molten carbonate rue1 cell (mcfc) product development test

DOE/MC/28065 - 5170 (DE96004438)

Molten Carbonate Rue1 Cell (MCFC) Product Development Test

Annual Report October 1994 - September 1995

January 1996

Work Performed Under Contract No.: DE-FC2 1-92MC28065

For U.S. Department of Energy Office of Fossil Energy Morgantown Energy Technology Center Morgantown, West Virginia

BY M-C Power Corporation Burr Ridge, Illinois

DOE/MC/28065 -- 5170 (DE96004438)

Distribution Category UC-I 10

Molten Carbonate Fuel Cell (MCFC) Product Development Test

Annual Report October 1994 - September 1995

Work Performed Under Contract No.: DE-FC21-92MC28065

For U.S. Department of Energy

Office of Fossil Energy Morgantown Energy Technology Center

P.O. Box 880 Morgantown, West Virginia 26507-0880

BY M-C Power Corporation 8040 S. Madison Street

Burr Ridge, Illinois 60521

January 1996

Abstract

This report summarizes the technical progress that has occurred in conjunction with Cooperative Agreement No. DE-FC2 1-92MC28065, Molten Carbonate Fuel Cell Product Development Test (PDT) during the period of October 1,1994 through September 30,1995. Project status is summarized as follows:

Subtask 1.2

Subtask 1.3

Subtask 2.1

Subtask 2.2

Subtask 2.3

Subtask 3.1

Subtask 3.2

Subtask 3.3

Subtask 4.1

Subtask 4.2

Subtask 5.1

Subtask 6.1

Subtask 6.2

Environmental Information - Complete

Local Permits - Complete

Stack Design - The baseline design has been completed. Design changes are being made based upon recommendations fiom the Unocal demonstration project.

BOP Design - The original BOP design has been completed. Design changes are being made to modi@ piping, valving and instrumentation imported by changes to the plant start-up and standby procedures.

Site Interface Design - Complete

Component Manufacturing - Stack number one components have been manufactured. A decision has been made to incorporate intermediate separator plates.

Stack Assembly - Stack fit up studies have been completed. Final assembly is scheduled for February, 1996.

Shop Test and Shipping - Scheduled for June 1996 completion.

Equipment Procurement - All major pieces of equipment have been received with the exception of the distributed control systems and gas chromatograph. Piping and valves are on order to accommodate design changes instituted in Subtask 2.2.

BOP Assembly - Complete with the exception of the enclosure. The integrity of the hot gas blower seal system is being reevaluated.

Site Preparation - All foundations and trenching are in place in accordance with the baseline design. Minor foundations will be added to accommodate pipe supports resulting from additional work in Subtask 2.2.

Operating and Maintenance Manuals - 90% complete.

Test Plan - 10% complete.

iii

Table of Contents

ExecutiveSu mmary .......................................................... 1

1.Introduction .............................................................. 3

II.Purpose ................................................................ 5

111 . TechnicalResults ......................................................... 6 Task 1 Project ManagementPermitting ..................................... 6 Task 2 Demonstration Design ............................................ 7 Task 3 . Stack Manufacturing ............................................ 16 Task 4 . BOP Fabrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 TaskSSiteWork ..................................................... 17 Task 6 Testing ....................................................... 19 Task 7 . ARPA Enhancements ............................................ 19

List of Figures

Figure 1 Project Schedule .................................................. 8-10 Figure 2 Milestone Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

List of Tables

Table 1 Bechtel Design and Associated BOP Work ................................. 13 Table 2 Current Status of Equipment Procurement ................................. 18

iv

DOE Cooperative Agreement No.: DEFC2 1-92MC28065 Project Start Date: 9/30/92 Project Finish Date: 3/31/97

PDT Technical Progress Report (Yearly) Reporting Period: 10/1/94 to 09/30/95

Executive Summary

M-C Power Corporation and the U.S. Department of Energy (DOE) have entered into Cooperative Agreement Number DE-FC2 1 -92MC28065, Molten Carbonate Fuel Cell Product Development Test (PDT). M-C Power will install, test and evaluate a 250 kW Proof-of-Concept Molten Carbonate Fuel Cell (MCFC) Power Plant.

