1. 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.

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

3. 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

4. CONCEPT

5. 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 %

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

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

8. 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

9. 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

10. 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

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

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

13. 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

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

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

16. CAPACITY PAYMENT Capacity Payment Plant Availability Plant OutputCC
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 %

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

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

19. 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

20. 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.

21. Source : MAN Retrofit case studies

22. Source : MAN Retrofit case studies

23. Investment Costs

24. 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

25. Other Retrofit Benefits
Component
Service life (Retrofit)
Service life (NA57)
Plain Bearing
50,000 hrs.
hrs.
Nozzle ring
40,000 hrs.
– hrs.
T/C Rotor
100,000 hrs
hrs
Shroud ring
30,000 hrs
– 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

26. 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

27. 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

28. THANK YOU
THANK YOU