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## 79 ) IV-E-7 3 Docket Number: 

## A-90-3 7

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# Routin e Turbin e Overhau l
Presented

to: U.S
. Environmenta l Protectio n Agenc y Offic e o f Ai rQualit yPlannin g an d Standard s

Presented

by: Membe rCompanie s o f th e Interstat e Natura l Ga s Associatio n o f Americ a (INGAA )

Durham , N C Novembe r5 , 2001

# Topic s

Issu e Summar

y Recen t Histor

yof th e Turbin e Maintenanc e Issu e U.S
. Natura l Ga s Transmissio n Syste m an d Turbin e Horsepowe r Turbin e Overhau l Exchang e Overhau l Exchang e i s Routin e Maintenanc e unde rNSP S an d NS R Impact s i f Overhau l Exchang e become s a modificatio n EP AConcer n wit h "Lif e Extension " Recommendation s

# Issu e Summar y Th e U.S
. natura l ga s pipelin e syste m relie s o n light-industria l an d aero-derivativ e ga s fired turbine s t o powe rga s compressor s Fo rth e pas t 30 + years , th e routin e maintenanc e o f ligh t industria l an d aero-derivativ e combustio n turbine s ha s involve d exchang e o f turbin e component s i n a centra l overhau l facilit y Overhau l exchang e doe s no t increas e capacit yo remission s Recently , som e EP ARegion s an d stat e ai ragencie s hav e take n th e positio n tha t exchang e o f overhaule d turbin e component s require s re-permittin g ^^v^^w ^ Th e efficienc yan d reliabilit yo f interstat e natura l ga s pipeline s i n deliverin g energyresource s t o consumers , commercia l facilitie s an d electri cgeneratin g plant s wil l b e adversel yaffecte d i f eac h turbin e overhau l exchang e trigger s re-permittin g T^TTT- ~ ?

# Recen t Histor yo f th e Turbin e Maintenanc e Issu e (1 )

Marc h 1 , 199 0 Lette rfro m G E t o Regio n 9 "A s discussed..
. engin e change-ou t shoul d no t b e considere d a n 'upgrade ' situatio n possibl ysubjec t t o Ne wSourc e Review. " Octobe r8 , 199 8 Lette ro n NS R fro m AGA/INGA A t o Docke t No.A-90-3 7 "We urg e EP

At o clarifythat..
. 'routin e change s woul d includ e natura l ga s transmissio n turbin e componen t change s o rtemporar yreplacemen t o

f turbine s fo rth e purpose s o f maintenanc e of th e origina l engine. " Marc h 24 , 199 9 Lette rfro m Sola rTurbine s Inc
. t o OAQP S "...th e componen t replacemen t doe s nothin g t o increas e th e operatin g lif e o f th e ga s turbin e beyon d tha t o f a properl ymaintaine d ga s turbin e tha t neve rutilize d replacemen t component s Septembe r9 , 199 9 Lette rfro m Washingto n Departmen t of Ecolog yt o Regio n 1 0 Re : Ga s Fire d Turbin e Engin e Replacemen t at Natura l Gas Pipelin e Compresso rStation s "Ecolog ydesire s a solutio n tha t doe s no t requir e a PS D permi t t o b e rescinde d an d reissue d ever yfou r years fo reac h compresso rstation. "

# Recen t Histor yo f th e Turbin e Maintenanc e Issu e (2 )
Novembe r9 , 199 9 Meetin g o f INGAAMembe rCompanie s wit h OAQP S Recommendation : "Us e o f replacemen t ga s produce rand/o rpowe rturbin e component s as par t of th e overhau l proces s als o i s exempt fro m th e definitio n o f "modification " unde rPS D o rNSP S Decembe r3 , 199 9 Lette rfro m INGA At o OAQP S "W e ar e concerne d tha t th e Agenc yi s attemptin g t o merg e it s polic yconcern s abou t th e usefu l lif e o f gas turbine s wit h th e Agency' s technica l finding s concernin g routin e maintenance... " Jul y27 , 200 1 Lette rfro m INGAAo n NS R 9 0 DayRevie w "Efficien t Overhau l Procedure s are Critica l t o th e operatio n o f Gas Pipelines. " Augus t 2 , 200 1 Presentatio n t o NS R Inter-Agenc yTas k Forc e Recommendation : "Determin e tha t 'routin e maintenance ' fo rligh t industria l an d aeroderivativ e turbine s include s us e o f centra l overhau l facilitie s an d componen t exchanges. " Octobe r25 , 200 1 Tou rb yEP ARepresentative s o f Sola rOverhau l Facilit yan d