At the onset of the project activities the plant was to be located at the Kaiser Permanente Medical Center in San Diego, California. The site design work was almost complete when the estimated costs for construction escalated beyond acceptable levels. These escalations were primarily due to previously unidentified underground constraints and increasingly stringent architectural requirements. Based upon these site conditions, the decision was made to seek a more suitable demonstration sit e.

I

The plant is to being located at the Naval Air Station Miramar in San Diego, California. originally the DOE was providing funds for two 250 kW natural gas-fieled IMHEX@ MCFC stacks to be manufactured and shop tested by M-C Power. The project has been modified and the DOE is providing only one stack under this cooperative agreement. The Gas Research Institute (GRI) is providing finds for the balance of plant engineering and construction. San Diego Gas and Electric Company (SDG&E) will host the PDT. The Electric Power Research Institute is providing fbnds through a tailored collaboration agreement with SDG&E. In addition to the fbnds provided by GRI and EPRI, in-kind cost sharing is provided to the project by the Bechtel Corporation, Stewart & Stevenson Services, and SDG&E.

M-C Power has formed a team with the Bechtel Corporation and Stewart & Stevenson Services. M-C Power is designing and manufacturing the MCFC stack. The Bechtel Corporation is pe&orming balance of plant engineering and major equipment procurement administration. Stewart & Stevenson Services is fabricating the balance of plant equipment on to a skid that can be truck transported to the power plant site.

As host of the PDT, SDG&E is constructing and will operate the power plant. SDG&E is coordinating all site related activities including the securing of the necessary construction and operating permits. SDG&E is coordinating the power plant design with the United States Navy who manages and operates the military reservation.

The PDT project represents the first truly integrated MCFC power plant in a cogeneration application. The power plant will be fueled by natural gas and it will f i s h electricity to the SDG&E electrical distribution grid. It will also firnish thermal energy in the form of saturated steam to the Naval Air Station Miramar. Miramar was chosen as the site for the PDT to gain direct experience with an MCFC power plant in a military application.

This report summarizes the technical progress that has occurred in conjunction with this project for the period of October 1, 1994 through September 30, 1995.

1

I I

DOE Cooperative Agreement No.: DEFC21-92MC28065 Project Start Date: 9/30/92 Project Finish Date: 3/31/97


The U.S. Navy has continued to support the NAS Miramar Product Development Test (PDT) project. All steam piping and electrical interconnects with the Naval Base power plant complex has been accomplished. Trenehing, foundations and pipe alleys are complete. All foundations are in place for installation of major equipment. Minor footings are being designed to accommodate piping supports dictated by modifications resulting &om the Unocal demonstration start-up experience. The electrical and control room is complete.

All major pieces of equipment have been ordered and received. The Bailey distributed control system is in final shakedown and testing. Modifications were made to the Bailey system based upon changes to start-up and hot standby modifications. SDG&E operators have been trained on the Bailey system.

The IHI reformer has been received and is at the site holding area.

A gas chromatograph has been specified and is awaiting final approval prior to issuance of the purchase order. Stewart & Stevenson has purchased the remaining field piping and expansion joints specified by Bechtel. Due to modifications dictated by the recent process changes, additional piping and valves will need to be purchased. Bechtel is in the process of finalizing the design. A HAZOP review will be required prior to issuance of purchase orders.

Stewart & Stevenson has completed 90% of the BOP skid fabrication. The hot gas blower seal failed during testing at the Stewart & Stevenson factory. A major effort is underway to find a solution to the leaking seal.

Preliminary design work on the BOP enclosure has been initiated by Stewart & Stevenson. The enclosure and completed BOP skid is scheduled for delivery to the site by the end of January 1996.

SDG&E and Bechtel have prepared bid packages for the mechanical, electrical and control work that remains. These contracts will be awarded by January, 1996. SDG&E has begun work on development of the start-up and operating manuals.

DOE Cooperative Agreement No.: DE-FC21-92MC28065 Project Start Date: 9/30/92 Project Finish Date: 3/31/97

PDT Technical Progress Report (Yearly) Reporting Period: 1011194 to 09/30/95

L Introduction

M-C Power Corporation is designing, fabricating, installing, testing and evaluating a 250 kW Proof-of-Concept Molten Carbonate Fuel Cell (MCFC) Power Plant. The plant is under construction at the Naval Air Station Miramar in San Diego, California. The project is defined as "MCFC Product Development Test" (PDT) and has been developed in accordance with Department of Energy guidelines under Cooperative Agreement Number DE-FC21-92MC28065. The project was initiated on September 30, 1992 and has a completion date of March 31, 1997.

