Final Report: Distributed Generation Operational Reliability and Availability Database Submitted To: Oak Ridge National Laboratory P.O. Box 2008 1 Bethel Valley Road Oak Ridge, TN 37831-6065 Under Subcontract No. 4000021456 Submitted By: Energy and Environmental Analysis, Inc. 1655 N. Fort Myer Drive, Suite 600 Arlington, Virginia 22209 (703) 528-1900 January 2004 TABLE OF CONTENTS ES EXECUTIVE SUMMARY............................................................................................................................ ES-1 ES-1 OBJECTIVES ......................................................................................................................................... ES-1 ES-2 TECHNICAL APPROACH........................................................................................................................ ES-1 ES-3 RESULTS .............................................................................................................................................. ES-2 ES-4 CONCLUSIONS AND RECOMMENDATIONS ............................................................................................ ES-5 1 INTRODUCTION................................................................................................................................................1-1 2 BACKGROUND ..................................................................................................................................................2-1 2.1 RELIABILITY AND DG/CHP ........................................................................................................................2-1 2.1.1 Existing CHP Market .........................................................................................................................2-1 2.1.2 Value of Operational Reliability ........................................................................................................2-2 2.2 PROJECT OBJECTIVES..................................................................................................................................2-2 2.3 PROJECT WORKSCOPE.................................................................................................................................2-3 2.4 OPERATIONAL RELIABILITY TERMS AND DEFINITIONS ...............................................................................2-4 3 TECHNICAL APPROACH................................................................................................................................3-1 3.1 INTRODUCTION ................................................................................................................................................3-1 3.2 REVIEW PRIOR WORK.................................................................................................................................3-1 3.2.1 Key References..........................................................................................................................................3-1 3.3 CANDIDATE SCREENING AND SELECTION ...................................................................................................3-2 3.3.1 Screening Process ..............................................................................................................................3-2 3.3.2 Unit Selection Criteria .......................................................................................................................3-5 3.4 DATA COLLECTION AND MANAGEMENT PLAN ...........................................................................................3-8 3.5 COLLECTION OF RAW DATA .......................................................................................................................3-8 3.6 POST PROCESSING OF OPERATIONAL RELIABILITY DATA .........................................................................3-10 3.7 FAILURE CAUSE ASSESSMENT ..................................................................................................................3-11 4 SUMMARY OF DATABASE OPERATIONAL RELIABILITY ...................................................................4-1 4.1 INTRODUCTION ...........................................................................................................................................4-1 4.2 SUMMARY OR PERFORMANCE ...................................................................................................................4-1 4.3 RECIPROCATING ENGINE PERFORMANCE....................................................................................................4-3 4.4 GAS TURBINE PERFORMANCE.....................................................................................................................4-4 4.5 FUEL CELL AND STEAM TURBINE PERFORMANCE ......................................................................................4-5 4.6 COMPARISON TO CENTRAL STATION OPERATIONAL RELIABILITY PERFORMANCE .....................................4-5 5 ASSESSMENT OF EVENT CAUSES ...............................................................................................................5-1 5.1 OUTAGE EVENT SUMMARY.........................................................................................................................5-1 5.2 FORCED OUTAGE ASSESSMENT BY SUBSYSTEM .........................................................................................5-6 6 CONCLUSIONS ..................................................................................................................................................6-1 6.1 INTRODUCTION ...........................................................................................................................................6-1 6.2 DISCUSSION OF RESULTS ............................................................................................................................6-1 6.3 RECOMMENDED FOLLOW-ON ACTIVITIES ...................................................................................................6-2 7 REFERENCES.....................................................................................................................................................7-1 APPENDIX A CANDIDATE SOLICITATION LETTER ................................................................................. A-1 APPENDIX B DATA COLLECTION AND MANAGEMENT SOFTWARE STRUCTURE AND USER GUIDE ..................................................................................................................................................................... B-1 i APPENDIX C DG/CHP RELIABILITY DATABASE ...................................................................................... C-1 APPENDIX D TECHNOLOGY/DUTY CYCLE SUMMARY REPORTS AND UNIT CHARACTERIZATION REPORTS.................................................................................................................... D-1 ii LIST OF TABLES TABLE ES.1 – SUMMARY STATISTICS FOR RECIPROCATING ENGINE SYSTEMS ............................... ES-3 TABLE ES.2 – SUMMARY STATISTICS FOR GAS TURBINE SYSTEMS..................................................... ES-4 TABLE ES.3 – SUMMARY STATISTICS: FUEL CELLS AND STEAM TURBINES...................................... ES-4 TABLE 2.1 - INSTALLED CHP BY SECTOR........................................................................................................2-2 TABLE 3.1 - FACILITY/PLANT INFORMATION.................................................................................................3-9 TABLE 3.2 - UNIT INFORMATION.......................................................................................................................3-9 TABLE 3.3 - UNIT MONTHLY GENERATION HISTORY DATA ....................................................................3-10 TABLE 3.4 - EVENT LOG DATA .........................................................................................................................3-10 TABLE 4.1 – SUMMARY OPERATIONAL RELIABILITY STATISTICS BY TECHNOLOGY GROUP..........4-2 TABLE 4.2 – SUMMARY OPERATIONAL RELIABILITY STATISTICS BY DUTY CYCLE ..........................4-3 TABLE 4.3 – SUMMARY STATISTICS FOR RECIPROCATING ENGINE SYSTEMS.....................................4-4 TABLE 4.4 – SUMMARY STATISTICS FOR GAS TURBINE SYSTEMS ..........................................................4-4 TABLE 4.5 – SUMMARY STATISTICS: FUEL CELLS AND STEAM TURBINES............................................4-5 TABLE 4.6 - NERC GAR 1997-2001 SUMMARY OR STATISTICS ....................................................................4-6 TABLE 5.1 - RECIPROCATING ENGINE (<100 KW) OUTAGE STATISTICS..................................................5-1 TABLE 5.2 - RECIPROCATING ENGINE (100-800 KW) OUTAGE STATISTICS.............................................5-2 TABLE 5.3 - RECIPROCATING ENGINE (800-3,000 KW) OUTAGE STATISTICS..........................................5-2 TABLE 5.4 - FUEL CELL OUTAGE STATISTICS ................................................................................................5-3 TABLE 5.5 - GAS TURBINE (0.5-3.0 MW) OUTAGE STATISTICS....................................................................5-3 TABLE 5.6 - GAS TURBINE (3-20 MW) OUTAGE STATISTICS........................................................................5-4 TABLE 5.7 - GAS TURBINE (20-100 MW) OUTAGE STATISTICS....................................................................5-5 TABLE 5.8 - STEAM TURBINE (<25 MW) OUTAGE STATISTICS ...................................................................5-6 iii LIST OF FIGURES FIGURE 2.1 – OPERATIONAL RELIABILITY