August 15, 2006

Brooklyn Navy Yard Cogeneration Facility, Brooklyn, New York

Dr. Robert Peltier, PE

Riding to the rescue

Where others saw uncertainty, Delta Power saw opportunity. Delta Power, formed in 1997 and staffed by executives with decades of energy industry experience—in cooperation and consultation with its partner and co-owner Metalmark Capital—understood that BNYC was a diamond in the rough and that all its technical problems were solvable. In the spring of 2004, Delta Power and Metalmark Capital purchased a controlling stake in BNYC and developed a plan to revitalize the project with the right mix of technical talent and investment dollars.

Upgrades began immediately after the deal was inked, with major repairs planned for the spring 2005 outage. By the end of 2004 contracts were in place for major upgrades to the HRSGs.

Purchasing replacement tube assemblies may have been the easiest part of the project. BNYC is fully enclosed in a 12-story building (with no elevator) and surrounded by narrow streets and other buildings, making delivery and installation a logistical nightmare. Delivery of replacement harps for the HRSG had to be completed at night to reduce traffic snarls. Two cranes, a hole cut in the roof, and around-the-clock work by trades and plant staff kept the project on schedule (Figure 4). Two years later, BNYC continues to operate efficiently with no recurrence of any of the problems that plagued Mission Energy.

 4. Close quarters. Replacing the HRSGs was a challenge for the land-locked, 12-story building enclosing the power plant. Courtesy: Delta Power Co.

Upgrades were not confined to the HRSGs but included the gas turbines, to increase efficiency and reduce emissions. More-efficient premix HR3 burners use water for NO_x control when burning gas. These upgrades not only reduced NO_x emissions by 5% but also lessened the demand for ammonia injected into the SCRs by 3%. Actual emissions levels in 2003 were 0.0079 lb NO_x/mmBtu. The 2007 goal calls for a further reduction in NO_x emission level to 0.0075 lb NO_x/mmBtu. BNYC has committed through the EPA Performance Track program (see below) to reduce NO_x to 151,775 lb per year by 2007, almost 50% below the annual permitted level of 299,000 lb.

BNYC has also tackled a major plantwide program to reduce water usage, targeting a net 2% reduction through engineering controls, improved treatment and recovery techniques, operational management procedures, and new equipment. The HRSG repairs alone will reduce wastewater discharges by 40 gpm, reducing the load on the New York City water supply and wastewater systems by millions of gallons of water every year.

Gas turbine controls were also upgraded with a Siemens XP-based Teleperm system. The plant controls, based on the Bailey Infi 90 (Figure 5), were upgraded with new operator interface screens. The UPS system was upgraded by configuring two existing UPS units to share critical bus load and by adding a new backup unit.

Environmental recognition

Industry-leading environmental performance is a very important part of Delta Power's and the plant's culture. In 2005, BNYC earned the distinction of being one of the few cogeneration plants accepted into the U.S. EPA National Environmental Performance Track (www.epa.gov/ performancetrack) and also received preliminary approval by OSHA's Voluntary Protection Program (www.osha.gov/dcsp/vpp). These two voluntary programs recognize companies committed to environmental excellence and outstanding workplace safety.

BNYC was inducted as a member of the Performance Track Program recognizing excellence in maintaining a strong environmental performance record and an outstanding facility compliance record. BNYC joined an exclusive group, as only a handful of power plants are members. According to the EPA, to qualify, applicants must meet four criteria: They must have implemented an independently assessed environmental management system, have a record of sustained compliance with environmental laws and regulations, commit to achieving measurable environmental results that go beyond compliance, and provide information to the local community on their environmental activities. Performance is reassessed annually to maintain the facility's certification.

Delta Power and BNYC are equally committed to being good neighbors in their communities, improving the environment, and striving for efficiency, no matter how challenging the circumstances. Delta Power, along with Metalmark Capital, had the vision, experience, and financial support to allow a dedicated and creative staff to turn around a prematurely aging plant into the environmental superstar it is today. BNYC is now operating at the efficiency it was designed for and is friendlier to the environment than ever before.