As host of the PDT, SDG&E is managing the plant construction and will operate the power plant. SDG&E is coordinating all site related activities including the securing of necessary construction and operating permits. SDG&E is coordinating the power plant design with the United States Navy who manages and operates the military reservation.

The PDT project represents the first truly integrated MCFC power plant in a cogeneration application. The power plant will be fiieled by natural gas and it will firnish electricity to the SDG&E electrical distribution grid. It will also fbrnish thermal energy in the form of saturated steam to the Naval Air Station Miramar. Miramar was chosen as the site for the PDT to gain direct experience with an MCFC power plant in a military application.

This report summarizes the technical progress that has occurred in conjunction with this project over the period October 1, 1994 through September 30, 1995.

The he1 cell demonstration project site was originally at the Kaiser Permanente Medical Center in San Diego, California. Due to escalating site construction cost estimates, the Kaiser Medical Center location was deemed prohibitive, M-C Power and San Diego G a s and Electric relocated the fitel cell demonstration project to an alternate site at the Naval Air Station Miramar. An Environmental Assessment has been prepared by the Department of Energy (DOE) in compliance with the National Environmental Policy Act of 1969 (NEPA). The Environmental Assessment resulted in a categorical exclusion of the proposed action fiom all environmental permit requirements. All requisite permits have been achieved for the construction and operation of the 250 kW demonstration which will be operated under the supervision of SDG&E.

During 1994, the cooperative Agreement was modified to accommodate movement of the demonstration site to Naval Air Station, M i m located in San Diego. The Department of Defense, through the Advanced Projects Research Agency (ARPA), provided fbnding for the following tasks:

Task 7.1, Site Design, Permits, and Manuals Task 7.2, Site Preparation and Installation Task 7.3, Stack Conditioning and Shipment Task 7.4, NEPA Documentation, Update and Approvals Task 7.5, Full-Area, 20 kW Stack Verification Task 7.6, Advanced Separator Plate Qualifications Task 7.7, Pressure Vessel Design Improvement

3



These tasks were added to the Cooptive Agreement to help maintain project schedules and provide technical verification of components to be used in the Product Development Test Demonstration.

4



IT, Purpose

The mission of this project is to cany out the planning, coordination, support, management, development, construction, and demonstration of a MCFC power generation facility utilizing the IMHEX@ design. The demonstration project is configured to promote the commercialization of MCFCs by the demonstration of the viability of natural gas-fueled molten carbonate &el cells to produce electricity in an environmentally benign manner for use in commercial and industrial applications

Project activities have been performed in accordance with the "Statement of Cooperative Agreement Objectives". The major objective of the project is to support the production, development, and testing of kll-area, full-height 250 kW MCFC stacks in order to accelerate commercialization of the MCFC technology.

In addition to the U.S. Government's role in the PDT project as defined above, the G a s Research Institute (GRI) is sponsoring balance of plant efforts. SDG&E and EPRI are participating in site related and operational activities. The roles of GRI, EPRI and SDG&E are particularly important as their emphasis is on addressing design issues which will impact acceptance by the utility industry.

5


III. Technical Results


PROJECT OBJECTIVES

The objective of this project is to design, construct, operate, and evaluate a natural gas-fueled MCFC power plant. The plant is based upon the IMHEX@ fie1 cell design for converting natural gas fie1 to electric power. The PDT project will demonstrate the technical, economic, and environmental viability of the IMHEX@ technology. Design objectives include improved performance at reduced cost compared with the Unocal Product Development Unit (PDU) demonstration which incorporated the IMHEX@ technology.

Design goals for the PDT include: I

1) 2) Cogeneration acceptability 3) 4) Site acceptance (size, aesthetics) 5 ) 6) Reliability/availability/maintainability/safety 7) Potential for cost competitiveness

High electrical and overall efficiency

Environmental acceptability (noise and emissions)

Ease of operation (start-up, shutdown, unattended operation)

Task 1 Project Managemenflermitting I Objective: Development of project management system for planning, budgeting, executing, and controlling the costs and schedules associated with the work. To obtain permits required for stack and BOP fabricatiodtesting and site related activities.

