Commissioning and Startup Services

Together, Sterling Energy and its principals have managed or served in leadership roles in more than 80 startups totaling more than 45,000 MW.

TechnologyFuels

Plants

Total MW

Combined cycleGas and dual fuel

37

27,808

Simple cycleGas and dual fuel

10

4,666

CogenerationGas and dual fuel

10

3,312

Steam turbineCoal

7

3,050

Steam turbineGas, oil or dual fuel

3

1,200

Landfill gasLandfill gas

2

30

Hydro 

8

200

Flue gas desulfurization 

2

1,700

NuclearNuclear

3

3,100

  

82

45,066

As shown below, we have extensive experience with numerous manufacturers of the major pieces of power generation equipment.

Gas TurbinesSteam TurbinesHRSGsPower BoilersControls
Aeroderivative:WestinghouseAlstomFoster WheelerFoxboro IA
GE LM 2500, 5000, 6000ToshibaNooter EriksonCombustion EngineeringEmerson Delta V
MHIGeneral ElectricAalborgHitachiWestinghouse Ovation
SolarAllis ChalmersVogt-NemBabcock & Wilcox 
Alison 501KABBFoster WheelerABB 
Industrial:Shin-NipponATS ExpressZurn 
GE MS6000, 7000, 9000Fincantieri   
Westinghouse 251G, 501F, 701Terry   
MHIDresser   
Alstom    

Click on the links below to see summaries of our most recent commissioning projects.

Commissioning and Startup of a 110 MW Solar Plant
Owner’s Representative for the Commissioning of a 523 MW Cogeneration Plant
Owner’s Representative for Construction and Commissioning a 580 MW Combined Cycle Plant
Commission and Startup of a 36 MW Biomass Power Station in Canada

Owner’s Representative for Construction and Commissioning a 683 MW Combined Cycle Plant
Commissioning and Startup of a 560 MW Combined Cycle Plant
Commissioning Management of a Utility Peaking Plant
Commissioning and Startup of a 450 MW Coal Plant

Consulting Services Related to Commissioning and Startup Activities
Startup Management of a 550 MW Combined Cycle Facility
Commissioning and Startup of 48 MW Cogen Plant in the Midwest
Commissioning Management of an LM6000 Utility Peaking Plant

Recommissioning of Two LM6000 Peaking Units in California
Commissioning Management of a 600 MW Ultra-supercritical Coal Plant

.

Commissioning and Startup of a 110 MW Solar Plant                                                               Sterling Energy recently completed providing construction and commissioning management services for the Crescent Dunes Solar Power Plant. The facility is a 110 MW solar power plant, located in Tonopah, Nevada, utilizing molten salt technology. We were initially contracted in early 2013 to provide the Commissioning Manager for the project to organize preoperational testing and organize System Turnover Packages. We were subsequently requested to provide the Construction Manager to manage the construction effort, and also provide key discipline (mechanical, electrical, I&C, LOTO) commissioning engineers.

.

Owner’s Representative for the Commissioning of a 523 MW Cogeneration Plant
Sterling Energy was engaged by TransCanada Energy to act as owner’s representative during the commissioning of a 523 MW combined cycle plant that included two GE 7FA gas turbine generators, two Alstom HRSGs, and a Siemens extraction steam turbine generator. Sterling’s scope included a design review to facilitate future maintenance, oversight on commissioning activities provided by the EPCC contractor, review of the system turnover packages, and system walk-downs. Sterling also researched electrical and piping specifications to ensure construction complied with local code requirements and managed and balanced the fuel gas budget and power generation during commissioning. Sterling represented TransCanada at all meetings with the EPCC contractor, steam host and utilities.

.

Owner’s Representative for Construction and Commissioning a 580 MW Combined Cycle Plant
Sterling Energy was engaged by TransCanada Energy to act as owner’s representative during the commissioning of a 523 MW combined cycle plant that included two GE 7FA gas turbine generators, two Alstom HRSGs, and a Siemens extraction steam turbine generator. Sterling’s scope included a design review to facilitate future maintenance, oversight on commissioning activities provided by the EPCC contractor, review of the system turnover packages, and system walk-downs. Sterling also researched electrical and piping specifications to ensure construction complied with local code requirements and managed and balanced the fuel gas budget and power generation during commissioning. Sterling represented TransCanada at all meetings with the EPCC contractor, steam host and utilities.

.

Commission and Startup of a 36 MW Biomass Power Station in Canada
Sterling Energy provided a Commissioning Manager and a small team of Commissioning Engineers to re-commission the 36 MW Conifex biomass power plant in Mackenzie, British Columbia. Sterling was engaged after an unsuccessful start-up effort by another party resulted in serious damage to the plant’s Dresser Rand steam turbine. Our team successfully managed the commissioning and start-up of the plant. We were also engaged to develop and implement a Training and Qualifications Program for the operations staff. This was successfully completed prior to turbine roll.

.

