1. MOHAMED ELMI Electrical Technician - Geothermal
MSc in Energy Technology, Bsc Energy, Dip Elec & Electronics Engineering
Registered with the institute of engineers, NEMA as an Associate expert, ERC, Association of Energy Professional.
Has knowledge of energy finance, Natural resource protection strategies, electricity tariffs, subsidy and fiscal policy
Designed rain detector device for rural agricultural

2. GEOFFREY NGETICH Mechanical Technician - Geothermal
MA Project Planning and Management, B.Tech, Dip. Mechanical Engineering
Participated and directly involved in restoration of various power projects at Baker Hughes, Marriott drilling group (UK), Weatherford (Canada) among others

3. Mohamed Elmi & Geofry Ngetich/ Cornelius Korir
USING FAILURE MODE EFFECT AND ANALYSIS TO DETERMINE CRITICAL SPARE PARTS HOLDINGS AT KENGEN
Mohamed Elmi & Geofry Ngetich/ Cornelius Korir
2017 G2G TECHNICAL SEMINAR, ENASHIPAI RESORT
3RD JULY - 7TH JULY 2017

4. Presentation Outline INTRODUCTION JUSTIFICATION CONCEPT DEVELOPMENT
JOH-KGN JvW-X1
Presentation Outline
INTRODUCTION
JUSTIFICATION
CONCEPT DEVELOPMENT
RESULT & FINANCIAL MODELLING
CONCLUSION 1 2 3 4 5

5. INTRODUCTION
What is FMEA
It is a structured qualitative analysis of system, subsystem, component or function that highlights potential failure modes, their cause and their effects of failure on system operation.
proactive tool, technique and quality method that enables the identification and prevention of process or product errors before they occur.
It firstly used by NASA in early 1960s. In 1967, civil aviation started using it.
The use of FMEA in industries began from mid 1970s.

6. Meaning of FMEA
Failure Mode: The way in which a specific process input fails If it is not detected and either corrected or removed, it may cause a negative “Effect” to occur. Effect: Consequence of a failure mode on the operation, function or status of the item A product or process that does not perform satisfactorily to design Cause: Whatever causes the Failure Mode to occur. How a specific part of the process (operation or component) can cause a Failure Mode

7. Component of equipment down time
Failure
Equipment downtime
Active repair time
Logistic time
Administrative time
Equipment Restored
MTTR ?
Staff meetings
Reports
High TDC

8. In KenGen Logistic time is a constant problem especially drilling and logistic division.
It is estimated that above 70 percent of all equipment taken to the workshop (Central workshop, olkaria) require spares of which are not immediately available, leading to long equipment downtime even up to more than six months.
The study intends to use Failure Mode, Effect and Criticality Analysis as a risk-based strategy to address catastrophic failures or unplanned events that have significant impact on safety, environment and or business profitability.

9. Procedure for FMEA Define functions of the system/Process
Describe effects of failure modes (severity ratings)
Determine causes of failure modes (occurrence ratings)
Calculate risk priority numbers (RPNs)
Corrective plan of action

10. Reference to N370 Slush pump No.2.
In obtaining the best method possible to come up with a solutions that can enhance sustainability, reduce cost in the company and improve logistics time within the organization, failure mode effect and critical analysis was used.

11. Process
System
Mud Pump
Subsystem
Transmission system
Components
Seals, Bearing, Torque convertor, gears •Sleeve •Oil Pump •Shaft •Bolt and Nut, Chain

12. Lost Time Determination
In obtaining the lost time during critical breakdown, lost time was calculated using the following equation.
Tdt = 7 hrs
Tdi = 12 hrs
Tf = 6 hrs
Cost of failure Determination
The failure cost mainly includes three components: labor cost Cl , material cost Cm and opportunity cost Co . The meanings of labor cost and material cost are explicit by their names. The opportunity cost is the cost that incurs when a failure inhibits the main function of the system and prevents any value creation.
Labour Cost (Cl) = (Tdt ×Tdi ×TF) ×R1×N (Where Rl means labor rate, and N represents the number of operators that are assigned to fix problems)
The material cost (Cm) = Cp ×Np

13. Critical Component being Steel chain:
Cm =200000/Ksh
Loss incurred by KenGen when the material is not in the store
Total time lost (TT) =25hrs
Total cost (CT) = Ksh
Total Cost of failure (CF) =TT ×CT
CF = Ksh
Loss when the material is available in the store
TT = 10 hrs assuming (Tdt = 4 hrs, Tdi = 2 hrs, TF = 4 hrs)
CT = (three technicians)
CF = Ksh

14. Loss when the material is not available in the store
Labour cost (Cl) for 3 technicians)
Material Cost (Cm)
Total time lost (TT)
Total cost (CT)
Total Cost of failure (CF) =TT ×CT
18000
200000
25hrs
218000

15. Loss when the material is available in the store
Labour cost (Cl) for 3 technicians)
Material Cost (Cm)
Total time lost (TT)
Total cost (CT)
Total Cost of failure (CF) =TT ×CT
18000
200000 10
218000
Kengen savings when FMEA is used= (Loss when the material is not available in the store) – (Loss when the material is available in the store) =

16. Cost of implementation
ITEM DESCRIPTION
COST (Ksh.)
Training
600,000
Travelling and Accommodations cost
350,000
Stationaries
10,0000
Miscellecious cost
100,000
Total
1,060,000

17. Challenges of implementation
Lack of experts in fmea
Difficulties in defining failure modes, causes and effects
Implementation also requires a commitment of the team and support from and across all the functions.

18. Conclusion
Using the failure mode effect and critical analysis, the company will save Ksh.This savings can therefore be budgeted elsewhere within the company. This is adequate to cater training programs for twenty technicians