Subtask 1.1 Management Plan

Discussion: This subtask is complete. The Management Plan was previously revised to reflect the change in project site fiom Kaiser Permanente Medical Center to NAS Miramar.

Subtask 1.2 Environmental Information

Discussion: This subtask is complete. An environmental document containing the information necessary to allow DOE to prepare documentation to comply with NEPA requirements has been prepared to reflect the new project site. A categorical exclusion was received. All local environmental permitdapprovals have been obtained for site construction which is 50% complete.

Subtask 1.3 Local Permits

Discussion: All local permits/approvals have been obtained. SDG&E finalized the site agreement with NAS Miramar.

6


Subtask 1.4 Management and Reporting

PDT Technical Progress Report (Yearly) Reporting Period 10/1/94 to 09/30/95

The management plan, budget and schedule was previously revised to reflect movement to the new project site. There has been an increase in the project budget which was caused by rework of the site design. Balance of Plant activities continue to be supported by the Gas Research Institute (GRI). See Figure 1 for the project schedule. Figure 2 contains the milestone log.

Task 2 Demonstration Design

Objective: Prepare designs for the stack, Balance of Plant, and site which are integrated and consistent with the 250 kW PDT demonstration plant performance objectives.

Subtask 2.1 Stack Design

Discussion: The original stack design concept included having the first 250 kW stack as a duplicate of that used in the Unocal demonstration. Based upon experience gained on the Unocal project, there have been a number of design changes included in the PDT stack. Changes relate to a more simplified clamping device7 thinner electrodes7 new matrix formulation and an improved separator plate design. A number of trade-off studies have been performed regarding stack sealing, box plenum and the pressure vessel.

LVDT Svstem

The LVDT system has been modified to fbnction outside of the high temperature zone.

Intermediate Plates

Based upon experience gained at the Unocal demonstration and stack component fit-up studies in M-C Power’s fktory, a decision was made to incorporate intermediate plates in the stack. These plates were designed, specifications issued, and they are now in manuf8cturing. There were also pressure vessel design changes which were dictated by analysis of the Unocal demonstration stack.

Guard Heaters

Thermocraft is in the process of providing new drawings for the guard heaters. They are addressing the issue of anchoring the guard heater during stack shipment and operation. Design changes were dictated by the Unocd demonstration experience. A design for the anode bus support in the pressure vessel that comes off the guard heater fiame has been completed and incorporated in the final guard heater design.

7


PDT Technical Progress Report ('Yearly) Reporting Period: 101y94 to 09/30/gS

Figure 1 Project Schedule

. ^ " . . . f : -1: : r ......"... ... "... -- ..."._. ...... ....... ...... ...... ......... .... "... ...... ........ .......... eF ........

8 .

DOE Cooperafive Agreement No.: DE-FC21-92MC28065 project Start Date: 9/30/92 Project Finish Date: 3/31/97


Figure 1 (Cont'd)

. . I . --1.. . . . - I - . . . . I . . - - I - . .

........... - __.I- I ........ ...

........ - - . ........... ........... -$.I$ ....... .......... .....

. . . . . . . . . . -:+p-+i+-\;

......... ..........

~ - ~ - - : q . . I-. .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. ................ . . . .. .. . . I . . . . 1. ..I . . ..I.. . . . . ....

9

DOE Cooperative Agreement No.: DEFCZ 1-92MC28065 PDT Technical Progress Report (Yearly) Project Start Date: 9130192. Project Finish Date. 3/31/97 . Reporting Period: 1011194 to 09/30/g5

Figure I (Cont’d)

10



Figure 2

Molten Carbonate Fuel Cell Product Development Test Cooperative Agreement No. DEFC21-92MC28065

211@730

2.1 10791

21 10792

U l O o l O .

8 U l o p s o

9 3.1 11190

10 3.1 I1191

11 3.2 I 1290

3.2 I1292

33 I 1390

33 I U91

4.1 1 ism 16 4.1 I1592

4.3 Ill91

6.412630

6.412691

6 5 m m 6.5 I2791

~~

24 I 6512792

7.1 10410

7.2 I 1910

27 7.3 I xi10

7.512910

7.6113000 .

