COVID19 : Deferred Maintenance : Operational Plants
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Philani Mbatha & Nyiku Nkuna 16 March 2021 COVID19 : Deferred Maintenance : Operational Plants
Transcript of COVID19 : Deferred Maintenance : Operational Plants
Philani Mbatha & Nyiku Nkuna
16 March 2021
COVID19 : Deferred Maintenance : Operational Plants
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316 March 2021
Agenda
1. Introduction
2. Equipment characteristics
3. Maintenance
4. Loss example
5. Conclusion
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IntroductionSection Subtitle 1
Munich Re Facultative & Corporate (F&C) bundles the worldwide facultative and corporate business in one unit
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MR F&C
Corporate Insurance
Partner
Facultative Reinsurance
Units
• This gives us even more power to serve our cedants, corporate clients and brokers to sustainably expand and accelerate the insurance industry
• With the new set up, we are an even stronger partner for our cedants, corporate clients and brokers
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Munich Re merges its worldwide single risk units, creating Munich Re Facultative & Corporate (MR F&C)
>2.800Clients
>20Countries
> €2bnExpected premium
>550Experts
MR F&C is based on a strong international presence to be close to its cedants, corporate clients and brokers
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Bogotá
MunichLondon
North America
Latin America and Iberia
Munich
Asia Pacific,Middle East, Africa
We serve our cedants, corporate clients and brokers from MORE THAN 20 LOCATIONS worldwide
Our organization is based on LINE OF BUSINESS TEAMS IN MUNICH and 3 REGIONAL RESPONSIBILITIES for the local offices
All offer products and solutions ACROSS ALL LINES
COMPETENCE CENTERS FOR CYBER AND ENERGY are located in Munich
Chicago
San Francisco
Mexico City
Sao Paulo
MilanMadridParis
Mumbai
Johannesburg
Singapore
Toronto
DubaiTokyoSeoul
Beijing
Sydney
PrincetonNew York
Hong Kong
The fascinating world of EngineeringWho we are … and what we stand for
8
More than 100 Engineering experts with worldwide
experience
Working hand-in-hand with Contractors, Manufactures,
Governments, Business Owners, large
corporates to provide tailor-made insurance solutions
Strong playerwith significant net capacity
up to €300m
We are committed to
long-term relationship
Partner in sophisticated
Construction projects and all kind of
Operational Power plantsacross the globe
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Facultative Property / Engineering TeamMRoA
Daphne SitoleSenior Underwriter
Uwe KutscheraMR F&C APA / MR Singapore
Simon RobinsonManager Fac Underwriting
Irmgard BremSenior Underwriter
Munich
Philani MbathaSenior Underwriter
Teresa SardinhaUnderwriter
Linda WeleguelaUnderwriter
Falko SchwaetterSenior Underwriter
Munich
NNUnderwriter
Alice ShobaJunior Underwriter
Shannon-Lee Pires Junior Underwriter
Munich
Nyiku NkunaJunior Underwriter
Munich
Thomas KibetUnderwriter
Belhassen TonatHead of Non-Life MRoA
Nomxolisi SoloJunior Underwriter
Property Engineering
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Facultative Engineering TeamMRoA
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Falko SchwaetterSenior Underwriter
+49 (89) 3891-3754 [email protected]
Philani MbathaSenior Underwriter
+27 11 242 [email protected]
Manager fac UnderwritingSimon Robinson
+27 72 397 [email protected]
Thomas KibetUnderwriter
+27 11 242 [email protected]
Nomxolisi SoloJunior
Underwriter+27 11 242 [email protected]
Nyiku NkunaJunior
Underwriter+49 (89) [email protected]
NNUnderwriter
16 March 2021
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EquipmentSection Subtitle 2
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Equipment600 MW Steam Turbine
HP : 30% (180MW)Pressure. inlet 160barTemp. inlet 535°C
IP : 50% (300MW)Pressure. inlet 37barTemp. inlet 535°C
LP : 20% (120MW)Pressure. in (37bar), exit (0,05bar)Temp. inlet (264°C), exit (45°C)
Source : Introduction to Steam Turbines, Abhimanyu Gupta, GE
