SOO_Attachment_2.docx

Appendix 1 New Remote Fixed Facilities Failures to Date

The New Remote Fixed Facility (RFF) Power Plants were turned over to the USCG for operational use in September 2014, since that time the USCG has experienced the following failures and issues at the respective sites.

Middle Cape

· SOFC failures on both the #1 and #2 units; likely cause: igniter issues and/or bad stack bundle in each unit.

· This is the site’s primary source of power generation, which charges the battery bank.

· When the SOFCs fail, the PPG should turn on as backup power generation for the battery banks, however the PPG was left in “Manual” operating mode and did not start automatically.

· The PPG’s 12V starting battery is dead making a PPG start impossible; if replaced the PPG should start.

· Due to the lack of a regenerative power generation device, the battery bank was completely drained by the site’s electronics radio load.

· The site has an LVD to protect the batteries for a situation as described above; however this LVD was left open, draining each of the 2.0V batteries down to an average of 0.27V. Additionally, the batteries were subject to the winter in a non-temperature controlled hut, furthering potential battery damage.

· The battery manufacturer indicates that batteries subjected to these conditions are likely damaged beyond repair and will need to be replaced.

Issues Recap:

Duffield

· SOFC failures on both the #1 and #2 units; likely cause: igniter issues and/or bad stack bundle in each unit.

· This is the site’s primary source of power generation, which charges the battery bank.

· The start batteries for the SOFCs have been found dead and drained; swapping batteries with fresh one has enable for start of #1 SOFC; #2 SOFC will not start due to bad bundle.

· However, continued issues within the SOFC, likely related to the igniter (and potentially the bundle) have forced the #1 unit to trip offline or fail to start.

· This has lead to the continued and prolonged running of the PPG; this generator needs regular maintenance and an oil change based on the Hobbs meter engine run time.

· Another issue identified is a short to ground for the SOFC 50A breakers. These breakers trip offline periodically, which adds additional stress to the SOFCs (if running) as the machines are not powered on to run through the critical cool-down period (pre-mature bundle failure due to improper thermal cycles).

· This short to ground issue is sporadic and has not received thorough troubleshooting for a cause. It is likely associated with the DC distribution panel and/or a cable shorting to the site’s grounding system.

· The site might also have an issue with the propane system. A regulator immediately after the outdoor propane tanks reduces the amount of propane fed into the generator hut. This is then regulated down again by a regulator inside the generator hut. It is theorized that the elevation of the site and the pressure settings of these regulators are causing the propane to liquidize in the propane lines, thus starving the power generation equipment. However, this problem is difficult to detect due to an inability to access the site in the winter months.

Issues Recap:

Deception Hills

· SOFC failures on both the #1 and #2 units; likely cause: igniter issues and/or bad stack bundle in each unit.

· This is the site’s primary source of power generation, which charges the battery bank.

· The start batteries for the SOFCs have been found dead and drained; swapping batteries with fresh one has enable for start of #1 SOFC; #2 SOFC will not start due to bad bundle.

· However, continued issues within the SOFC, likely related to the igniter (and potentially the bundle) have forced the #2 unit to trip offline or fail to start.

· This has lead to the continued and prolonged running of the PPG; this generator needs regular maintenance and an oil change based on the Hobbs meter engine run time.

Issues Recap and Number of Instance Observed:

1. SOFC Failures (both units) (6) failures combined on both units