Customized Operation and Maintenance For Fossil ... - · PDF fileCustomized Operation and...

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.


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,


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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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.


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


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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GT Online Thermodynamics Module (Screenshot)


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.


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.


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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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

ess\------ACTIVECONFERENCES-------\pennwell\europe2003\working\fromthem\ID266_Illbruck.doc/2003-04-09


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

page 12 of 21 C:\workinprogr

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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.


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


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);


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


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


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


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.


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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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


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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