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HomeMy WebLinkAboutAP&T O&M costs October 21, 2009 Nexterra Reference: 09018-3 Thomas Deerfield Dalson Energy Anchorage, AK Re: Expected Operating Costs For Internal Combustion Engine Demonstration project Dear Thomas, As requested, we are pleased to present you with a preliminary operating and maintenance costs for the Nexterra biomass gasification cogeneration system that will convert woody biomass into renewable heat and electricity in Tok, Alaska. 1. Introduction Alaska Power and Telephone (AP&T) is a leading utility based in Alaska. AP&T is interested in being a 2 MWe demonstration site for a new cogeneration application developed by Nexterra which will combine Nexterra’s gasification equipment with a GE Jenbacher high efficiency engine. 2. Expected Operating Costs Below is the expected operating and maintenance costs for the gasifier to internal combustion engine application. Given that this application is pre-commercial, these numbers are an estimate based on information from Nexterra and GE Jenbacher. Real numbers may vary based on location and initial demonstrations. Cost Assumption Annual Cost Operators 1 - 2 FTE @ $80,000/yr $80,000 - $160,000 Gasification Maintenance 1.5% of capital $175,000 - $250,000 Engine Maintenance $0.011 – 0.017/kWe-hr $170,000 - $263,000 Consumables $0.010/kWe-hr $155,000 $580,000 – $828,000 3. Gasifier Maintenance Schedule The Nexterra system is designed for uninterrupted around the clock operation. Nexterra recommends a maintenance shutdown for inspection and repair every 6 months. The shut down is typically 5 days in duration. While the system is in operation, Nexterra recommends the following inspection schedule: ! Daily – 1 – 2 hours/shift ! Weekly – 8 –10 hours/week ! Monthly – 8 – 12 hours/month 4. Expected Jenbacher Schedule GE Jenbacher engines are designed for stationary, continuous duty operation, and are characterized by particularly high efficiencies, low emissions, durability, and high reliability. For optimal performance Jenbacher recommends a daily, weekly, and monthly preventative maintenance schedule (see attached schedule). The expected cost of this maintenance program is $0.011 - $0.017/kwh. This maintenance can be performed by a 3rd party or Alaska Power and Telephone. I trust that this information is sufficient for your needs at this time. Please feel free to contact me if you have any questions or require additional information. Sincerely, Darcy Quinn Nexterra Systems Corp. CC: Jonathan Wilkinson, Nexterra Systems Corp. Keyword: Standard Unit no.: J xxxx Module no.: xxxxxx x Module type : J 620 GS Version: special gasses _ Direct ignition engine E40/53 Engine no.: xxxxxx x Issued: Doku./Bilek Checked: VMP_Schneider Martin/TEPM_Kneißel Erik/CSA_Sonnerer Herbert Date: 2006-05 WP620_Sondergas_Direktzuender_E40_53_EN.doc Index: h1 Page - No.: 1 / 5 J 620 GS; Version: special gasses _Direct ignition engine - E40/53 Maintenance scheduleJenbacher Documentation EN Intervals independent of the number of operating hours Inspection task Number/ section Interval Note Daily inspection round I 9001 6 daily Carry out daily visual inspection of the unit. Operating data log --- daily Log the operating data daily. Intake air filter-Engine IW 8041 A6 daily If the manometer at the pocket filter shows negative pressure >10 mbar (1 kPa), the filter