31 7.7 13100

I

BoPsIlipmt Dee. 15,1995 --- April 15,1996

BednNolmrlOpention June 4,1996

atoadTatReport J.a 27,1997

DOE Cooperative Agreement No.: DE-FC21-92MC28065 Project Start Date: 9/30/92 Pmject Finish Date: 3/31/97

PDT Technical Progress Report (YearIy) Reporting Period: 1011194 to 09/30/95

Acceptance Test Facility (ATF)

Electrical and structural modifications to the Acceptance Test Facility (ATF) are underway. Modifications are being made to the load device. The potentiometer is being relocated outside of the ATF. Heat trace cable has been installed.

Start-up procedures are being modified to accommodate ventilation capacity. A training program for operators is being developed.

New stack shrinkage measurement equipment has been installed.

Transportation

During transportation of the stack to Unocal, stack clamping pressure was lost. Back-up transportation springs to accomfnodate the bellows have been designed. The nitrogen supply cabinet used in the Unocal demonstration has been returned to M-C Power and retrofitted for the PDT stack shipment. The nitrogen pressure is required to ensure clamping pressure. A back-up spring system is also designed into the transportation system.

Subtask 2.2 BOP Design

Discussioxr The balance of plant (BOP) design represents a significant improvement over the Unocal design. The PDT plant design is more compact, approximately 40% of the Unocal demonstration site area. Work completed by Stewart & Stevenson includes:

0

0

0

e

0

0

0

0

Submittal of fabrication drawings and bills of material for all BOP process pipe runs to Bechtel for review and comment. Incorporated Bechtel's input from earlier drawing submittals. Detailed design and installation drawings for pipe supports. Design of HRSG exhaust stack. Completed installation drawing for same. BOP Skid Wiring Diagrams and released to Bechtel. Low voltage wiring and conduit design. Instrumentation air system design. Developed bill of material for procurement. Reviewed vendor bid packages for thermal insulation on the BOP skid. Pipe stress analysis for new piping configuration. Lift and load details for the BOP skid to SDG&E. Procurement specification for thermal insulation on the BOP skid. Detailed design of the K-200 blower cooling water system.

Bechtel's design activities are summarized in Table 1.

12


PDT Technkal Progress Report (Yearly) Reporting P e w . 10/1194 to 09130195

DescriD t ion

Permitting;

Building

System Process Design

Process Description PFDS P&IDs Hazop Review Utility Summary

Table 1

Bechtel Design and Associated BOP Work

YO Comdete

Mechanical

Reformer - Fuel Cell Line Designation Tables Piping Class Sheets Valve List

Preliminary

Equip. Install. Manuals Equipment Maint. Manuals

Major Equipment: HRSG Recycle Blower Turbocharger Start-up Blower Gas cooler Desulfbrizer Seal Pot Air Compressors Nitrogen Storage System Boiler Water Treatment

Site Noise Attenuation

13

100

90 100 95

100 0

95 100 100

100

70 70

100 100 100 100 100 100 75

100 100 100

100

DOE Cooperative Agreement No.: DEFC21-92MC28065 Project Start Date: 9/30/92 Project FMMh Date: 3/31/97

Table 1 (Cont’d)

Major Skid Interconnect Piping, Supports & Insul.

Anode Inlet Anode Outlet Cathode Inlet Cathode Outlet

Small Skid Interconnect Piping, Support & Insul.

H.V. A. C.

ElectricaVControl Room

Site Utility Services:

Nitrogen Instrument Air

Electrical MCC Single Line Diagram MCC Load Tabulation Schematic & Block Diags Skid Interf Wiring Diag.

Junction Box Layout Point-to-Point & Grounding Details

Major Equipment: DC Cable Bus

Cables from Cell to Inverter Motor Control Center (breakers, motor starters, variable speed motor drive and transformers) Heater Control Panels Inverter Anode Inlet Heater Cathode Startup Heater


95 95 95 95

100

100

100 100

100 100 100 80

100 100

100

100 100 100 100 100

14

DOE Cooperative Agreement No.: DE-FC21-92MCZS065 Project Start Date: 9/30/92 Project Finish Date: 3/31/97


Table 1 (Cont’d)

Lighting & Misc. Power

Skid Interconnection Conduit & Trays

Control and Instrumentation

Major Equipment: Dist. Control System Operator Interface Stn.