Mitchel l Energ yPlan t "Domesti cflee t - 5,80 0 engines...Approximatel y60 0 overhaul s pe ryea rexecute d b yexchange. "

# U.S
. Natura l Gas Transmissio n Syste m

Natura l ga s i s move d fro m sourc e area s t o consumer s b ya nationa l syste m o f pipeline s » 278,00 0 mile s of transmissio n lines , i n al l lowe r4 8 state s » 22. 8 TC F pe ryea ri n 200 0 » Compresso rstation s are locate d approximatel yever y7 0 mile s alon g pipeline s Interstat e pipeline s ar e regulate d b yFER C » Eac h compresso rstatio n mus t compl ywit h FER C certificate d horsepowe rP ^ -^- , Deman d i s expecte d t o reac h 30 + TC F i n 201 5 * u h< Syste m i s nea rcapacit yi n West , Northeast , an d Southeas t 12. 3 BCF/da

ycapacity » I n 199 9 an d 2000 , 6 0 pipelin e constructio n project s have adde d ' /s j ^ i*yL.

/Tyyyl JiWK. 't-f V

# Turbine s Provid e Horsepowe rfo rth e

U.S
. Ga s Transmissio n Syste m Mor e tha n 1,10 0 natura l gas-fire d turbine s a t ga s transmissio n compresso rstation s provid e 40+ % o f horsepower * ^ k ^\* ^ Mos t ar e simple-cycle , aero-derivativ e o rligh t industria l turbine s \ A yz-,
• Averag e siz e i s approximatel y6,30 0 horsepowe r(4. 7 MW) , \ T^O Media n siz e i s approximatel y4,40 0 horsepowe r(3. 3 MW ) / } ^

s k \
• Principa l manufacturers : $<wl 52L( L » Sola rTurbine s (56%) , Genera l Electri c(25%) , s *«.*.^ „ * ^ » Als o Roll s Royce , Allison , Dresser-Clark , Westinghous e
• Routine , periodi coverhau l i s require d t o provid e saf e & reliabl e turbin e operatio n an d maintai n permitte d emissio n limit s » Los s o f turbin e availabilit ywil l resul t i n curtailmen t o f natura l ga s supplie s i n critica l market s 'Base d o n 199 8 surve yo f 5 7 o f 16 5 ga s transmissio n companie s

# Turbin e Exchang e Overhaul s

Th e desig n tim e betwee n overhaul s (TBO ) fo rmos t ligh t industria l an d aero-derivativ e turbine s i s abou t 30,00 0 hours , 3 t o 4 year s Unlike large rturbine s tha t canno t b e truck-transported , ligh t industria l an d aero-derivativ e turbine s ar e designe d t o b e overhaule d a t specialize d centra l facilitie s Currently , abou t si xweeks ' los s o f turbin e availabilit yi s avoide d b y installatio n o f identica l overhaule d component s whe n turbin e component s ar e remove d an d sen t t o th e overhau l facilit y Th e exchange d turbin e ha s th e sam e mode l number , capacit y rating , operatin g characteristic s an d emission s limit s a s th e replace d turbin e

# Example : Sola rTurbine s (1 )

5,80 0 Sola rTurbin e installation s i n U.S
. » Ga s compressio n servic e >1,00 0 unit s Al l Sola rturbine s mus t b e remove d an d sen t fo roverhau l a t a specialize d facility ; unit s canno t b e overhaule d i n th e fiel d » Overhau l result s i n retur n t o Origina l Operatin g Specification s » 60 0 overhaul s b

yexchang e i n 2000 , 32 0 fromXTS " » 80 % of overhaul s are exchang e program , others are "custome rproperty 

