arecibo, Puerto Rico, ASME-ATP-046

3 ZNX Catalysts Technology — Engelhard Corporate TechProcedure

4Diaz Brito, Dost, von Rappard, "Gas Turbine SpinningReserve Operation to Support Frequency Drops in SmallGrid", 1998 - Presented at ASME Stockholm `98

Fg' Figure 1 - Relative unit efficiency (%) vs. Relative Load(%) for Steam Injection and Water Injection GTI 1NI

Fg. 2 Top to Bottom Velocity Distribution EnteringSCR cavity

rig. 3 Side to Side Velocity Distribution Entering SCRcavity

Fg. 4 Cambalache Unit Physical Flow Model

rig Cambalache Original Plant Site

Fg. 5b Cambalache Redesigned Plant Site

Fig. 6 Single Line Diagram

Fig. 7 Cambalache Construction Schedule

Fig Completed Cambalache Power Plant

10

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