Long Term Facility Ownership / Performance Testing Protocol
AppendixN4
Start-Up and Performance Testing Protocols
1.Performance Testing
The performance tests shall be conducted to verify Project compliance with the performance guaranteesspecified in Article 2.7 (a), and to demonstrate the ability of the Project and Units to achieve the Generation Operating Characteristics specified in AppendixN3.
Table F-1 lists the required performance tests for each type of generating unit design. For facilities consisting of more than one independent Unit, Table F-1 designates whether a test is to be conducted on each Unit or on the overall Project. For facilities that consist of one Unit, all applicable Unit tests shall be conducted for the Project.
Table F-1 – Performance Guarantee and Demonstration Tests
Test / Project Design-Basis* / Project Test / Unit TestsPerformance Guarantee Tests
- Project Base Electrical Output and Heat Rate
- Base Reliability
- ProjectPeak Electrical Output
- Extended Guaranteed Electric Output and Heat Rate
Demonstration Tests
- Unit Base Electric Output and Heat Rate
- UnitPeak Electric Output and Heat Rate
- Air Emissions
- Sound Level Emissions
- Cooling Tower Drift Rate
- Evaporative Cooler Effectiveness (if applicable)
- Raw Water
- Demineralized Water
- Waste Water Discharge or Zero Discharge (as applicable)
- Deaerator
- Standby Electric Generator
- Minimum Load
- Regulation with Automatic Generator Control
- Ancillary Services (as applicable)
- Unit Start-Up Times
- Fuel Switching
* Project Design Basis
1 – Reciprocating engine-generator
2 – Combustion turbine without water or steam injection or evaporative cooler
3 – Combustion turbine with water or steam injection or evaporative cooler
4 – CC with water or steam injection
5 – CC with cooling tower
1.1.Test Procedure
Seller shall prepare a plant specific test procedure for each test. The test procedures will provide details for the conduct of the test. If appropriate, one test procedure may cover more than one test. The test procedures must be mutually agreeable to both Purchaser and Seller.
The following are included in the test procedures:
- Objective of test
- Test acceptance criteria for test completion
- Base reference conditions
- Seller test personnel and their responsibilities
- Purchaser operations support and their responsibilities
- Defined test boundaries identifying inputs and outputs and measurements locations
- Requirements regarding operating conditions, performance guarantees, and environmental compliance
- Complete pretest uncertainty analysis, with bias uncertainties established for each measurement
- Specific type, location, and calibration requirements for all instrumentation and measurement systems and frequency of data acquisition
- Measurement requirements for applicable emissions, including measurement location, instrumentation, and frequency and method of recording
- Sample, collection, handling, and analysis method and frequency for fuel.
- Method of unit and facility operation
- Identification of testing laboratories to be used for fuel and other analyses
- Required operating disposition ,accounting for all internal thermal energy and auxiliary power consumers having a material effect on test results
- Required levels of equipment cleanliness and inspection procedures
- Valve line-up requirements
- Preliminary testing requirements
- Pretest stabilization criteria
- Required steadiness criteria and methods of maintaining operating conditions within these limits
- Allowable variations from base reference conditions and methods of setting and maintaining operating conditions within these limits
- Number of test runs and duration of each run
- Test start and stop requirements
- Data acceptance and rejection criteria
- Allowable range of fuel conditions, including constituents and heating value
- Correction curves with curve-fitting algorithms or performance correction software with verification and validation procedures
- Sample calculations or detailed procedures specifying test run data reduction and calculation and correction of test results to base reference condition
- The method for combining test runs to calculate the final test results
- Requirements for data storage, document retention, and test report distribution
- Reportingrequirements
1.2.Test Report
The test report will include:
- Method of the test and operating conditions
- Changes and other deviations to test procedures
- Tabulation of instrumentation used for the primary and secondary measurements, including make, model number, serial number, operating range
- Diagram and description of the instrumentation locations
- Identification of the instrument and measurement used as back-up or information purposes
- Methods and frequency of data collection for each data point
- Description of data acquisition system(s)
- Pretest and post-test calibration procedures and results
- Tabular summary of measurements and observations including the reduced data necessary to calculate the results and a summary of additional operating conditions not part of such reduced data
- The corrected auxiliary power calculations
- Presentation of the test results, including the test results computed on the on the basis of the test operating conditions with instrument calibrations applied and with the test results corrected to specified conditions
- Example calculations of test results from the reduced data including the post-testuncertainty. This will include detailed calculations of primary flow rates and heat input based on fuel constituents and properties.