### in-shop " U A *U~ ^ J ^ „ ^
. K



### l^(h Overhau l Exchang e Result s in : l X/ ^ » Minimize d dow n tim e (~2 day s v . 6 weeks ) » Us e o f highl yspecialize d personne l an d equipmen t » Rigorou s inspectio n specification s an d Q A » Vertica l assembly/disassembl y » Verificatio n of performanc e an d emission s i n tes t cell s

# Example : Sola rTurbine s (2 )

"Uprates " occu rinfrequentl ywit h overhau l » Ma yoccu ra t tim e o f overhau l i f custome rbuy s i t » Require s uprat e t o entir e turbomachinerysyste m » Subjec t t o contractua l terms , increase d cos t » Mode l numbe ran d capacit yratin g chang e » Uprate s trigge rpermi t revie w 

### "Upgrades " ma

yoccu rdurin g overhau l Sola rdoe s no t suppor t historica l part s inventory Replacemen t part s mee t curren t productio n standard s Sam e fit/form/functio n Uni t retain s mode l ratin g operatin g specification s Emission s ar e th e sam e 

### £~kr<^<H -

# Overhau l Exchang e i s Routin e

Maintenanc e Unde rNSP S an d NS R (1 ) Fo rth e pas t 3 0 years , i n almos t al l case s owner/operator s an d ai ragencie s hav e regarde d overhau l exchang e a s routin e maintenanc e Th e Turbin e NSP S Support Documen t state s tha t replacement s tha t occu ra t overhau l wil l no t b e considere d a modification : "Th e followin g physica l o roperationa l changes wil l no t be considere d a

s modification s t o existin g gas turbines : a . Change s determine d to b e routin e maintenance , repair , o r replacemen t i n kind . Thi s wil l includ e repai r o r replacemen t o f stato r blades , turbin e nozzles , turbin e buckets , fue l nozzles , combustio n chambers , seals , an d shaf t packings . (Vol . I , pag e 5-6 ) Th e NSP S Suppor t Documen t note s that , becaus e o f thes e exemptions , th e "impac t o f th e modificatio n provisio n o n existin g ga s turbine s shoul d b e veryslight. " (Vol
. I , pag e 5-6 )

# Overhau l Exchang e i s Routin e

Maintenanc e Unde rNSP S an d NS R (2 )

NSP S regulation s 60.14(e)(1 ) stat e tha t th e Administrato rshal l determin e whic h activitie s ar e "routine " fo ra particula rsourc e category » A t th e tim e EP Aissue d th e NSP S fo rturbines , EP Adecline d t o includ e a mor e specifi cfindin g abou t turbin e maintenanc e an d argue d i n th e NSP S Support Documen t tha t th e genera l NSP S definitio n wa s sufficien t (Vol
. II , page s 2- 9 throug h 2-11 ) NS R an d NSP S hav e simila rexemption s fo rroutin e maintenanc e Exchang e overhau l meet s EP Atest s fo r"routine " fo rth e purpose s o f NSR : » Nature , Extent , Purpose , Frequency , Cos t » I t i s industr

ypractice tha

t a typica l facilit

ywil l frequentl y conduc t overhau l exchang e o n a routin e basi s

# Overhau l Exchang e i s Wel l Belo w Reconstructio n Threshol d
50 % Threshol d define d unde rNSP S regulation s 4 0 CF R 60.15(b) : "Reconstructio n mean s th e replacemen t o f component s o f a n existin g facilit yt o suc h a n exten t that : (1 ) th e fixe d capital cos t o f th e ne wcomponent s exceed s 5 0 percen t o f th e fixe d capita l cos t tha t woul d b e require d t o construc t a comparabl e entirel yne wfacility... " 

### Turbin e NSP S suppor t documen t states : Althoug h substantia l portion s o f turbine s ar e replace d durin g norma l overhauls , "suc h routin e maintenanc e shoul d b e exempte d fro m th e regulatoryconsequence s o f becomin g a reconstructed turbine , subject t o th e '5 0 percen t rule ' discusse d i n 5.1.2. " (Vol
. I , Pag e 5-6 ) 