Owner’s Representative for Construction and Commissioning a 683 MW Combined Cycle Plant
Sterling Energy is currently engaged by TransCanada Energy to act as its representative during the erection and commissioning of a 683 MW gas-fired combined cycle plant utilizing an air-cooled condenser. Sterling’s scope included a design review and recommendations to facilitate future maintenance activities, oversight on the erection of all equipment, oversight on the EPCC contractor’s commissioning activities, and management of the fuel gas and power generation budget during commissioning. Sterling also advised TransCanada on performance testing issues.

.

Commissioning and Startup of a 560 MW Combined Cycle Plant
Sterling Energy provided complete commissioning and startup services for a 560 MW combined cycle plant in the western U.S. The plant included two MHI 501F gas turbine generators and one GE D11 steam turbine. The site utilized used equipment from two decommissioned power plants and a large air-cooled condenser. Sterling mobilized to the site early and assisted with the field engineering and construction of all balance of plant equipment, identified startup-related design problems and generated recommendations to resolve them.

Sterling also developed a commissioning manual and startup procedures, scoped the P&IDs with system boundaries and assembled system turnover packages. Sterling also trained the operations staff on the safe and correct way to operate the plant equipment. The Sterling Energy commissioning team consisted of a startup manager, discipline leads, startup engineers and startup technicians.

.

Commissioning Management of a Utility Peaking Plant
Sterling Energy provided commissioning oversight and management services for the installation of SDG&E’s new GE LM6000 simple cycle gas turbine generator, switchyard and water treatment plant. Sterling reviewed the P&IDs, wrote startup procedures, generated turnover packages and maintained the site punch list. Sterling also scheduled system walk downs for construction turnover and coordinated SDG&E’s witnessing of electrical testing in preparation for back feed. Sterling managed the startup schedule and coordinated, through daily startup meetings, the testing of all systems.

.

Commissioning and Startup of a 450 MW Coal Plant
Sterling Energy provided complete commissioning and startup services for a 450 MW pulverized coal-fired power plant in the West. Sterling’s responsibilities included commissioning manual and startup schedule development, subcontractor technical scope development, subcontract administration, OEM coordination and oversight, daily startup meetings and startup staff HR functions.

Sterling Energy’s startup engineers directly supervised the commissioning of all plant systems and equipment. Sterling’s operations specialists provided strategic guidance to the plant operations staff and coordinate system and unit startup activities with the startup department.

.

Consulting Services Related to Commissioning and Startup Activities
Sterling Energy provided, over a period of several years, ongoing consulting services to a global engineering and construction company. Sterling’s consulting services ranged from the development of startup budget and schedules to audits of the client’s field startup programs.

.

Startup Management of a 550 MW Combined Cycle Facility
Sterling Energy managed the startup on a 550 MW combined cycle facility on the East Coast. Sterling’s services included the direct supervision of the client’s startup staff engaged in commissioning all plant systems and equipment. On the owner’s behalf Sterling directly interfaced with the local utility on all startup-related activities.

.

Commissioning and Startup of 48 MW Cogen Plant in the Midwest
Sterling Energy provided commissioning and startup management services for a 48 MW combined cycle cogeneration plant that exported power to the local grid and provided steam to an adjacent industrial facility. The plant includes a GE Frame 6B gas turbine, an Alstom HRSG and a 10 MW steam turbine generator. The HRSG can also be operated on duct burners alone using GT isolation dampers and a forced draft fan. Sterling Energy directed owner’s personnel in the execution of all commissioning and startup activities.

.

Commissioning Management of an LM6000 Utility Peaking Plant
Sterling Energy provided commissioning oversight and management services for the installation of a new GE LM6000 simple cycle gas turbine generator, switchyard and water treatment plant. The plant is located in San Diego County and provides peaking power to SDG&E. Sterling reviewed the P&IDs, wrote startup procedures, generated turnover packages and maintained the site punch list. Sterling also scheduled system walk downs for construction turnover and coordinated witnessing of electrical testing in preparation for back feed. Sterling managed the startup schedule and coordinated, through daily startup meetings, the testing of all systems.

.

Recommissioning of Two LM6000 Peaking Units in California
Sterling Energy recommissioned two LM6000 simple cycle combustion turbine units outfitted with mechanical chillers. Sterling’s scope included electrical and control system checkout, re-flushing oil systems, development of system turnover packages, system walkdowns, and initial operations. Sterling operated the plant for the first six months of commercial operations. The plant provides peaking capacity under contract to SDG&E.

.

Commissioning Management of a 600 MW Ultra-Supercritical Coal Plant
Sterling Energy has been retained by Shaw Power Group to direct the commissioning effort and to augment the commissioning staff with five Lead System Engineers. The Sterling Energy team provides strategic guidance and direct supervision of the EPC contractor’s commissioning personnel, coordinates with the various project entities to facilitate project commissioning, startup, and operations activities, and keeps management continually apprised of commissioning progress and issues. Among other responsibilities, Sterling Energy will direct and oversee plant operations from first-fire through commercial operation.

 

Read more about our commissioning and startup services.

For more information please contact Tom Burns.

Comments are closed.