needs to be replaced, (or else replace them after 2000 operating hours at the latest). Check ignition voltage/ spark plug IW 0309 M0 weekly < 250 oh The result of the ignition voltage check to be carried out weekly, serves as the indicator for the actual service life of the spark plug. Lubricating oil IW 0101 M6 TA 1000-0099A TA 1000-0099B TA 1000-0099C first time after 150 oh The results from the engine lubricating oil analyses are decisive for the actual oil change periods. Battery TA 1000-0050 once in a month Check the acid level. Check if the pole binders are properly secured. Cooling water TA 1000-0200 TA 1000-0201 TA 1000-0204 once in a year Concentration inspection W 8080 A0 20000 oh after having completed the overhaul activities Cooling water exchange Crankshaft main bearing W 8050 M6 20000 oh (4000 engine starts) at 20000 operating hours or 4000 engine starts maximum - replace Battery in DIANE module --- every two years Replace Storage battery at battery charger --- every five years Replace Fuel gas quality TA 1000-0300 --- Complying with the limit values for oxicat Proper maintenance according to the maintenance schedule is a condition for honouring any claims under warranty. After the „Overhaul“ 60000 operating hours, the maintenance work to be carried out is repeated at the same interval periods. Keyword: Standard Unit no.: J xxxx Module no.: xxxxxx x Module type : J 620 GS Version: special gasses _ Direct ignition engine E40/53 Engine no.: xxxxxx x Issued: Doku./Bilek Checked: VMP_Schneider Martin/TEPM_Kneißel Erik/CSA_Sonnerer Herbert Date: 2006-05 WP620_Sondergas_Direktzuender_E40_53_EN.doc Index: h1 Page - No.: 2 / 5 J 620 GS; Version: special gasses _Direct ignition engine - E40/53 Maintenance scheduleJenbacher Documentation EN Interval reference number = Operating hours/1000 ZK = on the occasion of cylinderhead disassembly Number Operating hours Interval ref. nr. Maintenance task/ Inspection task < 100 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 15000 - Maintenance after first start-up W 1000 6 !! ! ! ! ! 2 Valve clearance W 0400 M6 !!!!!!!!!!!! 2 Ignition system W 0303 M0 !!!!!!!!!!!! 2 Inspection I 0103 6 !!!!!!!!!!!! 2/10/ 30 Gas mixer W 0701 M6 !!!!!!!!!!!! 2/20/ 30 Regulating rods/Throttle valve/Actuator W 0200 M6 !!!!!!!!!!!! 2/30/ 60 Gas train W 8045 A0 !!!!!!!!!!!! 4 Oil filter insert W 8038 M6 !!!!!!"! 4/30 Crankcase vent W 0506 M6 !!!!!!!! 10 Turbocharger W 8023 M6 ! ! ! ! !! 10 Crankshaft thrust bearing W 8060 M6 ! ! ! !!! 10 Starter W 8032 M0 ! ! ! ! !! 10/30 Engine coolant pump W 0203 A6 ! ! ! ! !! 20 Mixture bypass valve W 0802 M6 ! ! ! ! ! 20 Torsion vibration damper W 0601 M0 ! ! ! ! ! 20 GE Jenbacher-switch cabinets W 8031 A0 ! ! ! ! ! 20 Engine oil pump W 8046 M6 ! ! ! ! ! 20 Piston/Piston cooling W 8047 M0 ! ! ! ! ! 20 Con rod/Con rod bearing W 8048 M0 ! ! ! ! ! 20 Cylinder liner/Scraper ring W 8049 M0 ! ! ! ! ! ZK 20 Camshaft/Control parts W 8052 M0 ! ! ! ! ! 60 Plate-type heat exchanger W 8043 A0 ! ! ! ! ! 60 Pre-lubricating pump W 8054 M0 ! ! ! ! ! 