### Overhau l cost s ar e typicall ybelo w25 % o f th e tota l cos t o f a ne wturbin e installatio n

# Impact s i f Overhau l Exchang e

Become s a Modificatio n State s an d Region s woul d hav e t o addres s a larg e increas e i n th e numbe ro f permi t action s Decreas e i n turbin e availabilit ydu e t o permittin g an d "customer-property-in-shop " overhaul s Decrease d turbin e availabilit ywil l resul t i n » curtailmen t o f natura l ga s suppl y » increase d us e o f reciprocatin g I C engine s wher e reserv e horsepowe ri s availabl e 

### Example : singl e turbin e boos t statio n fo rdedicate d lin e t o a n electri cutilit y » overhau l woul d caus e curtailment , shif t t o back-u p fue l i f availabl e

# Example : E l Pas o Compresso rStation s

• Regio n 9 action s o n Par t 7 1 permit s i n India n land s indicat e tha t overhau l exchang e require s tes t fo rPS D significanc e • Navaj o Statio n » Sola rTauru s unavailabl e fo r74 days , Apri l 29-Jul y12 , 200 1 » 6 0 MMSCF/dayimpac t o n syste m capacity » Reciprocatin g I C engine s use d t o mak e u p horsepowe r 

### • Windo wRoc k

Statio n » Sola rCentau runavailabl e fo r5 7 days , Jul y1 8 - Sept
. 13 , 200 0 » 5 7 MMSCF/dayimpac t o n syste m capacity » Syste m capacitydecrease d

# EP AConcer n Wit h "Lif e Extension "

Ther e i s n o increas e i n turbin e lifetim e wit h exchang e compare d t o customer-property-in-sho p overhau l » Component s ar e overhaule d t o th e origina l operatin g specificatio n 

### Turbine s i n natura l ga s transmissio n are replace d becaus e o f economi cfactors , not mechanica l deterioratio n » Becaus e mor e efficien t turbine s ar e availabl e » Becaus e cos t o f operatio n an d overhau l increase s » Becaus e pipelin e syste m require s ne whorsepowe rsolutio n 

### Pipeline s continuall yevaluat e horsepowe rreplacemen t » I n th e pas t 2 5 year s E l Pas o ha s replace d 8 9 units , 150,00 0 hp , a t 1 0 V° ^ *y stations , includin g 1 3 turbine s \s v » Las t year , E l Pas o replace d 6 9 units , 133,00 0 hp , includin g 5 G E Fram e 3 turbine s V

# Recommendatio n

EPA' s ai rregulation s an d guidanc e shoul d facilitate , no t discourage , overhau l exchang e a s a highl yefficien t syste m fo r maximizin g turbin e availabilit ywhil e safeguardin g th e operatin g performance , emissions , an d reliabilit yo f turbine s EP Ashoul d issu e a determinatio n unde rNSP S G G tha t "routin e maintenance " fo rligh t industria l an d aero-derivativ e turbine s include s overhau l exchang e EP Ashoul d exten d th e NSP S routin e maintenanc e definitio n t o NS R fo rga s pipelin e source s EPA' s polic yobjectiv e t o defin e a n endpoin t fo ra turbine' s usefu l lif e shoul d b e addresse d i n th e large rcontex t o f th e agency' s refor m o f th e NS R regulation s Th e Agency' s findin g regardin g routin e maintenanc e fo rturbine s shoul d b e base d o n fact-findin g regardin g routin e practices , an d no t a polic yprescriptio n

# NS RApplicabilit y a t Ga s Transmissio n Station s Scopin g Meetin g wit

h EPA an dth e Natura l Ga s Transmissio n Industr

y November

5 . 200 1 Purpose : T o discus s option s wit hindustr y representative s on ho w NS Rshoul dappl y t o periodi c turbin e overhaul s a t ga s compresso r

stations .

