OMAR SALIM Senior Engineer - Kipevu Bachelor of Engineering (Mechanical) with 24 years experience in thermal plant operations. Has a passion for energy efficiency measures- Energy Auditor Has started the Initiative on power Imports avoidance with the first project being done in 2008 between KDP1 & GT's at the steam plant Has Introduced many saving Initiatives during the G2G transformation journey to date. Current area of interests is renewable energy and power plant design. Ambition: introduction of Gas conversion and Combine cycle in the thermal plants i.e. two diesel power plants with a total capacity of 180 MW. Has presented a total of 11 papers in the G2G Innovation Seminar winning one in 2015.

KIPEVU TURBOCHARGER RETROFIT Presented by: JULIUS ODUMBE & OMAR .A. SALIM 2017 G2G TECHNICAL SEMINAR, ENASHIPAI RESORT 3RD JULY - 7TH JULY 2017

1 2 3 4 5 Introduction: Conceptual Idea Challenges/Current Situation Agenda Introduction: Conceptual Idea 1 Challenges/Current Situation 2 Opportunities/Proposed Solution 3 Cost Benefit Analysis 4 Recommended Next Steps 5

CONCEPT

Fitted with Turbochargers that increase Efficiency by 300 % INTRODUCTION Currently KenGen operates two thermal plants at Kipevu Kipevu I 75MW Kipevu III 120MW Fitted with Turbochargers that increase Efficiency by 300 %

INVESTMENT COSTS US $/MW Source : Business daily April 2016 , KenGen Finance projects, Wikipedia and Well head Paper

Cntd… High due to Forex Adj = 4.42 KES/kWh Source : Mar 17 KPLC Merit order & Billing system

Kipevu I 75MW Kipevu III 120MW Cntd… Kipevu I 75MW Kipevu III 120MW Savings Turbocharger retrofits reduce Fuel Costs. Lower Maintenance Costs Improve Engine output. OP2 The study recommends retrofitting Kipevu I Turbocharger to increase revenues With Success at Kipevu I, we do this at Kipevu III during 60,000 hrs. Service Time between overhaul (TBO) is increased. Over 161 M KES in Savings

Turbocharger Retrofit (TCA Retrofit on L58/64 MAN Engines) Definition: To modify equipment that is already in service using parts developed or made available after the time of original manufacture. . The NA turbochargers will be replaced with the latest design type of TCA Source : MAN Retrofit manual

Turbocharger Retrofit After High running hours, below problems typically occur High exhaust gas temperatures  Exhaust gas temperatures Extreme wear on all heat related parts Reduced output High SFC Tech. problems  Technical problems Over speed Vibrations Deformed Casing

ENGINE CHARGE AIR & EXH GAS .SYSTEM Output 7.5 MW Source: DCS Graphics on Exhaust system

Source : MAN Turbocharger retrofit Manual Retrofit Features Source : MAN Turbocharger retrofit Manual

CURRENT SITUATIONS High SFC Engine Output SFC= Fuel Cons./Production (Kg/kWh) Kipevu I SFC has increase by over 10 g Decreased Fuel incentives earnings. Emission levels on the Higher side Increased Maintenance costs High SFC Plant Output is affected due to load limits. Over the years unable to attain rated output of 12.5 MW. Affects our Monthly Availability and reduces earnings Engine Output Loss of Revenues from Capacity and Energy payments Source : Energy Billing and Kipevu I Efficiency reports

CURRENT SITUATION/CHALLENGES SFC Source : SAP FMS & KIPEVU I ANNUAL REPORTS

Source : SAP FMS & KIPEVU I ANNUAL REPORTS IDEAL OUTPUT 10.4 MW Capacity Payments Source : SAP FMS & KIPEVU I ANNUAL REPORTS

CAPACITY PAYMENT Capacity Payment Plant Availability Plant Output CC 60 MW= 72.9 M Max Ava= 100 % Current Output 52.8 MW= 64.4 M Max Ava= 88 % Plant Availability Actual payment 64.4 x(AMA/MTA) MTA = 85 % K Below 80 %

Loss of Revenue Due to Lower Output JOH-KGN001-20071212-JvW-X1 Loss of Revenue Due to Lower Output 55 MW =66.8 M Source : Energy billing system 2016/2017

Source : Energy billing system 2016/2017 At 55 MW Source : Energy billing system 2016/2017

Source : MAN Retrofit proposal with successful plants PROPOSED SOLUTION Max. Availability increase from 88 to 92 % We retrofit the turbochargers at Kipevu I This will lower the SFC and MAN assured an improvement of I g per kWh. Engine Output should reach the rated load but our Target is 11 MW. RETROFIT Old turbocharger spares are costly and only manufactured on request. Retrofit turbocharger easy to maintain and High TBO Spares Availability Annual Savings= 8.9 M Source : MAN Retrofit proposal with successful plants

METHODOLOGY Matching This is where the engine is thermodynamically matched to the retrofit turbocharger. This should be done by MAN Preparation Preparation of attachment kit by MAN Preparation of full scope of supply by MAN Removing the old turbocharger by MAN service Engineer assisted by Kipevu staff. Ins./Comm Installation of new turbocharger with attachment kit by MAN service Engineer assisted by Kipevu staff. Commission of new turbocharger Matching of new turbocharger that involves fine tuning of turbocharger and safety system checks by MAN engineer.

Source : MAN Retrofit case studies

Source : MAN Retrofit case studies

Investment Costs

COST BENEFIT ANALYSIS Projected Savings   Amount Saved Kg Average weighted price KES/KG Total Savings KES. 1 Annual Fuel savings 235,639 38 8,912,540.48 2 Capacity payment savings 197,374,496 (Loss of Revenue) 75% 148,030,872.26 3 Extra Energy Sales kWh 14,292,000.00 0.3 4,287,600.00 TOTAL 161,231,012.74 Pay back 1.2 yrs. Excluding reduction in MTCE costs Source : Energy billing system & FMS

Other Retrofit Benefits Component Service life (Retrofit) Service life (NA57) Plain Bearing 50,000 hrs. 25.000 - 40.000 hrs. Nozzle ring 40,000 hrs. 24.000 – 36.000 hrs. T/C Rotor 100,000 hrs 100.000 hrs Shroud ring 30,000 hrs 12.000 – 18.000 hrs. Compressor wheel 80,000 hrs Casing Unlimited The retrofit also comes with CBM system unlike the conventional T/C. e.g. the water washing system and monitoring equipment. Source : Kipevu Manual Vol 1 and MAN Data on retrofit T/C

CONCLUSION & RECOMMENDATIONS Reduction or avoidance of engine downtime Reduced costs. Improved overall engine performance Downtime More output more earnings = 161 Million Longer TBO Easier Maintenance Reduced O&M Costs Secure long term supply of spare parts Faster spare part procurement Cheaper spare parts Spare parts

Explore external Financing due to the short Payback period WAY FORWARD 1.Plant Audit by MAN. 2. Preparation. 3. Installation. 4. Commissioning 5. Fine tuning and monitoring. Installation 1. After approval plan in the next budget. 2. Procurement plan. 3. Procurement Approvals Budget 1. Introduce the concept. 2. Exco. Approval. 3. Explore possibility of partnering with the Manufacturer Approval Explore external Financing due to the short Payback period

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