Islip Resource Recovery Agency, MacArthur Resource Recovery Facility

Posted on July 29, 2010

Client: Islip Resource Recovery Agency
Location: Ronkonkoma, New York
Project Type: MacArthur Resource Recovery Facility

Project Description

irra-facilty_webThe MacArthur Resource Recovery Facility (“MRRF”) is a 486 ton per day (“tpd”), mass burn facility that utilizes O’Connor Rotary Combustor technology. The MRRF began operations in 1990. Montenay Islip, Inc. (“MII”) operates the MRRF.

The Islip Resource Recovery Agency (“IRRA”) entered into an agreement in 1985 with the Pennsylvania Energy Resource Company Ltd. (“PERC”) for the design, construction, and operation and maintenance by PERC of a RRF for the processing of a minimum of 146,000 tons of municipal solid waste (“MSW”) per year, the recovery of materials, and the generation of steam and electricity.

In order to finance the costs of the Facility, on December 23, 1985, the Agency issued its $38,685,000 Resource Recovery System Reserve Bond.

The IRRA terminated the agreement with PERC after a finding of default on the part of PERC by the Independent Construction Engineer.

Montenay Islip, Inc. (“MII”) was selected to complete the construction and perform the operations portion of the Service Agreement.

Project Responsibilities 

Attend Monthly Operations Meetings With the IRRA and MII, and Prepare Meeting Notes.

D&B Engineers and Architects, P.C. (“D&B”) attends monthly meetings with the IRRA and MII.

D&B’s ongoing work associated with the monthly meetings is as follows:

  1. Research and prepare information related to meeting agenda items and as follow up to meeting discussions.
  2. Maintain an ongoing punch list of facility maintenance and operating concerns based on walk through inspections prior to or following each operations meeting. Review the punch list at each meeting.
  3. Prepare the agenda one (1) week prior to the meeting and meeting notes one (1) week following the meeting.

Permit Compliance.

D&B monitors the status of the MRRF permits and reports to the IRRA any non-compliance or other problems associated with permits and licenses, including tracking of timely submission reports and renewal deadlines.

As needed, D&B prepares a written summary of newly proposed or adopted regulations and significant permit-related activities for submission to the IRRA on a timely basis. This includes a discussion of any potential impact on the MRRF operations, including potential Service Agreement implications.

D&B reports on the compliance with air, water, dust, noise, and odor permit conditions and standards. Any exceedances of permit conditions or standards that come to our attention will be immediately reported to the IRRA irregardless of the timing or deadlines for formal reports.

Emissions Compliance Test Program, RATA, GCA, LOI, and Ash Test.

D&B attends, observes, and reports on the results of the Annual Air Emissions Sampling and analyses (stack testing) and the RATA. This includes review of testing protocol, observation of the emissions sampling program, and review of the test report prepared by MII. D&B also reviews and comments on Quarterly Excess Emissions Reports, CGAs and related LOI test, and Semi-Annual Ash Test, as well as all other reports filed through regulatory agencies.

D&B’s work with regard to both air emissions (stack test, RATA, and GCA), ash sampling (LOI and ash test), and analyses includes the following:

  1. Review sampling program and laboratory analysis protocols to be utilized at the MRRF, prepare comments thereon, and report comments to the IRRA.
  2. Obtain notification from MII regarding the scheduling of sampling. Observe the Air Emissions Compliance Test Program and RATA.
  3. Obtain and review the daily sampling program log sheets prepared by MII.
  4. Review and comment on the sampling and analysis program results and reports to be prepared by MII, including the final laboratory report.
  5. Attend meetings with MII and the IRRA, as necessary, to coordinate and discuss the sampling and analysis program.

Detailed Inspection of the Rotary Combustor Seals.

