customized operation and maintenance for fossil … · 2009-08-17 · values such as temperature...
TRANSCRIPT
ID266
Customized Operation and Maintenance
For Fossil Power Plants
Holger Illbruck
Siemens AG, Power Generation
Germany
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1. Introduction
The primary objective of every power plant owner is to get constructed and to operate his
plant as cost-effectively as possible to maximize his profit. This means that he has to
minimize – besides the investment costs for construction - the life cycle costs, which are
influenced by different factors. One of them is the operation and maintenance cost incurrent in
course of operation period of the power plant.
The power plant utilities are further driven to reduce their life cycle costs by the deregulation
of the different power markets.
Cost reduction by outsourcing of O&M activities is one opportunity to meet such
requirements.
This presentation shall give an overview of the O&M Services shown on the example of the
Arrúbal project in Spain as well as the approach to customize services in compliance with
different clients and market requirements.
In general our service experiences are based on operation and maintenance of combined and
open cycle power plants being equipped with gas turbines and other OEM components. A
track record of the performances of the power plants under an O&M contract is shown
exemplary for the power plants Paka (800 MW) and Pasir Gudang (400 MW). Both plants are
located in Malaysia and are owned by the Malaysian construction company YTL Corporation.
The track record has been published by the operations company YTL Power Services, a joint
venture of Siemens AG (51%) and YTL Corporation (49%). After the know how transfer to
YTL Power Services was achieved the joint venture contract was terminated as planned in the
year December 2001. Since, that date YTL Power Services is a 100% subsidiary of YTL
Corporation.
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2. Range of Service Products
wide range of service products from the simple supply of spares to integrated asset
et developments, the focus is now, more and more on Long Term
stomized as to meet customers specific needs:
May 6-8, 2003 Power Generation 12Kodierung
OEM
Whole Plant
Full Scope O&MFull Scope O&M (Lump Sum)
Service Product Portfolio
Long Term Maintenace (LTM)
Turnkey Outages
OEM Parts & technical Field Assistance
Full Scope O&M (Pass Through Accounts)
O&M Managers + LTM
Full Scope Maintenance
Long Term Maintenance (LTM)
Turnkey Outages
OEM PartsOEM Parts
A
management is offered.
Due to the recent mark
Service products. The scope of such Long Term service products can vary according to
customer demands. To optimize customer’s benefit and to minimize customer’s risk in the
project several service products are available.
A service package of O&M products can be cu
comprehensive maintenance programs for Gas Turbine, Power Train or for the whole Plant
can be provided.
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3. Competence Network
It is of great importance to a power plant owner to be informed about the concept of how the
fleet experience of an OEM/O&M contractor is introduced and available to his power plant.
Since the experiences gathered by people is among others a significant source of know how,
thus we deem it as essential to use OEM managers as O&M managers at the power plants.
The use of OEM managers at the plants facilitates the exchange of information across the
plants as well as across
OEM works.
May 6-8, 2003 Power Generation 27Kodierung
O&M Competence Network
O&M Team Project A
Generator Works
Gas Turbine Works
Engineering O&M Team Project ...
O&M Team Project C
O&M Team Project B
Steam TurbineWorks
ServiceBackoffice Annual Plant
Manager Meeting
Due to the high availability demand and the life cycle cost reduction requirements of power
plants a permanent improvement of the O&M services is requested. To fulfill these
requirements a competence network has been established.
The Service Back Office located in Erlangen collects all O&M experience of the individual
Power Plants. Depending on the results of this ongoing evaluation, new improvements and
developments are being pursued.
The Service Back Offices evaluate and assess all the improvements and distribute this
information to the individual Power Plants. In addition to these procedures annual global
O&M manager meetings ensure direct exchange of experience.
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3.1 Power DiagnosticsTM
An essential part of the competence network is Power DiagnosticsTM which enables operators
to minimize the life cycle costs of power plants and at the same time maximize the output of
electrical energy. The drive to reduce life cycle costs results among other things in the
reduction of staff and labor costs. Whereas the desire to maximize electrical output requires to
raise the availability, reliability and efficiency of the plant. A solution for high availability,
reliability and efficiency with minimum staff is Power DiagnosticsTM.
