1. Ibraim Voroga Iliga Mechanical Superintendent, Mechanical workshop,
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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).

2. 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

3. + COMMERCIALIZATION Internal Bearing Remetalling capacity
Additional company revenue

4. 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

5. 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.

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

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

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

9. 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

10. Bearing Remetalling used to be carried out in KENGEN at the Kipevu Power Station Mechanical Workshop From (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;

11. Olkaria 1 bearings
Olkaria 2 bearing pads
Kiambere pads

12. Turkwel thrust ring pads Wellhead bearings Gogo bearings
Gas turbine bearings

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

14. 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

15. 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.

16. 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

17. HOW MUCH SAVING?
Lets do a comparison

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

19. 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
15% = ksh.23,250.00
Taxes @ 16% = ksh.26,737.50
Total quotation = 204, Ksh
KenGen paid ksh.453, for the size of Bearing (LPO no )

20. COMMERCIALIZATION PROCESS COST
STAFF TRAINING COSTS
WORKSHOP SETUP COSTS

21. 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, 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 tuition fee per student.
Cost is 2,000,000 Ksh ,400,000 Ksh = Million Ksh

22. WHITE METAL WORKSHOP LAYOUT

23. 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.

24. 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.

25. Thank You