Ibraim Voroga Iliga Mechanical Superintendent, Mechanical workshop, Click to add Photo Ibraim Voroga Iliga Mechanical Superintendent, Mechanical workshop, Kipevu Power Station I joined Kenya power and lighting in 02nd April 1984, as a workshop Foreman 11 and rose through the ranks to Workshop Superintendent 1 I trained as a Mechanical Technician production option, where I ventured more on metallurgy, which I practice in white metalling and other work shop jobs(machinist, fabrication and maintenance).

COMMERCIALISATION OF WHITE METALLING BEARING PROCESS IN KENGEN Presented by: Ibrahim Iligha 2018 G2G INNOVATION SEMINAR, PRIDE INN SPA & RESORT 18TH JUNE - 22ND JUNE 2018

+ COMMERCIALIZATION Internal Bearing Remetalling capacity Additional company revenue

WHAT IS A BEARING A Bearing is a mechanical part that supports a rotating shaft either horizontal or vertical Plain bearings for horizontal shafts Thrust Bearing for vertical/horizontal shafts

WHAT IS WHITE METALLING Is the processes of receiving worn bearing shells, removing old white metal lining ,do tinning and refill new white metal and machine to size of journal given. The processes give new life time to a bearing as new.

WHITE METALLING METHODS Capillary method Centrifugal method Brazing by torch method Laser torch method(being developed)

KENGEN MACHINES THAT USE BEARINGS STEAM TURBINES Olkaria 1 Olkaria 1AU Olkaria 2 Olkaria 4 Olkaria wellheads

KENGEN MACHINES THAT USE BEARINGS Horizontal Hydro Turbine Wanjii Mesco Sagana Gogo Vertical Hydro turbines Kiambere Gitaru Kindaruma Kamburu Masinga

Bearing Remetalling restores it to ‘AS NEW’ CONDITION The white metal bearing wears either as a failure or with time in use and has to be replaced. Worn bearing Bearing Remetalling restores it to ‘AS NEW’ CONDITION Remetalled Bearing

Bearing Remetalling used to be carried out in KENGEN at the Kipevu Power Station Mechanical Workshop From 1986-2016.(30 Years) Personnel were trained and equipments bought to serve steam plant turbines as was delays in remetalling of bearing for the station from out sourced workshops. The steam plant was de-commissioned,. The equipment were still in use for other KenGen stations as shown below;

Olkaria 1 bearings Olkaria 2 bearing pads Kiambere pads

Turkwel thrust ring pads Wellhead bearings Gogo bearings Gas turbine bearings

KENGEN BEARING REMETALLING EQUIPMENT Ultra sonic crack testing(analog Tinning Bath Melting Oven Heating oven Bond meter mark 3 Melting pot

The equipment is however no longer being used and white metalling of bearings is being done in external workshops. The only hindrance to KenGen carrying out in-house remetalling is lack of enough skilled personnel

Due to staff retirements and natural attrition there is only one member of staff skilled enough to carry out the work to an acceptable standard Olkaria 1 turbine 3 bearing.

Cost Saving Extra Revenue We intend to train enough staff on remetalling to acceptable standards in order to Do remetalling for external customers on a commercial Basis Carry out white metalling for KenGen units Cost Saving Extra Revenue

HOW MUCH SAVING? Lets do a comparison

BEARING REMETALLING ORDERS TO STEELSTONE LTD. IN 2018 JOH-KGN001-20071212-JvW-X1 BEARING REMETALLING ORDERS TO STEELSTONE LTD. IN 2018 PO WORK AMOUNT ksh. DATE STATION 4500047978 Bearing remetalling 42,600 19.03.2018 Tana 4500047827 Rotating Ring remetalling 450,000 13.03.2018 Sondu Stationery Ring remetalling 357,670 Shaft Sleeve remetalling 253,450 4500047429 Thrust Pads remetalling 42600 16.02.2018 Wanjii Surge Pads remetalling 19500 Journal Remetalling 337,686 16.01.2018 4500046779 Journal bearing Remetalling 453,840 12.01.2018 Total 1,957,346

COST COMPARISON ON ONE BEARING BEARING SIZE bore 200mm x height 160mm by 15mm thickness of white metal lining Cost of other materials = ksh.12,000.00 White metal = ksh.120,000.00 Jig Fabrication = ksh. 3,000.00 Labour and Machining = ksh.20,000.00 Profit @ 15% = ksh.23,250.00 Taxes @ 16% = ksh.26,737.50 Total quotation = 204,737.50 Ksh KenGen paid ksh.453,840.00 for the size of Bearing (LPO no. 4500046779)

COMMERCIALIZATION PROCESS COST STAFF TRAINING COSTS WORKSHOP SETUP COSTS

STAFF TRAINING COSTS   Internal training The ideal staffs for training are ten to achieve commercialization of the processes. The training takes minimum of ten days as per syllabus and approximately 200,000.00.Ksh per person. Materials are available at stores Olkaria 1.   External Training Osborne engineering ltd, Dubai, Britain and Germany have good practical training facilities.    External trainings can be carried out after getting the internal training and been exposed to the procedures. The external training may take about 10 days for at least 4 staffs that will show more understanding on the processes. The cost is a minimum of USD 2000.00 tuition fee per student. Cost is 2,000,000 Ksh + 2,400,000 Ksh = 4.4 Million Ksh

WHITE METAL WORKSHOP LAYOUT

INTENDED EXTERNAL CUSTOMERS Cement factories Sugar factories Quarries(pitman bearings) Private power generators Kenya pipeline company Costing for External firms remetalling R/Mill Neck Bearings Rematalling for Bamburi Cement Factory carried out by Marine Engineering Works. Cost KSH 1,624,000 Ready market we can source for.

RECOMMENDATION AND CONCLUSION Commercialization of the whitemetalling processes is a viable project that need to be implemented. The Workshop can be set up at the proposed central workshop at Tana Power Station to reduce transportation and other costs- will serve Eastern, Upper Tana and Nairobi area. The Olkaria set up with serve western and Olkaria areas.

Thank You