Skid Mounted Instruments: Instruments & Transm Control Valves

Field Mounted Instruments Gas Analyzers Termination Cabinets

Detailed Plot Plan Gen. Arrangements Drgs Pipe Supports outside skid ControlElectrical Room

Subcontract Bid Packages

Civil worWStructural Mechanical, Piping & Insulation Electrical Instrumentation

System Operation Manuals

Plant Operating Manual Start-up Procedures Operating Modes

100

100

70

60 60

90 90

85 . 100 80

100 100 100 100

100

100 90 90

0 0 0

Plant Test Plan 0

15

DOE Cooperative Agreement No.: DE-FC21-92MCZS065 Project Start Date: 9/30/92 Project Finish Date: 3/31/97

PDT Technical Progress Report (Yearly) Reporting Period: 10/1/94 to 09130195

Task 3. Stack Manufacturing

Objective: Fabricate stack repeat and non-repeat components, assemble and test two 250 kW stacks. One stack shall remain at M-C Power‘s plant in Burr Ridge, Illinois for testing. The stack shall be made available as a spare for installation at the site, if required. During this reporting period, the second stack was taken out of the PDT objectives.

Subtask 3.1 Component Manufacturing

Discussion: 453 cathodes were tape cast; 424 were accepted. 435 cathodes were sintered; 358 were accepted. All of the active area components for the stack are completed.

All of the non-repeat parts for the stack are complete.

A new plate design for improved sealing compared to stack fabricated for the Unocal Demonstration was developed. Pressing of the improved design separator plates is complete. A new automated aluminization procedure was developed. The new procedure was developed to reduce the laborious task of manually masking the separator plates before aluminization. The separator plates are completed.

The box plenum has been received.

Subtask 3.2 Stack Assembly

Discussion: Stack assembly work is scheduled for the first quarter of 1996. Subassembly drawings for the stack are complete. Three mock-up tests have been completed. The fourth test will include the intermediate plates. Pressure sensitive film is used to ensure sealability. The initial mock-up test revealed little contact in some “T.” areas.

Subtask 3.3 Shop Test and Shipping

Discussion: This work is scheduled for the second quarter of 1996.

Task 4. BOP Fabrication

Objective: Purchase major equipment items, shop test equipment, fabricate skid in accordance with design specifications, and ship the BOP skid to demonstration site.

Discussion: Stewart & Stewenson Services, Inc.’s primary responsibility is to design a unitized equipment module to incorporate the piping, valves, instrumentation, and equipment required to operate the 250 kW demonstration plant. The design requirements are derived &om information developed by Bechtel Corporation and M-C Power Corporation, and represented on project PFD’s, P&ID’s, Instrument Data Sheets, and Description of Operation. Major components of the systems, such as the recycle blower, turbocharger, turbocharger start-up blower, cathode start-up heater, hot

16

DOE Cooperative Agmement No.: DE-FC21-92MC28065 Project Start Date: 9/30/92 Project Finish Date: 3/31/97


gas cooier, heat recovery steam generator, desulfbrization vessels, electrical conditioninglprotection, motor control center, distributed control system, and the fuel cell stack are specified by Bechtel and procured by M-C Power. Material used in the fabrication of the equipment module is purchased by Stewart & Stevenson. The equipment module will be delivered to the Naval Air Station, Miramar.

Subtask 4.1 Equipment Procurement

Discussion: The status of equipment purchases is shown in Table 2.

The IHI plate reformer represents the largest piece of equipment procured for the PDT demonstration. To minimize reformer problems during pre-commissioning and start-up, all four 62.5 kW sections of the reformer were hot tested. A purchase order was placed with an independent inspection company, Japan Inspection Company (JIC). JIC witnessed the hot tests and conducted a pre-shipment inspection on M-C Power’s behalf.

SDG&E is storing and inspecting the reformer as recommended by IHI.

Subtask 4.2 BOP Assembly

Discussion: The BOP assembly is scheduled to be completed by the end of January 1996.

