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Outage Optimization of  Steam Turbine and Auxiliaries Objective Present in CEPSI2008 at The Venetian Macao Resort-Hotel   by Parichart Suttiprasit Steam Turbine Maintenance Engineer, Electricity Generating Authority of Thailand   (EGAT)
Topics A. Performance B. Condition Monitoring C. Risk Assessment D. Auxiliaries Optimization E. Conclusion
Performance ,[object Object],[object Object]
[object Object],Heat Rate (kJ/kWh) 10300 - 10250 - 10200 - 1996 1999 2001 2003  2006  10216.37 10285.72 Operation Time (year) 2008   2010 Current 1995 Assumption: Heat rate has been constantly increased since 1995. Source: EGAT production efficiency division, 2006 Performance
If this Steam Turbine is operated in this  condition  until the year of 2010 , approximately  2.45 million US$ will be lost  by heat rate increasing. Performance ,[object Object]
[object Object],“ Replacement Energy Concept”  1 Coal 2 Natural Gas 3 Oil Performance
[object Object],1 Coal 2 Natural Gas 3 Oil Performance “ Replacement Energy Concept”
[object Object],1 Coal 2 Natural Gas 3 Oil Performance “ Replacement Energy Concept”
[object Object],1 Coal 2 Natural Gas 3 Oil Performance “ Replacement Energy Concept”
[object Object],1 Coal 2 Natural Gas 3 Oil SB-C10 MO (Standard)= 45 days MO –    = 37 days Performance “ Replacement Energy Concept”
[object Object],1 Coal 2 Natural Gas 3 Oil SB-C10 MO (Standard)= 45 days MO –    = 37 days BPK-T3; operated instead of  SB-C10 for  8 days  ,  3.44 million US$  lost  Performance “ Replacement Energy Concept”
Performance ,[object Object],[object Object],[object Object],[object Object],So, the benefits is approximately  1 million US$
Condition Monitoring ,[object Object],[object Object],[object Object],[object Object]
 Vibration Bearing no.1 Bearing no.2 Condition Monitoring 1Y 2X 2Y 1X
Condition Monitoring Shaft Vibration (  m  p-p ) Operation Time (year)  Vibration 1996 1999  2001 2003  2006 1 X
[object Object],[object Object],[object Object],[object Object],Condition Monitoring
[object Object],Condition Monitoring Temp( o C)  Bearing no. 1 2 3 4 Trip 121  o C Alarm 107  o C 99.0  o C 80.1
[object Object],by ThermaCAM PA695 at Bearing no.1 Insulation Condition Monitoring
Risk Assessment Failure Mode Likelihood 1 Very unlikely has not happened to equipment or similar equipment 2 Unlikely >2 times in 5-10 years to equipment or similar equipment 3 Likely >3 times in last 5 years 6 Likely >2 times in last year 10 Very likely many times to this equipment
Risk Assessment Failure Effect Weight Unit Shut down 10 Unit Through put Loss 8 Minor Through put Loss 4 Start up Delay 4 Personnel Hazard 10 Personnel Hazard – Low Probability of Injury 5 Environment Regulations Event – Major Incident 10 Environment Regulations Event – Incident 7 Environment Regulations Event – Near Miss 3
Risk Assessment Failure Mode Likelihood x Failure Effect  =  Risk 1  x  10  =  10 % Moderate Probability
Auxiliaries Optimization ,[object Object],[object Object],[object Object],[object Object],[object Object]
Auxiliaries Optimization ,[object Object],When “ Increased Power Consumption = Overhaul Cost”, it is the  Optimum Time to Overhaul, T. T  =  2 x Overhaul Cost Deterioration Cost Rate/month Source:  H.P. Bloch, and A.R. Budris,  Pump User’s Handbook: Life extension , 2004
Auxiliaries Optimization ,[object Object],[object Object],[object Object],[object Object],[object Object]
[object Object],Auxiliaries Optimization
Auxiliaries Optimization ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Auxiliaries Optimization ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Auxiliaries Optimization Time Based Maintenance (TBM) vs. Condition Based Maintenance (CBM) Benefits of 0.08 million US$ per outage
Conclusion ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Conclusion (cont.) ,[object Object],[object Object],[object Object],[object Object],[object Object]
Question & Answer “ Thank you for your attention”

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Optimizing Steam Turbine and Auxiliaries Outages Through Condition Monitoring

  • 1. Outage Optimization of Steam Turbine and Auxiliaries Objective Present in CEPSI2008 at The Venetian Macao Resort-Hotel by Parichart Suttiprasit Steam Turbine Maintenance Engineer, Electricity Generating Authority of Thailand (EGAT)
  • 2. Topics A. Performance B. Condition Monitoring C. Risk Assessment D. Auxiliaries Optimization E. Conclusion
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  • 14.  Vibration Bearing no.1 Bearing no.2 Condition Monitoring 1Y 2X 2Y 1X
  • 15. Condition Monitoring Shaft Vibration (  m p-p ) Operation Time (year)  Vibration 1996 1999 2001 2003 2006 1 X
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  • 19. Risk Assessment Failure Mode Likelihood 1 Very unlikely has not happened to equipment or similar equipment 2 Unlikely >2 times in 5-10 years to equipment or similar equipment 3 Likely >3 times in last 5 years 6 Likely >2 times in last year 10 Very likely many times to this equipment
  • 20. Risk Assessment Failure Effect Weight Unit Shut down 10 Unit Through put Loss 8 Minor Through put Loss 4 Start up Delay 4 Personnel Hazard 10 Personnel Hazard – Low Probability of Injury 5 Environment Regulations Event – Major Incident 10 Environment Regulations Event – Incident 7 Environment Regulations Event – Near Miss 3
  • 21. Risk Assessment Failure Mode Likelihood x Failure Effect = Risk 1 x 10 = 10 % Moderate Probability
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  • 28. Auxiliaries Optimization Time Based Maintenance (TBM) vs. Condition Based Maintenance (CBM) Benefits of 0.08 million US$ per outage
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  • 31. Question & Answer “ Thank you for your attention”