The Power Plants covered under a long term service contract can be connected via telephone
line to the Power Diagnostic Centers in Erlangen or in Orlando. The Power Diagnostic Center
has access to the data monitored continuously at the power plant for all important operation
values such as temperature distribution at gas turbine outlet, vibrations, operation hours, gas
turbine start-up curves, performance curves etc. Experienced plant managers monitor the data
in the Power Diagnostics Center and analyze these values with the objective to:
• Determine the actual conditions of systems and installed components,
May 6-8, 2003 Power Generation 44Kodierung
Data Acquisition Plant 1
ST Specialist
Worldwide Network for Remote Service CommunicationWorldwide Network for Remote Service Communication
Data Acquisition Plant 3Data Acquisition Plant 2
GT-Specialist
Generator Specialist
Power Diagnostics™ Center Servers Central Data Base,Analysis Tools, Rule Based DiagnosticsData
Handling Hardware / Software
PlantTechnology
Data Acquisition via WIN_TS
Access
Power Diagnostics™ Services - Structure
Engineering and Process Specialist
• Evaluate the power plant performance.
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If needed the Power Diagnostics Center has direct access to specialised OEM know how, i.e.
consultancy through specialists for Gas turbine, Generator or Steam turbine. In case of
detected abnormal trends, events or trips, recommendations for predictive maintenance
actions are given. The Power Diagnostics Center is one of the important features for early
detection and prevention of damages.
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May 6-8, 2003 Power Generation 1Kodierung
Advantages of Remote Monitoring by OEM
Early detection of abnormal operationRemote diagnostics is more sensitive than equipment protection criteria/thresholds of I&C
Profound root cause analysis by applying the entire knowledge of the Original Equipment Manufacturer
Continuous Monitoringgives Customer more security for further operation.In several cases it was possible to run the faulty equipment under close observation until the next planned outage.
Timely Repair PlanningBy early fault detection and continuous remote monitoring it is possible to optimize the repair process as it can be planned ahead and spare parts can be shipped in advance.
May 6-8, 2003 Power Generation 50Kodierung
Benefits of Online Plant Thermodynamics
Identical thermodynamics code for plant design and online monitoring provides highest accuracy due to applied OEM knowledge
Online Thermodynamics detects as well decreases in performance of plant components (failures, degradation) as also drifting measurements (which can have an impact on operation due to I&C settings)
Advantages also for understaffed plantsRemote performance evaluations are offered by Siemens PG Power DiagnosticsTM
Organization as a service, carried out by highly trained specialists.
Learned limits from WIN_TS
Slope Change Occurs Over weekend
Temp Begins to Drop at 1 deg per hour
Learned limits from WIN_TS
Slope Change Occurs Over weekend
Temp Begins to Drop at 1 deg per hour
May 6-8, 2003 Power Generation 49Kodierung
Wk 1 Wk 2 Wk 3 W k 4 W k 5 Wk 8-40
-35
-30
-25
-20
-15
-10
-5
0
5
10
Wk 6 Wk 7 Wk 9
Channel 1 = gasSub channel 1 = 0-5 deg IGVTC #2 Upper Li mit = 5TC #2 Lower Limit = -11
W IN_TS Alarms
On going disc uss ions with LTP Manager a nd Cus tomer
~.5 deg / day
>1 deg / day
Wk 1 Wk 2 Wk 3 W k 4 W k 5 Wk 8-40
-35
-30
-25
-20
-15
-10
-5
0
5
10
Wk 6 Wk 7 Wk 9
Channel 1 = gasSub channel 1 = 0-5 deg IGVTC #2 Upper Li mit = 5TC #2 Lower Limit = -11
W IN_TS Alarms
On going disc uss ions with LTP Manager a nd Cus tomer
~.5 deg / day
>1 deg / day
Analysis of unit data utilizing diagnostic tools can identify problems before they become critical
inspect
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May 6-8, 2003 Power Generation 52Kodierung
GT Online Thermodynamics Module (Screenshot)
May 6-8, 2003 Power Generation 53Kodierung
Compressor Efficiency- ISO Corrected -
Offline Compressor Wash
GT Online Thermodynamics Trending Screenshot
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3.2 Reliability Centred Maintenance
A logic supplement to Power Diagnostics with its feature of predictive maintenance is the
introduction of a Reliability Centred Maintenance (RCM) method. The RCM Method allows
to reduce the number of maintenance tasks specified in the product manuals of the various
component suppliers. The component oriented maintenance schedule of the OEM suppliers
will be redefined by an expert team consisting of OEM experts, maintenance managers,
technicians and others. The expert team will define maintenance schedule with focus on the
functionality of systems in the context of the actual operating regime.