Work status is as follows:

Completed installation for desulhrization vessel area Fabrication of turbocharger structural support underway Piping assembly fabrication underway Installation of permanent and temporary pipe supports are underway Initiated installation of instrument transmitters Superstructure work underway Completed alignment, mounting and testing of K-200 recycle gas blower

Subtask 4.3 BOP Shop Test and Ship

Discussion: This subtask will be initiated at the completion of subtask 4.2. Stewart & Stevenson will make final preparation for shipment of the BOP equipment module. Components inside the skid will be secured. Exterior equipment that might protrude tiom the enclosure will be removed and packaged to ship-loose. A protective tarp and bottom covering will be used to prevent dirt and debris fiom entering the skid during transportation.

Task 5 Site Work

Objective: Prepare site, installation, and commission 250 kW demonstration plant.

17


PDT Technical Progress Report (Yearly) Reporting Period 10/1/94 to 09/30/95

Table 2

Current Status of Equipment Procurement

Equipment Item

Inverter Reformer DesulfUrization Vessels Hot Gas Recycle Blower Heat Recovery Steam Generator Recycle Gas Cooler Turbocharger Turbocharger Start-up Blower Natural Gas Compressors Instrument Air System Nitrogen Storage System Boiler Water Treatment System Distributed Control System Data Sheets for Control Valves &

Instruments Motor Control center Electric Heaters

% Complete

100 100 100 100 100 100 90 90 80 20 10 10 90 50

100 100

18



Subtask 5.1 Site Preparation

Discussion: SDG&E has completed all site preparation work. Site construction began on July 18, 1995 with relocation of the existing electrical service and installation of a sewer line to the main line.

Subtask 5.2 Plant Installation

Discussion: Plant installation is 50% complete. Remaining mechanical, electrical and control work is scheduled to be complete in March 1996. Both Bechtel and Stewart & Stevenson will provide start- up assistance.

Task 6 Testing

Objective: Prepare manualdtest plans and execute test programs which document the PDT demonstration plant's performance.

Discussion: The following subtasks will be executed based upon experience at the Unocal demonstration:

6.1 Operating and Maintenance Manuals 6.2 Test Plan 6.3 Performance Testing 6.4 Emission Testing 6.5 Test Reports

Task 7. ARPA Enhancements

Objective: Provide support to the PDT demonstration work related to movement of the site and in areas which will improve chances of project success.

Subtask 7.1 Site Design, Permits and Manuals

Discussion: All site design and permits are complete. Operating manuals are under development.

Subtask 7.2 Site Preparation and Installation

Discussion: Site preparation is 80% complete and installation 30% complete. Stewart & Stevenson will help with the installation, debug, and commissioning of the BOP module. This includes on-site engineering support, as well as off-site engineering and procurement assistance.

Subtask 7.3 Stack Conditioning and Shipping

Discussion: Work will be initiated by M-C Power as described in Subtask 3.3.

19


PDT Technical Progress Report (Yearly) Reporting Period: 1011/94 to 09/30/95

Subtask 7.4 NEPA Documentation, Update and Approvals

Discussion: As described in Subtask 1.2, this work has been completed.

Subtask 7.5 FuU-Area, 20 k W Stack Verification

Discussion: A 20 kW stack test was initiated in May and reached its test objectives. The stack contained the same components to be used in the 250 kW PDT demonstration. On July 10, 1994 the 20 kW test was terminated after approximateIy 1200 hours of operation. It reached a maximum current of 1400A and a maximum power output of 20.8 kW. All test objectives were net.

Subtask 7.6 Advance Separator Plate Qualifications

Discussion: This work is complete.

MOD 4 Plates

A complete review package of the MOD 4 separator plates is underway. Initial plates were pressed and aluminized. They are currently undergoing certification review:The MOD 4 prototype clamping device has been completed. Prototype matrix cutting is awaiting the plate delivery.

Subtask 7.7 Pressure Vessel Design Improvement

Discussion: This work is complete. I Pressure Vessel

The pressure vessel was reduced in weight by 30% and the diameter was reduce by 15%. This was accomplished by employing a reusable cage for stack lifting. A change in the specification for the inverter to DC input negative pole grounded resulted in simplified internal piping. Additionally, the &el cell stack instrumentation has been significantly reduced. An on-line gas chromatograph will be purchased for better control of start-up and material balances.

Insulation in the pressure vessel is complete as is hydro testing of the pressure vessel.

A thermal analysis of the stack in the pressure vessel was conducted by Ricardo North America.

20

molten carbonate rue1 cell (mcfc) product development test

Documents