Presenter
Presentation Notes
GE 600MW steam turbine Steam turbine converts thermal energy (steam) to mechanical energy, generator converts mechanical energy to electricity Weight 4,500KG Space : 1.5 X 2.5 X 2m Steam admission via ESV (cuts out steam in case of emergency) & CV (control steam admission for turbine operation) Though it’s a massive machine, it has very tight clearances of 0.5 to 1,5mm Why 3 casings? Ability to manufacture (length) & transport
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Equipment600 MW Steam turbinePressure differential along the rotor shaftline Temperature differential along the rotor shaftline
Source : Introduction to Steam Turbines, Abhimanyu Gupta, GE
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Equipment600 MW Steam turbine
High centrifugal forces, high blade tip speed (510m/s) & wet steam flow (8 - 10% moisture)
LPT contributes 20% of MW output (could be increased)
Blade Length is 1,08 metre long
Source : Introduction to Steam Turbines, Abhimanyu Gupta, GE
Presenter
Presentation Notes
Blade length reduces the aerodynamic qualities
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Equipment110 MW gas turbine (GE 9E.03)
17 stage compressor (atm to 17bar)Ambient temperature to 400°C
14 combustor cans firing at 1100 °C
3 stage turbineExhaust temperature (450°C)
Source : https://energyeducation.ca/encyclopedia/Gas_turbine
Presenter
Presentation Notes
GE 9E 110MW steam turbine Compression ratio (13:1) Space : 1.5 X 2.5 X 2m Steam admission via ESV (cuts out steam in case of emergency) & CV (control steam admission for turbine operation) Though it’s a massive machine, it has very tight clearances of 0.5 to 1,5mm Why 3 casings? Ability to manufacture it Length
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Equipment110 MW gas turbine (GE 9E.03)
Bellmouth direct air into the compressor inlet
64 variable (34°C - 84°C) inlet guide vanes controls amount of air into the compressor
Source : Gas turbine components and operation
Presenter
Presentation Notes
The inlet casing : houses the bellmouth & IGV Forward casing : Compressor
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Equipment110 MW gas turbine (GE 9E.03)
17
Air is extracted from stage 5 & 11 of the compressor to cool the
Combustor casing
Turbine shaft (hollow)
Turbine casing
Nozzles (stator) & buckets : blades
Source : Gas turbine components and operation
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Equipment110 MW gas turbine (GE 9E.03)
Cross fire tubes
Spark plug
WLE (Water injection to reduce NOx)
Source : Gas turbine components and operation
Presenter
Presentation Notes
DLN (DLE) – dry low emission WLE – Wet Low Emission, when combustion takes place at lower temperature, NOx emissions are reduced WLE – results to deposits in the turbine section i.e. erosion, fouling, etc..
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Equipment110 MW gas turbineCooling & TBC
Thermal Barrier Coating (TBC) is applied on components exposed to excessive heat (combustor liner, 1st nozzles & buckets, turbine shaft)
Source : Gas turbine components and operation
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MaintenanceSection Subtitle 3
Maintenance
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Presenter
Presentation Notes
OEM’s gas turbine: General Electric (US) bought Alstom in 2015 at $13bn. GE power is $18bn at 2% margin, while renewables are $15bn at (4,3%) loss, GE is very big on the aircraft engines ($32bn) so COVID19 hurts. Alstom had huge coal & gas business but it has subsequently declined due to renewable energies and de-carbonization Siemens (Germany) $18bn gas & power at 3,8% margin, $10bn renewables at 5% margin, industries & smart infrastructure ($31bn) at >10% margin
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MaintenanceSA power : 49 000MW installed1. Deteriorating generation energy availability factor (EAF) to 33 000MW at 67%
2. Unplanned maintenance of 10 000MW exceeding 20%
3. Planned maintenance of 6 000MW at 13%
Why?