May 6-8, 2003 Power Generation 17Kodierung
RCM Method optimises the number of scheduled maintenance tasks
Comparsion of RCM Maintenance workload with time based workload for a Siemens V94.2 Gas Turbine
YTL Power Service Journal Nov-Dec 1997
539170110,238,5Total
Number of Maintenance Tasks according to Product Manual (Yearly)
750011931562,6Total
28,1%41,2%65,0%38,5%Percentage Reduction
54
1460
30
0
1121
367
14
40
0
2253
52
Operations
2
54
12
0
0
0
0
2
0
0
0
Electrical
24
2
0
4
2,5
12
6
10
4,7
44,5
0,5
MechanicalC&I
2Cooling System
0Generator / Transformer
0Static Frequency Converter
4Governor Control
9Lubricating Oil
2,5Diverter Damper
2Ignition
16Fuel Gas
0Blow Off System
1GT Mechanical
2Air Intake
Number of Maintenance Tasks Recommended by RCM (Yearly)
System
As published by YTL Power Services a significant reduction of maintenance tasks has been
achieved through introduction of RCM.
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4. Quality
A certified quality system, ISO 9001 or equivalent, is a measure of growing importance of
protection of owner’s assets especially on deregulated markets where beside electrical power
also power plants are a merchandise. The perception of potential buyers is expected to be
influenced positively if all processes related to operation and maintenance are integrated in a
certified quality system, which is audited by an independent third party.
As integral scope of an O&M agreement it is possible to develop and implement a quality
system including a third party certification.
May 6-8, 2003 Power Generation 28Kodierung
First Class Power Operationby ISO 9001:
• Comparison with global competitors• Transparent processes give common
goals and motivation to the staff• Living these processes means maximumcontrol of the technical and financial aspects of plant operation
• Maximum Plant Availability• Maximum Plant Profitability• Positive Public Perception• Maximum Staff Motivation
Quality means “First Class Plant Operation”.The Prerequisite: ISO 9001 Certification
The benefit of a quality system can be maximized through combination with a computerized
plant management system.
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4.1 Computerized Plant Management System
The increasing competition in power markets is making cost-optimized power plant
management indispensable. A significant cost factor is labor cost for plant staff. It is
considered that 20% till 40% of the working hours are spent for finding, compiling and
archiving information, e.g.
• Recording and maintenance of plant documentation,
• Provision of information on present plant’s conditions,
• Monitoring of defects, failures and their follow up,
• Prepare, issue and expedite orders for spare parts, material and services,
• Cost control for spare parts, material and services
• Process Permit to Work system,
• Control and follow up of deenergizing processes of related systems,
• Scheduling and Follow Up of plant outages
• Management of spare parts inventory.
The preferred solution is an intelligent, plant-wide IT support in the form of a plant
management system – in particular for maintenance work, modifications, documentation and
spare parts management. The experiences of our O&M projects show that the workload for
information management can be limited to about 10% of the daily working hours, with the
help of our IT solution for computerized plant management, BFS++TM System.
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May 6-8, 2003 Power Generation 62Kodierung
Tie your Team together
Management Shift MaintenanceEngineers/Technicians
Workshop
Storehouse Doc. Archive . . . MonitoringConsumables
BFS++Administration
The functions offered by BFS++-System are in line with standard power plant practice (i.e.
extensive adaptation is not necessary), and special needs can be readily integrated as required.
The system is delivered in a reconfigured form with power-plant specific catalogues which
consider the fleet experiences also derived from utilizing the fleet data storage collected
through applied BFS++ systems. All this ensures fast, smooth integration and high
acceptance.
BFS++ utilizes the hardware and software environment already in place in the power plant
and also features field-proven interfaces to other systems such as DCS and I&C, Spares
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May 6-8, 2003 Power Generation 31Kodierung
Track Record
3
31
8
3
46
28
2321
17 15,5
0
10
20
30
40
50
Day
s
OriginialStandard
Plan
Paka GT11Jun 1998
Paka GT12Aug 1998
Paka GT22Nov 1998
Paka GT21Feb 1998
Pasir GT11Aug 1999
Pasir GT12Jan 2000
Hot Gas Path Inspection at 33,000 running hoursYTL Power Service Journal
Jan-Feb 200045
Commissioning
Finding
Standard
Preperation
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Ordering System and electronic documentation. This minimizes client’s initial investments
and, ensures consistent, efficient processes. It offers it’s users a 3 in 1 solution covering
operation, maintenance and administration processes from fault detection, through permit to
work establishment up to spares cost control and inventory management.
