The existing RED-Rochester system consists of 17 utility systems, including 1,700 kpph steam, 130MW electrical and 45,000 tons of Chilled Water production. Historically these utilities had been balanced between electrical and thermal loads. Faced with more than 25% electric load growth but limited thermal growth, RED-Rochester explored a cost-effective way to increase electrical generating capacity while improving the efficiency of its legacy simple cycle utility generation system. The selected solution was a new combined-cycle cogeneration facility that decoupled steam production from on-site electric production while integrating with the utility infrastructure serving Eastman Business Park.
LocationRochester, New York
ServicesDistrict Energy, Thermal & Electrical Utilities
The project centered on a refurbished 38 MW General Electric Frame 6B gas turbine generator paired with a new heat recovery steam generator (HRSG) capable of producing up to 250,000 pounds per hour of steam. Rather than installing new generation equipment, RED-Rochester selected a reconditioned turbine that offered proven reliability, immediate availability, and a significantly lower cost than a new unit. Since thermal requirements were not increasing, costs could also be controlled by utilizing existing balance-of-plant (BOP) systems.
RMF worked directly for RED-Rochester on the mechanical balance-of-plant systems, existing electrical system upgrades and 15kV capacitor installation, and control system upgrades (“inside” the existing plant). Additionally, RMF served as the engineering partner to Frank Lill & Son on the Engineering, Procurement & Construction contract responsible for the cogeneration system installation (“outside” the existing plant). The project required integration of the new cogeneration assets with existing electrical, controls, steam, boiler feedwater, cooling water, demineralized water, instrument air and natural gas systems. RMF's multidisciplinary scope included mechanical, electrical, controls, civil and structural design engineering, along with construction administration. To support the aggressive schedule made possible by utilizing the refurbished turbine, RMF staffed the project with a full-time field engineer and also led the commissioning services both inside and outside the plant.
A significant portion of the design focused on accommodating high-pressure, high-temperature steam service and integrating the refurbished equipment into an operating utility system. Additional project components included a makeup water preheat system that recovers heat from the exhaust gas stream, reducing stack gas temperatures from 360°F to 150°F, a combustion turbine inlet air filtration system, a Continuous Emissions Monitoring System, multiple pipe racks, 180-foot freestanding stack, new 15kV switchgear, DC battery systems, control systems and a new building to support the turbine auxiliaries.
Highlights
38 MW Refurbished GE Frame 6B Gas Turbine Generator
250,000 PPH Maximum Steam Production
1,400 PSI at 900°F Steam to Existing Plant
25%+ Electric Load Growth Accommodated
3,000A, 15kV Electric Switchgear
15 MVAR Capacitors for Load Management
360°F to 150°F Exhaust Heat Recovery Temperature Reduction
180-Foot Freestanding Stack Height
Siting Constraints