- Calculations or other reasons supporting elimination of outlier data
- Comparison of the repeatability of test runs
- The correction factors applied because of deviations, if any, of test conditions from those specified
- Primary measurement uncertainties, including method of application
- Discussion and details of the test results uncertainties.
- Discussion of the test, its results and conclusions
- Appendices to the test report should include
-the approved test procedure with signed approval by all parties to the test for any modifications or deviations
-copies of original data sheets and/or data acquisition system(s) print-outs
-copies of operator logs or other recording of operating activity during each test
-copies of signed valve line-up sheets, and other documents indicating operation in the required configuration and disposition
-results of laboratory fuel analysis
-instrumentation calibration results from laboratories, certifications from manufacturers
1.3.Performance GuaranteeTests
1.3.1.Project Base Electric Output and Net Heat Rate
The Guaranteed Base Net Electrical Output and the Guaranteed Net Heat Rate tests shall be run concurrently.. The tests shall be conducted under the following operating conditions (the “Base Load Conditions”), as applicable:
- Combustion turbines operating on their base load temperature control curve with evaporative coolers out of service
- Reciprocating engines operating at base load as defined by the engine manufacturer for the expected interval between maintenance periods for normal duty operation.
- Heat recovery steam generators (HRSG’s) operating with zero duct firing and normal blowdown.
- All other equipment and systems operating as normally required for base load operation on a continuous operating basis.
- Steady-state operating conditions.
- Plant auxiliary equipment operated as normally required for base load operation on a continuous operating basis.
- All Project auxiliary power consumption, including miscellaneous house loadssupplied from the electric generators. No auxiliary load may be served from other on-site generators or interconnection with the local distribution system.
Emissions shall not exceed the Guaranteed Emissions Limits at any time during the test.
Equipment disposition for normal operation at ISO Conditions andSite Standard Barometric Pressure (as defined in AppendixN3) shall be specified in the performance test procedures. All equipment shall be operated in accordance with the performance test procedures during the test. Intermittent auxiliary power loads shall be measured under normal operating conditions and the daily average electrical energy consumption calculated based on the actual daily use at Base Load Conditions. Intermittent loads should not be operated during the test, if possible. If operation is required, the electric energy consumption shall be measured during each test period.
The performance test will be performed without evaporative coolers in service. A separate effectiveness test will be performed to demonstrate the evaporative cooler performance. The test without the evaporative coolers in service will be the basis for determining guaranteed plant performance requirements.
During the performance test, the stack exhaust emissions shall be monitored for compliance using the Projectcontinuous emissions monitoring system or via manual sampling. The continuous emissionmonitoring system shall be certified using the manual sampling data either before or during the performance test.
The tests will be conducted in accordance with the performance test procedures and in general accordance with ASME PTC 46. Any exceptions to the requirements of PTC 46 shall be identified in the performance test procedures. The performance test procedures shall be developed by Seller and approved by Purchaser.
The test shall be designed to achieve test uncertaintiesthat are no greater than 0.75% for net electric output and 1.25% for net heat rate (collectively, “the Maximum Uncertainties”). The performance test procedures shall include a pre-test uncertainty analysis that demonstrates the test procedures and test instrumentation will achieve test uncertainties below the Maximum Uncertainties.
The test shall consist of at least three consecutive one-hour test periods during which all conditions are maintained within the conditions specified in performance test procedures and with post-test uncertainties less than the respective Maximum Uncertainties for both net electric output and net heat rate. Test results will be averaged and corrected to specified conditions for each one-hour test period.
The higher heating value of the fuel will be the basis for the heat input used in the calculation of heat rate. The higher heating value will be determined by samples, taken near the beginning and end of each test period. The fuel heating value for each test period will be the average of the two samples. The fuel samples will be analyzed by an independent laboratory for composition and heating value. A minimum of three samples will be taken for each test period. Disposition of samples willbe; 1) to test laboratory, 2) to Seller, and 3) to Purchaser until Performance Test results are approved by all parties.
The ambient air conditions shall be measured to determine the average conditions at the inlet to each combustion turbine and the inlet to each cooling tower or air cooled condenser.
The measured net electrical output shall be the average of the electrical energy as measured at the CAISO revenue meter for each test period.
The measured net electrical output shall be adjusted for the following differences between the actual measured auxiliary electric energy consumption and the average design-basis auxiliary energy consumption at base load operation and at ISO Conditions andSite Standard Barometric Pressure (adjusted net electrical output):
- Any equipment operation different from the expected operating disposition at ISO Conditions and Site Standard Barometric Pressure, as defined in the performance test procedures.