# What' s a

t issue ? Certai n maintenanc e practice s a t ga s transmissio n station s coul db e considere da"physical change/ 5 

## or a lif e extensio n project , an dsubjec t t o Ne w Sourc e Review . Th e natura l ga s deliver

y industr y doe s no t

wan t thei r maintenanc e project s delaye db y NS Rpermitting , an d believe s thei r

periodi c overhaul s shoul db e exemp t fromNS Rb y wa

y o f bein g "routine. "

# What' s a

t issue ? (cont. ) I n th e absenc e o f

specifi c EPA guidance , overhaul s a

t ga s pumpin g station s hav e typicall y bee n treate da s routine ; however , recentl y thi s approac hha s bee n challenge di n afe w cases . Over th e summer , industr

y member s raise dthi s a s a n exampl e o f

EPA delay s in issuin g NS R guidance , an dINGAA later met wit h90-da y Revie w Tea

mt o spel l ou t

thei r concerns . INGA A want s a

n "routine " exclusio n fromNSR , barrin g uprates , andregulator y certainty .

# Industr

y Descriptio n Natura l gas-fire dturbine s use da t compresso r

station s t o mov e natural ga s aroun dth e countr y

- Turbin e sizes : 2 K

t o 20 K h p ( 1 t o 1 5 MW )

- 1 t o 4 turbine s pe r

statio n

- 140 0 turbine s i n servic e i n U S

- Simpl e cycle , aeroderivativ e models ; som e lightweigh t industria l turbine s (25-30 % efficient ) 

## Station s als o hav e backup gas-fire dreciprocatin g engines , emittin g twic e a s muc ha s sam e size dturbine s FER C require s uninterrupte dservic e a t interstate pumpin g station s Station s are locate din bot

hAttainmen t

an dN A area s

# Current

Maintenanc e Option s Overhaul s are don e periodicall y t o replac e wor n part s o n turbines . Planne doverhaul s ar

e preferre dover

waitin g unti l sustainin g significant

equipment

damage , an dthe y

- Restor e los t

output , an d

- Restor e fuel efficiency . 

## Overhaul s ca

n b e performed :

- O n sit e (done mainly w/larger turbines, &for

minor repairs)

- I n sho p (repaired/tested in shop for -30days, then returned)

- Throug hexchang e

# Exchang e Practice s

Exchang e programha s existe dsinc e 1960's . Ga s produce r

an dpower

turbin e section s ("ho t

side" ) designe dfo

r modula r replacement . Swappe dout

ever y 3O K hour s (4 yrs) , or

sooner/later dependin g on startup s andintermediate maintenance . Essentiall y ane w turbin e i s provide da t eac h exchang e Downtim e saving s i s the major incentive . > 24-3 6 h r

(exchange ) v s 3 0 day s (onsite/in-shop ) 

## Overhaul s cos t

6 % t o 17 % o f

turbin e "package " replacement . > Roughl y $200 K

for smal l unit s an d$1 M for

large r turbine s > Abou t 4 0 t o 50 % o f

turbin e replacemen t

cos t 

## No t intende dt o increas e rate defficienc y or output .

# Emissions/Control s

Turbin e NSP S (c.1979 ) require s 15 0 pp mNOx . Older turbine s (installe din 70' s an d80's ) operate a t 75-15 0 ppm . SMALLEXAMPLE : Sola r Centaur (3.3MW) , gas-fire d
• Uncontrolle d@ 130ppm : 8 8 tp y NO x • Wit hWater injectio n @ 4 2 ppm : 3 0 tp y NO x • Cos t effectivenes s o f

WI : $2,000/to n (NOTE: based

on site visit, water

controls are rarely installed on Solar 9 

### s units Cost

ofDLN "Solonox

" Conversion ?) 

