Sanger Repower Project

CLIENT: Algonquin Power Sanger LLC         LOCATION: Sanger, CA

IEC earned a contract with Algonquin Sanger Power LLC to provide preliminary design, detailed design, project management, and construction management services to support the Sanger Repower Project. The project is a power island repower of an existing Westinghouse 251 with a GE LM6000 PC Sprint at the Algonquin Sanger Cogeneration Facility for a total net plant generating capacity of 57 MW.

Preliminary Engineering StudyIEC initially performed an engineering feasibility study that included developing a power plant simulation model using GE Gatecycle software to predict the performance characteristics and adequacy of the existing equipment with the LM6000 PC or PC SPRINT combustion turbine. Major equipment included two pressure level HRSG with SCR, 13 MW Westinghouse steam turbine, condenser, cooling tower, and water treatment facility. The study also included developing a project cost estimate, site plan layout, repower project scope of work, site plan review proposal for City of Sanger, and photo simulation of the plant with the new LM6000 turbine.
LM6000 Turbine InspectionIEC inspected the condition of a new LM6000 S&S package that had been in storage for four years. In addition, our personnel reviewed documentation for completeness, and itemized and prioritized turbine upgrade product bulletins, service bulletins, and package options. IEC provided a final procurement recommendation to the client.
Repower Project DesignIEC led the engineering team for the detailed design of the repower project. Responsibilities included equipment specifications development, bid evaluation, equipment procurement, vendor coordination, P&ID and drawing development, building permit application process, construction bid package development, mechanical design, structural design, natural gas system modification with new compressors system, natural gas emergency shutoff system design, anti-icing system design, turbine inlet coil design, DI water system modification, cooling water system modification, boiler blowdown system modification, turbine exhaust duct elbow modification, and steam turbine bypass system design.
Construction and Start-up Management

IEC engineers provided construction management services, including scheduling, field engineering support, project management support, contractor coordination, design review, document control, interfacing with the Sanger Building Department, and field inspection services. The repower project was constructed in parallel with existing plant operation until the LM6000 PC SPRINT turbine and its ancillary equipment were installed. The W251 Westinghouse gas turbine was then decommissioned and removed. A new turbine exhaust elbow was installed and tied-in with the existing HRSG. Other equipment, such as the natural gas compressor system and anti-icing system, were also installed and connected. The repower construction was completed in six months, with a plant outage period of 45 days. System start-up consisted of natural gas system including gas blow, anti-icing system with steam blow, DI water system, cooling water system, turbine lube oil system, and GE LM6000 package.