1. Low availability of the 9 600MW delivered by new built stations due to inherent plant defects
2. Retiring of old fleet approx. 8 000MW to 10 000MW
3. Deferred maintenance of the operating units (anticipation of the new built stations + funding challenges)
Source : https://www.eskom.co.za/IR2020/Pages/default.aspx
Presenter
Presentation Notes
Industry : 52% Iron & steel – 18% Chemical & petroleum – 14% Residential : 8%
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Maintenance600 MW Steam turbineActivity Cycle time
(years)Duration (days)
Scope
Inspection (IN) 1 – 1,5 14 LPT rotor Last Stage Blade (LSB) inspection
Mini General Overhaul 3 49 Emergency Stop Valves (ESVs) & Control Valves (CVs)
Life assessments (Inlet pipes & valve chests) Barring gear
Mini General Overhaul 6 63 LP blades change out (ESVs) & (CVs) are replaced and refurbished Overhaul of boiler feed pumps All oil pumps refurbishment
General Overhaul 9 84 Overhaul of HP/IP/LP cylinder, blades, rotor removal, rotor truth checks & balancing, distortion
All turbine valves Life assessments of all parts Perform mechanical overspeed
Components theoretical life. Approx. 200K hrs. (rotor, casings)
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Maintenance110 MW gas turbine
Activity (inspection)
Equivalent Operating Hours (Equivalent Starts)
Duration (Typical)
Combustion 8,000/16,000 (400/800)
3 - 5
Hot Gas Path Inspection
24,000 (1,200) 14
Combustion 32,000/40,000 (1,600/2,000)
3/5
Major Inspection 48,000 (2,400) 35
Source : Heavy-Duty Gas Turbine Operating and Maintenance Considerations GER-3620M (02/15)
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Combustion InspectionGas turbine
Component Inspect for Action
Combustion liners (TBC), transition pieces, spark plugs, fuel nozzles, flow sleeves, flame detectors, cross-fire tubes
FOD abnormal wearcrackinghot spots/burning corrosion/erosion
Strip & recoatCreep repairFlow test
Borescope inspection of compressor & turbine 1st stage nozzle & bucket
Criteria Inspection methods
O&M manualGE Field EngineerTIL’s
VisualBorescopeLiquid penetrant
Source : Heavy-Duty Gas Turbine Operating and Maintenance Considerations GER-3620M (02/15)
Presenter
Presentation Notes
The combustion liners, transition pieces, and fuel nozzle assemblies should be removed and replaced with new or repaired components to minimize downtime. The removed liners, transition pieces, and fuel nozzles can then be cleaned and repaired after the unit is returned to operation
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Hot Gas Path InspectionGas turbine
Component Inspect for Action
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Major InspectionGas turbine
Component Inspect for Action
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Loss exampleSection Subtitle 4
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Industrial Park
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The Power Plant
XYZ Paris Electric, FranceSite Location : Lumbumbashi, DRC 80 MW Co Generation Plant 2 x 185 t/h Boilers steam at 525 degrees C
Bagasse + Coal
2 X 40 MW Steam Turbines
55MVA GSU transformer
Sums Insured MD – USD 300 mio
BI – USD 80 mio, IP 24 months
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Annual Planned Maintenance
Off Crop SeasonOn Crop Season
1 Jan 1 August 31 December
Coal Bagasse
Annual Planned MaintenanceMaximum/ Peak capacity
On Crop Season
Maximum/ Peak capacity
Deferred Maintenance
Presenter
Presentation Notes
Less Power Demand by : Sugar Milling Plant Bioethanol Plant Sugar Refinery
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OEM recommendation
Cracked turbine rotor New one ordered
9 months lead time Manufacturer in France France under lockdown Unknown lead time
Power is reduced by 50% Sugar Milling is affected Import grid power Limit power to other operations
Machinery Breakdown loss
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Loss Details
o Loss of the turbine due to cracked rotor
o Deductible EUR 150,000 each and every claim.
o Estimate (net of deductible) : EUR 4 561 583.
o 24 months IP
o 40 days time excess
o 50% reduced operation
o However, import additional power from the grid
o Reduced Power demand
o Off crop + On crop seasons
o BI Total Value ?
o Shipping to – 1 month
o Lockdown – 2 months
o Manufacturing + Testing - 4 months
o Failed Load Test additional - 4 months
o Shipping from – 1 month
o Installation + testing - 2 month
o Interrupted period - 14 months
Machinery Breakdown Interruption Business Interruption
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ConclusionSection Subtitle 5
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Conclusion
Deferred maintenance leads to unreliable equipment performance
manifesting itself in frequent breakdowns
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