Splash oil temperature monitoring: to eliminate crankpin failures JOH-KGN001-20071212-JvW-X1 Splash oil temperature monitoring: to eliminate crankpin failures Presented by: OMAR SALIM AMANI KONDE 18th to 22nd June 2018

OMAR SALIM Ag. Chief Engineer KDP1 Qualifications: BE (Mechanical) JOH-KGN001-20071212-JvW-X1 OMAR SALIM Ag. Chief Engineer KDP1 Qualifications: BE (Mechanical) C.E.M & C.W.E.P Responsibilities: In charge of Kipevu 1 plant Key milestones/achievements include: Initiated a number of Innovative ideas from the G2G Transformation journey and G2G Forum Participated in G2G Transformation journey and was Team Lead on Fuels Functional team lead in the ERP journey Member of the energy management team and carried a number of energy audits in KenGen installations. Committee member in KenGen C Team

Outline Introduction : Kipevu Plants, problem statement, Kipevu I Bearing & crankpin failures and its effect in Kipevu Availability and Loss of revenue. Challenges/Current Situation : Kipevu I Availability over the last five years, major causes of low availability, number of bearings and crankpin failures and RCA of bearing and crankpin failures. Opportunities from Splash oil system: The Splash oil system, expected benefits if the system was installed. Cost Benefit Analysis : The total cost of the splash oil system, Annual savings from Improved Availability. Conclusion & Way Forward :

Currently KENGEN operates two thermal plants at Kipevu INTRODUCTION Currently KENGEN operates two thermal plants at Kipevu Kipevu I 75MW Kipevu III 120MW SOURCE : Google photos

KDP1 Last 5yrs Capacity Revenue

DG 6 Crankpin No. 2 Failure & Causes

ANNEALING PROCESS

Repaired Crankpin & Diameter sizes Crankpin sizes (mm) Standard size 420   416 412  DG 5 Machined To this point 410 De-loading to 70% 405 Condemning limit 400

Expensive foreign expertise involved COST IMPLICATIONS Specialized tools use in the repairs Machine downtime: loss of revenue and penalties due to low plant availability Expensive foreign expertise involved

Specialized tools use in the repairs COST IMPLICATIONS Specialized tools use in the repairs Machine downtime: loss of revenue and penalties due to low plant availability Expensive foreign expertise involved

COST IMPLICATIONS Specialized tools use in the repairs Machine downtime: loss of revenue and penalties due to low plant availability Expensive foreign expertise involved

TOTAL COST KES 890M IN JUST 6 YEARS BACKGROUND DATA BEARING FAILURES: 2011 TO 2017 TOTAL COST KES 890M IN JUST 6 YEARS 60M PER YEAR (EXCLUDING DG 3)

CRANKSHAFT MAIN BEARING TECHNICAL BACKGROUND CRANKSHAFT MAIN BEARING BIG END BEARING

AS THE ENGINE ROTATES OIL SPLASHES OUT OF THE BIG END BEARING ENGINE ROTATES ABOUT 7 TIMES PER SECOND WHEN BEARING FAILS, THE TEMPERATURE OF THE BEARING INCREASES THE TEMPERATURE OF THE OIL SPLASHING OUT INCREASES AS THE ENGINE ROTATES OIL SPLASHES OUT OF THE BIG END BEARING

WEAKNESSES OF OIL MIST DETECTION

OIL SPLASH TEMPERATURE SYSTEM OIL SPLASHING RTD TEMPERATURE DETECTOR COLLECTION PAN ENGINE ROTATION

INVESTMENT COSTS TOTAL Unit Cost No of Total Euro. Engines. Costs   Unit Cost No of Total Euro. Engines. Costs Complete Splash system 57,440.00 5 34,464,000.00 TOTAL

BENEFITS AVAILABILITY REDUCED O/M COST MONITORING Improved availability increases revenue by around 62 Million annually AVAILABILITY Reduction of expensive maintenance works REDUCED O/M COST Improved monitoring parameters for better condition based maintenance MONITORING

CONCLUSION & WAY FORWARD Savings Reduce revenue penalties by around 62 Million annually Higher Availability increases maintenance allowances Process Approval granted. Tender and evaluation done PPO received, preparing purchase Order Planning & Installation Engine identification Start Installation during major overhaul Knowledge transfer and Install for the other engines internally.

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