1. THE KENGEN journey to world class innovation
Presented by: Peter Chege , Asst. Projects Execution Manager (Wellheads)
2017 G2G INNOVATION SEMINAR, ENASHIPAI RESORT
3RD JULY - 7TH JULY 2017

2. Presentation Outline INTRODUCTION 5.5MW PILOT PLANT IMPLEMENTATION
75.6MW WELLHEADS IMPLEMENTATION
CHALLENGES & SOLUTIONS
LESSON LEARNT & WAY FORWARD 1 2 3 4 5

3. INTRODUCTION
The wellhead early generation was conceived in1990’s due to delay in financing the power plants when enough steam had already been drilled.
In 2001, KenGen engaged Sinclair Knight Merz(SKM) to carry out the study and make implementation recommendations. Various options were analyzed for economic viability.
The results indicated the best return on investment was a unit cost of 9.4 USc / kWHr, which was very high, hence no implementation carried out.

4. INTRODUCTION
Lack of financing of conventional power plants prolonged draughts, affecting hydro generation resulting to national power rationing.
This impacted heavily on the company’s bottom line and therefore the need to revisit the early wellhead generation option.
To achieve this, in 2009, a team was constituted to explore implementation of a 5MW plant as research and development project.

5. 5.5MW PILOT PLANT IMPLEMENTATION
Through competitive bidding process, KenGen contracted Green Energy Group (GEG) in December 2009 to design, install and commission a 2X2.75MW KAPS units at well OW37as research and development project under regulatory division.
The Contract Price USD 8.25 million.
Successful test run achieved on 15th April 2012
Successful 18 months pilot run completed on 18th November 2013

6. 5.5MW PILOT PLANT IMPLEMENTATION
Wellhead 3D Impression
1 Well
2. Separator
3. Turbine
4. Condenser
5. Cooling tower
6. Electrical Control Unit
7. Silencer
8. Generator
Source: GEG website

7. 5.5MW PILOT PLANT IMPLEMENTATION
CHALLENGES
First Turbine failed before synchronization speed due to high vibrations.
Change of turbine-generator manufacturer
New design introduced, from KAPS unit to S25 model
Bad publicity of the project, Quotes like ”The mother of all scandals”, “massive rip-off”, “Engineers took off during testing” by media.
Unreliable power evacuation line. 33kV distribution Narok line, resulting to one or two trips daily.

8. 75.6MW MAIN PROJECT IMPLEMENTATION
On 30th May 2010, KenGen signed a Contract with GEG for design, supply, installation and commissioning of 65MW Wellhead generators at Olkaria consisting of S50 Modular units of 12 plants of 5MW each and 2 plants of 2.5 MW each, based each well data, totaling 65 MW.
The Contract price was USD 93,145, The Contract was to become effective on successful pilot plant implementation.

9. 75.6MW MAIN PROJECT IMPLEMENTATION
Due to the problems encountered during the implementation of the pilot, the Contract was amended on 19th September 2012 and the S25 and S50 modular plants of 2.5MW and 2.5 MW plants respectively were replaced with standard modular plant of C32, C50 and C64.
The 2X2.75MW S25 units (Pilot Plant) combined into 1X5.5MW, C50 unit
The Contract was packaged in three packages as follows;

10. 75.6MW MAIN PROJECT IMPLEMENTATION
Package I : 4 X 6.4 MW C64 Plants located as follows; 2 Plants OW43 and 2 Plants at OW914
Package II: 5 X 5 MW C50 Plants located as follows; 3 Plants at OW914, 2 plants at OW915
Package III: 5 X 5 MW C50 Plants located as follows; 1 Plant at OW919, 1 Plant at OW905, 2 Plants at OW37 and last 1 Plant at OW39.
The total installed output increased from 65MW to 75.6MW which has already been installed.

11. 75.6MW MAIN PROJECT IMPLEMENTATION
Other Contracts
Civil Works – Signed in June 2013, GEG
Sub-station Supply – Signed June 2013, GEG
Amendment No. 1 and No.2 to supply 11/220kV and 11/132kV substations associated switchgear
4KM 220kV Transmission line OW914 to Olkaria IV substation, KEC International, India
1.9KM 132kV Transmission line OW37 to Olkaria I, Telco- MacNaught JV
1.98KM 33kV Evacuation Line OW43 to Olkaria II Gate, KPLC
16KM 11kV Evacuation Lines, KPLC

12. WELLHEADS IMPLEMENTATION SCHEDULE
Source: GDD Report

13. Fact File about the Projects
The Project Duration: 2009 – 2017: 71/2 years
Projects Cost : 130million USD.
Number of Plants Installed: 15 Plants
Total Installed Capacity: 81.1MW
Number of well utilized : 14 Wells
Annual Average Generation: 400GWHrs at assumed load factor of 60%
Annual Revenue: Kshs 3.52 Billion .

14. Wellheads Location Map

15. OW43 WELLPAD

16. OW914 WELLPAD

17. CHALLENGES AND SOLUTIONS
The mobility of the plants was improved by containerizing most of the systems, using pre-cast foundations and all wiring above the ground.
Limited 33kV Evacuation system was replaced by construction of 132kV line from OW37 11/132kV substation to Olkaria I 132kV substation and 220kV line from OW914 11/220kV substation to Olkaria IV 220kV substation, 4 more contracts.
Due to long lead time for Transformers manufacturing, refurbished 220kV TX from Kiambere is being utilized at OW914 substation.
Wells in the same well pad are connected to mitigate the steam decline .

18. LESSON LEARNT
All Projects being implemented should have either a desktop or full feasibility study.
Teamwork is key to success , with each member playing their roles effectively.
Use of available power evacuation lines with little enhancement improved the wellheads revenue during the construction of step-up substations.
KenGen has internal capacity to implement power projects e,g. Technical Services, Transformers Installation and Testing, Projects Execution, Implementation supervision etc
If failure occurs in the first attempt, try again and again until success is achieved. .

19. WAY FORWARD
KenGen Geothermal knowledge should be utilized to realise more innovative projects, more revenue
The wellhead implementation strategy be fast tracked.
Improvement of the current plants systems should be undertaken, e.g. efficiency of Non- Condensable Gases (NCG) extraction, Central Control and Monitoring system.
KenGen to provide consultancy / project implementation to other utilities. .

20. Finally, the 75.6MW Wellheads Project was commissioned on Friday 28th April 2017