- Differences between theintermittent loads average daily electric energy consumption and the actual intermittent load electric energy consumption as measured during the test.
- The electric energy consumption of the fuel gas compressors corrected for difference between the test anddesign-basisfuel temperature and pressure, as listed in AppendixN3.
The total fuel heat input to the Facility for each test period shall be the product of the average fuel higher heating value for the test period and the total measured fuel flow during the test period. Natural gas fuel flow will be measured using the Project revenue meter, unless otherwise agreed to in the testprocedures. Fuel-oil flow will be measured using a calibrated flow element meeting the instrument and measurement accuracy requirements of PTC 46. The measurednet heat rate will be calculated as thequotient of the total heat input to the Project divided by the adjusted net electrical output for each test period.
The test corrected net electric output and test corrected heat rate for each test period will be calculated by correcting the adjusted net electric output and measured net heat rate for the following:
- Differences between the test measured inlet air conditions and the ISO Conditions at Site Standard Barometric Pressure. These corrections will be based on the inlet air conditions at the inlets to the combustion turbines or reciprocating engines and to the cooling tower or air cooled condenser.
- Difference between the test measured power factorat the CAISO revenue meter and the design-basis power factor of 1.0.
No additional adjustments shall be made to the test results for performance degradation, test tolerance, or any other adjustment or correction.
The test corrected base electric output of the Project for evaluation of the performance guarantees will be thearithmetic averageof the test corrected net electrical outputsfor the three test periods. The test corrected base net heat rate of the Project for evaluation of the performance guarantees will be the arithmetic average of the test corrected net heat rates for the three test periods.
1.3.2.Base Reliability Test
The reliability test will be conducted for168 consecutive hours (7 Days) with all Units operating atbase load conditions with no duct firing or power augmentation. The Plant net electric output will be the electric energy as measured using the CAISO revenue meter. For each of the 168 consecutive one-hour test periods, the average net electric output will be corrected to theISO Conditions atSite Standard Barometric Pressure and to a power factor of 1.0. The Availability, expressed as an percentage, will be calculated by the quantity 100 divided by 168 and multiplied by the quantity of the sum of the corrected average net electric outputs for the 168 hours divided by the Demonstrated Net Electric Output.
The test corrected net electric output will be set equal to the Demonstrated Net Electric Output for any hours during which:
- The test corrected net electric output is greater than the Demonstrated Net Electric Output,
- Purchaser or CAISO dispatch order requires the Project to reduce net electric output and the Project successfully maintains such load
- Other Force Majeure events that cause a reduction in the net electric output and the Project successfully maintains such load.
If Purchaser or CAISO directs the Project or one of the Units to be shutdown, the test will be stopped and restarted after the Project or Unit returns to service at base load. The test will continue as if the interruption had not occurred (i.e. the 168 hours will be the sum of results of all completed hours before the shutdown plus the required additional hours after the restart).
Emissions shall not exceed the Guaranteed Emissions Limits at any time during the test.
1.3.3.ProjectPeak Electric Output
TheProject Peak Electric Outputtest will be conducted using the same test procedures as for the Project Base Electric Output and Heat Rate Test, with the following modifications to the operating conditions (the “Peak Load Conditions”), as applicable:
- The combustion turbines operating on their base load temperature control curve with evaporative coolers out of service and with full power augmentation, or
- Reciprocating engines operating at peak load as defined by the engine manufacturer for continuous operation with full power augmentation
- HRSG’s operating with full duct firing and normal blowdown.
- All other equipment and systems operating as normally required for peak electrical output on a continuous operating basis.
- Plant auxiliary equipment operated as normally required for peakelectrical output on a continuous operating basis.
The test corrected net electric output and test corrected heat rate for each test period will be calculated by correcting the adjusted net electric output and measured net heat rate for the following:
- Differences between the test measured inlet air conditions and the Peak July Conditions (as specified in Exhibit E) at Site Standard Barometric Pressure. These corrections will be based on the inlet air conditions at the inlets to the combustion turbines or reciprocating engines and to the cooling tower or air cooled condenser.
- Difference between the test measured power factorat the CAISO revenue meter and the design-basis power factor of 1.0.
1.3.4.Extended Guaranteed Electric Output and Heat Rate
The Extended Guarantee Electric Output and Extended Guarantee Heat Rate test will be conducted using the same test procedures and the same general requirements specified herein for the Project Base Electric Output and Heat Rate Test. In addition to the corrections for auxiliary power and ambient conditions, the net electric output and heat rate will be corrected for equipment degradation by the following methodology: