Minutes of the Annual Meeting of the Power - New York Power ...

April 24, 2007
13. Richard M. Flynn Power Plant – Major Outage and Life
Extension Modifications – Capital Expenditure Authorization
SUMMARY
The President and Chief Executive Officer submitted the following report:
“The Trustees are requested to authorize capital expenditures of $8.642 million to extend the useful life of
the Richard M. Flynn Power Plant’s (‘Flynn’) gas turbine and other plant components for another 100,000 operating
hours.
BACKGROUND
“Flynn, a gas-turbine-powered combined cycle plant in Holtsville, was put into service in May 1994. The
gas turbine was purchased with an expected service life of 100,000 Equivalent Operating Hours (‘EOH’). EOH take
into account the number of starts, unexpected trips and severe events and types of fuel used. The Flynn gas turbine
crossed the 100,000 EOH threshold in January, 2005. It currently has about 120,000 EOH and is scheduled for its
next major overhaul (outage) in October, 2007, when components of the gas turbine, steam turbine and the balance
of the plant will be replaced. The last major overhaul was completed in October/November, 2003. Flynn is baseloaded
and rarely shuts down. A four-year cycle accumulates approximately 33,000 EOH.
“Some tasks covered by this Capital Expenditure Authorization Request will be scheduled for April and
May 2007 due to premature failure of the gas turbine generator rotor.
“These improvements will prepare Flynn for another 100,000 hours of service, which coincides with the
projected end (2020) of the current Capacity Supply Agreement between the Authority and the Long Island Power
Authority.
DISCUSSION
“Various components of Flynn’s Siemens V84.2 gas turbine, including diffusion gas and fuel oil burners,
dome bolts, turbine blades and vanes, compensators, dome plates, fuel oil and fuel gas lines, are at or near the end of
their useful life, which puts the safety and reliability of the gas turbine at risk. In addition, mixing elbows will be
upgraded to improve reliability.
“The steam turbine generator developed a stator ground fault in February, 2005; the generator was repaired
and returned to service 18 days later. During the repair, it became obvious that the general condition of the stator
bars was very poor, compromising reliable operation of the unit. Stator bars of superior design were procured and
the installation (rewind) was planned for the 2007 major outage. Contingency plans were developed in case the unit
faulted again before October, 2007.
“All gas turbines use some system of washing compressor blades when the unit is running and also when it
is turned off. When the compressor blades are dirty, they cause the gas turbine to lose efficiency. The original
water wash system on the Siemens gas turbine will be replaced with new technology that will provide superior
washes and less blade-coating damage.
“Modern technology will also be used to replace the steam turbine governor controls, excitation controls
and balance of plant controls, which are original equipment and have become unreliable in terms of performance,
service and available parts.
“The station batteries, which are near the end of their useful life, will also be replaced.
FISCAL INFORMATION
“Payments for costs associated with the major outage and life extension for the Flynn plant will be made
from the Capital Fund.
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