60 Overhaul W 2100 M0 ! ! ! ! ! ZK Exhaust gas manifold/Isolation W 8051 M0 ! ! ! ! ! - Cylinder head replacement W 8053 M6 if required - Crankshaft main bearing W 8050 M6 ! ! ! ! " - Generator (Leroy Somer_LSA47-64) W 8030 A0 !!!!!!!!!!!! - Generator (Stamford_Avk_BR 8 / Dig110_140) W 8030 A0 !!!!!!!!!!!!!!!!!!!! - Elastomer parts W 8034 6 !!!!!!!! " Please note that properly carried out maintenance work is to be acknowledged by filling in the maintenance protocol. Keyword: Standard Unit no.: J xxxx Module no.: xxxxxx x Module type : J 620 GS Version: special gasses _ Direct ignition engine E40/53 Engine no.: xxxxxx x Issued: Doku./Bilek Checked: VMP_Schneider Martin/TEPM_Kneißel Erik/CSA_Sonnerer Herbert Date: 2006-05 WP620_Sondergas_Direktzuender_E40_53_EN.doc Index: h1 Page - No.: 3 / 5 J 620 GS; Version: special gasses _Direct ignition engine - E40/53 Maintenance scheduleJenbacher Documentation EN Interval reference number = Operating hours/1000 ZK = on the occasion of cylinderhead disassembly Number Operating hours Interval ref. nr. Maintenance task/ Inspection task 16000 17000 18000 19000 20000 21000 22000 23000 24000 25000 26000 27000 28000 29000 30000 2 Valve clearance W 0400 M6 !!!!!!!!!!!!! 2 Ignition system W 0303 M0 !!!!!!!!!!!!! 2 Inspection I 0103 6 !!!!!!!!!!!!! 2/20/ 30 Regulating rods/Throttle valve/Actuator W 0200 M6 !!!!!!!!!!!!! 2/10/ 30 Gas mixer W 0701 M6 !!!!!!!!!!!!! 2/30/ 60 Gas train W 8045 A0 !!!!!!!!!!!!! 4 Oil filter insert W 8038 M6 !!!!!!!"!! 4/30 Crankcase vent W 0506 M6 !!!!!!!"!!! 10 Turbocharger W 8023 M6 !! ! ! ! ! ! ! 10 Crankshaft thrust bearing W 8060 M6 !! ! ! ! ! ! ! 10 Starter W 8032 M0 !! ! ! ! ! ! ! 10/30 Engine coolant pump W 0203 A6 !! ! ! ! ! !! 20 Mixture bypass valve W 0802 M6 !! ! ! ! ! ! 20 Torsion vibration damper W 0601 M0 !! ! ! ! ! ! 20 GE Jenbacher-switch cabinets W 8031 A0 !! ! ! ! ! ! 20 Engine oil pump W 8046 M6 !! ! ! !"! 20 Piston/Piston cooling W 8047 M0 !! ! ! ! ! ! 20 Con rod/Con rod bearing W 8048 M0 !! ! ! ! ! ! 20 Cylinder liner/Scraper ring W 8049 M0 !! ! ! ! ! ! ZK 20 Camshaft/Control parts W 8052 M0 !! ! ! ! ! ! 60 Plate-type heat exchanger W 8043 A0 ! ! ! ! ! ! 60 Pre-lubricating pump W 8054 M0 ! ! ! ! ! ! 60 Overhaul W 2100 M0 ! ! ! ! ! ! ZK Exhaust gas manifold/Isolation W 8051 M0 ! ! ! ! ! ! - Cylinder head replacement W 8053 M6 if required - Crankshaft main bearing W 8050 M6 ! ! ! ! ! ! ! Generator (Leroy Somer_LSA47-64) W 8030 A0 !!!!!!!!!!!!! - Generator (Stamford_Avk_BR 8 / Dig110_140) W 8030 A0 !!!!!!!!!!!!!!!!!!!! - Elastomer parts W 8034 6 !!!!!!!!!! " Please note that properly carried out maintenance work is to be acknowledged by filling in the maintenance protocol. Keyword: Standard Unit no.: J xxxx Module no.: xxxxxx x Module type : J 620 GS Version: special gasses _ Direct ignition engine E40/53 Engine no.: xxxxxx x Issued: Doku./Bilek Checked: VMP_Schneider Martin/TEPM_Kneißel Erik/CSA_Sonnerer Herbert Date: 2006-05 WP620_Sondergas_Direktzuender_E40_53_EN.doc Index: h1 Page - No.: 4 / 5 J 620 GS; Version: special gasses _Direct ignition engine - E40/53 Maintenance scheduleJenbacher Documentation EN Interval reference number = Operating hours/1000 ZK = on the occasion of cylinderhead disassembly Number Operating hours Interval ref. nr. Maintenance task/ Inspection task 31000 32000 33000 34000 35000 36000 37000 38000 39000 40000 41000 42000 43000 44000 45000 2 Valve clearance W 0400 M6 !!!!!!!!!!!!! 2 Ignition system W 0303 M0 !!!!!!!!!!!!! 2 Inspection I 0103 6 !!!!!!!!!!!!! 2/10/ 30 Gas mixer W 0701 M6 !!!!!!!!!!!!! 2/20/ 30 Regulating rods/Throttle valve/Actuator W 0200 M6 !!!!!!!!!!!!! 2/30/ 60 Gas train W 8045 A0 !!!!!!!!!!!!! 4 Oil filter insert W 8038 M6 !!!! ! ! !"!! 