### LARGE EXAMPLE : G

E L M 160 0 (13MW) , gas-fire d
• Uncontrolle d@ 133ppm : 29 6 tp y NO x • Wit hStea minjectio n @ 2 5 ppm : 5 1 tp y NO x • Cos t effectivenes s o f

SI : $l,500/to n

# Pas t

EP A Decision s
> Gas Turbin e NSP S SupportDocumen t(1977 ) > Suggest s periodi c overhaul s ar e routin e for th e purpose s of40CFRPart6 0 > "... substantial

portions of

a turbine may be replaced as a matter of routine maintenance during normal overhauls. " 

### > Allude s t o "usefu l lifetime " o f 3 0 years . 

## > Regio n 2 Lette rto Ne w Jerse y DE P(1999 ) > Provide s pla n t o trac k

serial number s o f

poo l o f overhaule dturbines , whil e subjectin g ne w & uprate d unit s t o PSD/NSR .

# Ke y EPA Issue s

PAL s may b e proble mif

SI P jurisdictio n doe s no t

allow . Ho w ca n w e justif

y asourc e gettin g ane w turbin e ever y 4 year s an dno t

considerin g it

amodification ? Ga s transmissio n industr

y i s deman ddriven . Seldo mare there ACTUALemissio n increase s followin g a n overhaul . Concern s wit

h"routine " determinatio n ma y ru n counter

t o opinion s o n enforcement

initiative s an dother

cases .

- Where do thes e repeate doverhaul s cros s th e lin e into life-extensio n projects ? Ho w woul dthi s decisio n impac t other industries ? W e learne do n ou

r site visi t tha t th e turbin e exchang e program i s no t limite dt o th e ga s pumpin g industry .

# Ke y EPA Issue s (cont. )

Wit hth e majority o f

th e fleet bein g uncontrolled , requirin g NS Ro n grandfathere dunits coul dyiel d5 O K t o 100 K ton s o f NO x reduction . Shoul da10-15 % maintenanc e expeditur e every 4 year s qualif y a s "routine"?.. . WEPCO directs us to consider Cost, Frequency, Nature and Extent when determining routine. Ca n w e trac k

non-routin e repair s i f

performe dvia exchange ? Ho w can w e b e sure tha t powe r "uprates " an d efficienc y boost s ar e no t

performe ddurin g swap-outs? Shoul dw e trea t

repair s mad e o n site differentl y tha n i f performe dthroug hexchange ?

# Possibl e Option s 1 ) Treat eac hoverhau l a s aphysical change . 2 ) Trac k overhaul s a

t agiven site andappl y NS Ronc e th e "usefu l lifetime " i s reached . 3 ) Optio n #1 , bu t

provid e Actual-to-Actual emission s test , plu s deman dgrowth . 4 ) Explore us e o f

PAL s an dState/local agenc y interventio n where ai

r qualit y i s jeopardized . 5 ) Set $/h p (per unit , per year ) maintenanc e cap . Al l maintenanc e beneat

hca p i s routine , al l abov e woul d b e evaluated . Year s coul db e average d(< 5 yr s max? )

# Possibl e Option s (cont. )

6 ) Lis t serial number s fo

r compresso r

unit s owne d b y acompany . Swap-out s do no t trigge r NS Ri f uni t come s fromwithi n pool . (Regio n 2 approach ) 7 ) Treat overhaul s a s "Routine " a s lon g a s d o no t resul t in power uprates . Uprate s ar

e aphysica l chang e an dNS Ri s triggere dwhere there i s a n actual emission s increase . 8 ) Provid e routin e determinatio n fo r al l non uprate dmaintenance , bu t

phas e i n NS Rfo

r older fleet t o ge t predetermine dcontro l (25-4 2 ppm ) vi asecto r base drule . \

# Next

Step s TODAY : Lis t pros/con s witheac hliste dOption , an dan y othe r optio n raise dtoday . Selec t 3 mos t viabl e options . Commi t t o reconvenin g group . NEX T 4 WEEKS : Stud y further

eac hselecte doptio n t o evaluat e workability . Establis hdat agatherin g needs ; determin e deadlines .

- Th e NEPD/90-da y NS RStudy report wil l lis t thi s a s aprioritize dinitiative .

# Nex t

Step s (cont. ) NEX T 3 MONTHS :

- Selec t option .

- Pu t ou t guidanc e o n selection . NEX T 1 2 MONTHS :

- Formaliz e throug hrulemaking ?