A parameter to measure the stability of processes at a power plant is the downtime for major
overhauls. The recorded downtime published by YTL Power Services for six consecutive hot
gas path inspections over a period of 18 month shows a steady trend of continuous outage
shortening.
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5. O&M Contracts
Our substantial experience in the field of power plants including our commissioning
experience is more than 500.000 MW installed capacity world wide. Our experience as
operator is represented through more than 33 contracts with more than 12.000 MW. Beside
this experience our Service organization has more than 90 Long Term Maintenance contracts
with more than 35.000 MW. Through all this several worldwide experience our service
organization has put in place a knowledge network sharing all relevant technical information
through a home based back office.
6. O&M at Work
As part of our global experience record of projects we awarded 3 major projects in the last 2
years. These 3 projects are just an example out of the record.
6.1 Arrúbal:
Arrúbal is Siemens first major O&M’s award in Europe. Signature of this contract was
completed in a fast track negotiation and will cover the full scope O&M for the whole plant
for a period of approximately 12 years. In the following the project will be presented in more
detail.
May 6-8, 2003 Power Generation 68Kodierung
O&M at Work: Arrúbal, Spain
Plant::Arrúbal, Spain
Owners:Gas Natural
Location:North of Spain
Frame: 2x1S. 94.3A Combined Cycle
Rating: 800 MW
Contract Order:2002
Contract Structure:Full Scope O&MMobilization & Operation Fee (fix&var);
Contract Duration: 12 Years
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6.2 Tahaddart:
he moroccan Tahaddart customer (Energy Electrique de Tahaddart) EET is a shareholder
May 6-8, 2003 Power Generation 67Kodierung
O&M at Work: Tahaddart, Morocco
Plant::Tahaddart, Morocco
Owners:ONE / ENDESA / Siemens SPV
Location:Near Tanger, Morocco
Frame: 1S. 94.3A Combined Cycle
Rating: 384 MW
Contract Order:LOI 12/2001, order 12/2002
Contract Structure:Full Scope O&MInitial Spares, Mobilization & Operation Fee (fix&var);
Contract Duration: 20 Years
T
company founded by ONE (Office National d’Electricite), ENDESA and Siemens as
investors. Siemens O&M will operate the full plant and maintain all equipment delivered
under the EPC contract. Tahaddart is a typical O&M project where all O&M activities are
included for 20 years from commercial operation date in a firm level payment structure.
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6.3 Kuo Kuang:
his 450 MW, 2 on 1 Combined Cycle Power Plant is an EPC Contract with Kuo Kuang
May 6-8, 2003 Power Generation 66Kodierung
O&M at Work: Kuo Kuang, Taiwan
Plant::Kuo Kuang, Taiwan
Owners:Kuo Kuang Power Co. Ltd.
Location:near Taipeh, Taiwan
Frame:2 x 1 V84.3A Combined Cycle, under Construction
Rating: 460 MW
Contract Order:2001
Contract Structure:Fix Mobilization- Operation Fee; Pass-through Accounts
Contract Duration: 14 Years
T
Power Co.Ltd., a single purpose company. For his newly ordered Power Plant, the customer
required an O&M contract in a new structure which considered that local supplies and
services are partly directly handled by the owner, others are purchased and specified by O&M
contractor in a guaranteed budget.. The project is based on a customized contract structure
tailored to owners needs. 14 years O&M including planned, unplanned and routine
maintenance and operation of the plant.
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7. Customer and Operator Synergies
The sum is more than just the addition ! The know how of the Customer together with the
O&M contractor’s experience ensure maximum long term asset protection.
An excellent example for synergies can be seen in the O&M procedures. What are the
synergy contributions in this specific case?
The contribution of the customer is the know how in regard to regional power production
requirements, and the long term experience in the local market as well as from the power
plant ownership.
On the other hand, worldwide long term O&M experience is brought in by us.
These synergy contributions from both parties allow fastest possible elaboration of the O&M
procedures and fastest possible installation of the ensuing engineering and administration
processes.
7.1 Arrúbal Milestones of the Project
The Arrúbal O&M project schedule starting from submission of the proposal up to signing the
contract was based on targeted negotiations in a very short time.