4/30 Crankcase vent W 0506 M6 !!!! ! !!!!! 10 Turbocharger W 8023 M6 ! ! ! ! !!! 10 Crankshaft thrust bearing W 8060 M6 ! ! ! ! !!! 10 Starter W 8032 M0 ! ! ! ! !!! 10/30 Engine coolant pump W 0203 A6 ! ! ! !!!! 20 Mixture bypass valve W 0802 M6 ! ! ! ! !!! 20 Torsion vibration damper W 0601 M0 ! ! ! ! !!! 20 GE Jenbacher-switch cabinets W 8031 A0 ! ! ! ! !!! 20 Engine oil pump W 8046 M6 ! ! ! !!!! 20 Piston/Piston cooling W 8047 M0 ! ! ! ! !!! 20 Con rod/Con rod bearing W 8048 M0 ! ! ! ! !!! 20 Cylinder liner/Scraper ring W 8049 M0 ! ! ! ! !!! ZK 20 Camshaft/Control parts W 8052 M0 ! ! ! !!!! 60 Plate-type heat exchanger W 8043 A0 ! ! ! ! ! ! 60 Pre-lubricating pump W 8054 M0 ! ! ! ! ! ! 60 Overhaul W 2100 M0 ! ! ! ! ! ! ZK Exhaust gas manifold/Isolation W 8051 M0 ! ! ! ! ! ! - Cylinder head replacement W 8053 M6 if required - Crankshaft main bearing W 8050 M6 ! ! ! ! ! ! - Generator (Leroy Somer_LSA47-64) W 8030 A0 !!!!!!!!!!!!! - Generator (Stamford_Avk_BR 8 / Dig110_140) W 8030 A0 !!!!!!!!!!!!!!!!!!!! - Elastomer parts W 8034 6 !!! ! !!!!! " Please note that properly carried out maintenance work is to be acknowledged by filling in the maintenance protocol. Keyword: Standard Unit no.: J xxxx Module no.: xxxxxx x Module type : J 620 GS Version: special gasses _ Direct ignition engine E40/53 Engine no.: xxxxxx x Issued: Doku./Bilek Checked: VMP_Schneider Martin/TEPM_Kneißel Erik/CSA_Sonnerer Herbert Date: 2006-05 WP620_Sondergas_Direktzuender_E40_53_EN.doc Index: h1 Page - No.: 5 / 5 J 620 GS; Version: special gasses _Direct ignition engine - E40/53 Maintenance scheduleJenbacher Documentation EN Interval reference number = Operating hours/1000 ZK = on the occasion of cylinderhead disassembly Number Operating hours Interval ref. nr. Maintenance task/ Inspection task 46000 47000 48000 49000 50000 51000 52000 53000 54000 55000 56000 57000 58000 59000 60000 2 Valve clearance W 0400 M6 !!!!!!!!!!!!! 2 Ignition system W 0303 M0 !!!!!!!!!!!!! 2 Inspection I 0103 6 !!!!!!!!!!!!! 2/10/ 30 Gas mixer W 0701 M6 !!!!!!!!!!!!! 2/20/ 30 Regulating rods/Throttle valve/Actuator W 0200 M6 !!!!!!!!!!!!! 2/30/ 60 Gas train W 8045 A0 !!!!!!!!!!!!! 4 Oil filter insert W 8038 M6 !!!!!!"!! 4/30 Crankcase vent W 0506 M6 !!!!!!"!! 10 Turbocharger W 8023 M6 !! ! ! ! ! ! ! 10 Crankshaft thrust bearing W 8060 M6 !! ! ! ! ! ! ! 10 Starter W 8032 M0 !! ! ! ! ! ! ! 10/30 Engine coolant pump W 0203 A6 !! ! ! ! ! !! 20 Mixture bypass valve W 0802 M6 ! ! ! ! ! ! ! 20 Torsion vibration damper W 0601 M0 ! ! ! ! ! ! ! 20 GE Jenbacher-switch cabinets W 8031 A0 ! ! ! ! ! ! ! 20 Engine oil pump W 8046 M6 ! ! ! !"!! 20 Piston/Piston cooling W 8047 M0 ! ! ! ! ! ! ! 20 Con rod/Con rod bearing W 8048 M0 ! ! ! ! ! ! ! 20 Cylinder liner/Scraper ring W 8049 M0 ! ! ! ! ! ! ! ZK 20 Camshaft/Control parts W 8052 M0 ! ! ! ! ! !! 60 Plate-type heat exchanger W 8043 A0 ! ! ! ! ! ! ! 60 Pre-lubricating pump W 8054 M0 ! ! ! ! ! ! ! 60 Overhaul W 2100 M0 ! ! ! ! ! !! ZK Exhaust gas manifold/Isolation W 8051 M0 ! ! ! ! ! ! - Cylinder head replacement W 8053 M6 if required - Crankshaft main bearing W 8050 M6 ! ! ! ! ! ! ! - Generator (Leroy Somer_LSA47-64) W 8030 A0 !!!!!!!!!!!!! - Generator (Stamford_Avk_BR 8 / Dig110_140) W 8030 A0 !!!!!!!!!!!!!!!!!!!! - Elastomer parts W 8034 6 !!!!!!!!!! " Please note that properly carried out maintenance work is to be acknowledged by filling in the maintenance protocol.