The Rotary Combustor Seals are unique to the O’Connor Rotary Combustor. Other stoker-fired mass burn systems, such as Martin, Von Roll, and VKW do not employ the rotary kiln feature used in the O’Connor system. During the development of RRFs utilizing the O’Connor systems in the 1980s, there was concern within the waste-to-energy industry regarding the performance of the Seals. This concern proved to be well founded, as problems with the Seals, including Seal steam and water leaks have arisen at each of the Rotary Combustor RRFs. The Rotary Combustor Seal separates high-pressure steam and water in the rotary joint between the Rotary Combustor and after-grate sections. The separation of high-pressure fluids in a rotary joint presents unique design and maintenance issues. Montenay required several years of operational experience with the Rotary Combustor systems before adequate preventive and corrective maintenance programs were put in place to ensure the integrity and reliability of the Seals. The Service Agreement between the IRRA and Montenay was amended to clarify MII’s obligation to perform regular inspections and maintenance of the Seals.

D&B performs the semi-annual detailed inspection of the Rotary Combustor Seals and report on their condition. These inspections shall occur during scheduled outages. We shall also conduct inspections necessary for the Annual Inspection and Inspection Report, as described in the next Task.

Annual Inspection of the MacArthur Resource Recovery Facility and Inspection Report.

D&B prepares the draft Inspection Report for review by the IRRA, revision and submission to the New York State Department of Environmental Conservation (“NYSDEC”) sixty (60) days following the end of the calendar year, in accordance with the Part 360-3.4(f)(3) requirements.

D&B develops the Annual Inspection Report using the information gathered by D&B, along with other relevant information provided by MII and/or the IRRA, including review of maintenance logs and maintenance records, analysis of plant performance data, visual inspections of the Facility, monthly reports submitted by MII, review of control room and shift supervisor logs, stack emission reports, and waste inspection logs. The Report measures the MRRF performance during the year against Service Agreement requirements and against past Facility performance in order to identify performance trends. The remainder of the presentation for this task describes the content of the Annual Inspection Report and D&B’s typical approach to gathering the key RRF performance and maintenance information necessary for the Report.

D&B conducts comprehensive visual inspections of all external and accessible internal (during outages) areas of the MRRF. We will also report to the IRRA on a comparison of the information provided by MII to information provided to other MII client agencies and information provided by other RRF operations companies (Wheelabrator, Covanta). This report may be used by the IRRA to adjust the information obtained in order to improve the thoroughness of performance reports from MII.

Outage Observations and Reports.

D&B coordinates with MII’s scheduled boiler outages and turbine-generator outages in order to conduct physical inspections of the internals of each of the two (2) combustion, boiler, ash handling and APC systems, turbine, condensers, cooling tower, and other key systems during off-line periods. D&B obtains and reviews the outage plans. D&B prepares an Outage Observation Report to the IRRA.

On-site Inspections.

D&B conducts an on-site inspection. During the visit, our staff conducts a top-to-bottom and front-to-back walkthrough of the MRRF.

Review the Causes of Failures Associated With Mechanical, Electrical and Electronic Equipment, Hardware, and Software.

Upon receiving an assignment from the IRRA to conduct a failure analysis, D&B reviews the MRRF operating data for the purpose of revealing key trends in performance. The specific information to be analyzed will be determined by the nature of the failure. Upon the identification of the negative trends, D&B undertakes a review of the data in order to prepare a root cause analysis. The root cause analysis involves reviewing subsystems data in order to trace the cause of a problem back to its origin.

Review and Evaluate the Need for and Costs of CEMS and Other Systems or Equipment Upgrade Requests from Montenay Islip, Inc.

D&B assists the IRRA with the review and evaluation of CEMS and other systems upgrades that may be proposed by MII. Our staff reviews conceptual proposals or detailed construction and installation plans and specifications for regulatory compliance, completeness, accuracy, and cost/benefit to the IRRA. During the construction and installation phases of mechanical changes and retrofit projects, D&B provides construction related services which may include review and approval of shop drawings, field construction monitoring and reporting, project schedule monitoring, percent completion certification, and recommendations regarding scheduled drawdown payments. During all project phases, D&B works to assure that the IRRA’s interests are protected by reviewing in detail all project elements to assure that the desired intent of the project is being met, the project will integrate well within the existing Facility and operations, and the project will be capital and operating cost effective. In order to accomplish this, D&B works closely with the IRRA and MII operating personnel to obtain input from various perspectives regarding desirable and undesirable aspects of a project’s design during the project planning stages.

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