Handing over of the O&M proposal to Gas Natural: November 2001
Negotiation and Clarification Summer & Autumn 2002
Signature of the O&M Contract November 2002
Start Pre-Mobilization Phase November 2002
Start Mobilization Phase August 2003
Start Operation and Maintenance Phase October 2004
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7.2 Arrúbal Brief Description of the Scope
he Arrúbal O&M project is divided into 3 distinguished phases.
n will be reviewed for it’s
n of the plant - Start of assess
rovisional acceptance of the plant, the O&M period starts and all
May 6-8, 2003 Power Generation 69Kodierung
ArrúbalBrief Description Scope
Pre Mobilization Phase (approx. 24 Months prior to COD)• Review of EPC design• Specification of High Availability Spare Part Package• Order of Strategic Spares
Mobilization Phase (14 Months prior to COD)
Operation Phase (after COD)
• Hiring of Expats and local Personnel• Training of local Personnel• Assistance during Commissioning• Setup of Computerized Maintenance
Management System• Preparation of O&M Policies and Procedures
• Daily Routine Maintenance• Planned Maintenance• Unplanned Maintenance• Day to Day Plant Operations• Material Schedule and Inventory Control
T
The first one is initial pre-mobilization phase in which EPC desig
maintainability. Within this period of time our implementation team puts also into place a
spare parts purchasing specification and specifies the high availability spare parts package.
This period starts at the beginning of the EPC implementation.
In the second phase - 12 months before the commercial operatio
and hire of local staff and training according to its specific needs. During that time the O&M
staff will be also involved in the commissioning of the plant and set up all necessary
administration and IT tools.
In the third phase, after the p
routine, planned, unplanned and day to day operation will be handled by operator.
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8. Benefits
Within the frame of O&M contracts, operator takes over significant share of customer’s risks.
For example one typical warranty in O&M contracts taken by operator is an availability
warranty.
An increased availability leads to increased revenues for the customer.
Siemens has a proven record of increased availability beyond the typical industrial averages
published in 2001 by EURELECTRIC, an independent non OEM organization. For
Combined Cycle or Cogen Plants the median of :
• 267 unit years resulted in a unit capability of 85.7% (unit capability is equivalent to
plant energy availability),
• 1966 unit years resulted in an accident rate per year and unit of 10.26 accidents.
May 6-8, 2003 Power Generation 36Kodierung
Track Record
93,65 93,71 94,04 95,4391,66
93,5390,84
94,7797,95
94,43 94,2596,21
93,2996,84
92,5896,10
0
20
40
60
80
100
perc
ent
Oct 95-Sep 96
Oct 96 -Sep 97
Oct 97 -Sep 98
Oct 98 -Sep 99
Oct 99 -Sep 00
Oct 00 -Sep 01
Oct 01 -Sep 02
Oct 02 -M ar 03
PakaPasir Gudang
Industry Average Availability 86%
Highest Availability due to tailor-made Maintenance and Operation Contract
Paka and Pasir Gudang
** ** **
** 2 GT Major Overhauls
* 1 GT Major Overhaul
**
*
Statement from YTL Oct 2002, PowerGen Singapore
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May 6-8, 2003 Power Generation 40Kodierung
Track Record
1
2
0 0
3
2
1 1
0
1
0
1
2
3
0
2
4
6
8
10
Acc
iden
ts
1 996 1997 1998 1999 2000 2001 2001
Year
P akaP asir Gudang
Minimum Number of Accidents due Health and Safety Competency
Statement from YTL Oct 2002, PowerGen Singapore
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9. Summary
May 6-8, 2003 Power Generation 43Kodierung
Conclusion
Quality ManagementIT-Tools
OEM Expert Know How via Power Diagnostics
Proven Standard Procedures for:
-Operation –Maintenance -Administration
Dedicated Back OfficePlant Managers with OEM Background
500.000 MW as OEM 12.000 MW as O&M
50.000 MW as LTM
• Comprehensive operation and maintenance services are provided for entire power plants
down to individual components.
• Services are based on worldwide operational experiences combined with detailed/country
specific knowledge of power generating and distribution market.
• O&M services are supported by dedicated service back offices and Power Diagnostics
Center. This center not only enhances the plant’s monitoring effectiveness but also
provides fast experience information on generic problems, gained worldwide.
• Own maintenance management system called BFS++, provides comprehensive, cost
saving services, contributing to plant’s availability and reliability increment.
• Presently trusted by clients worldwide to operate more than 12,000 MW and Long Term
Programs for more than 35,000 MW.
• The recent three O&M contracts placed in Europe, Asia and Africa are proof of our
competitiveness in this particular area,
• O&M services include also risks sharing with customers.
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