covid19 : deferred maintenance : operational plants
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16 March 2021 2
316 March 2021
Agenda
1. Introduction
2. Equipment characteristics
3. Maintenance
4. Loss example
5. Conclusion
Munich Re Facultative & Corporate (F&C) bundles the worldwide facultative and corporate business in one unit
16 March 2021 5
MR F&C
Corporate Insurance
Partner
Facultative Reinsurance
Units
• This gives us even more power to serve our cedants, corporate clients and brokers to sustainably expand and accelerate the insurance industry
• With the new set up, we are an even stronger partner for our cedants, corporate clients and brokers
16 March 2021 6
Munich Re merges its worldwide single risk units, creating Munich Re Facultative & Corporate (MR F&C)
>2.800Clients
>20Countries
> €2bnExpected premium
>550Experts
MR F&C is based on a strong international presence to be close to its cedants, corporate clients and brokers
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Bogotá
MunichLondon
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We serve our cedants, corporate clients and brokers from MORE THAN 20 LOCATIONS worldwide
Our organization is based on LINE OF BUSINESS TEAMS IN MUNICH and 3 REGIONAL RESPONSIBILITIES for the local offices
All offer products and solutions ACROSS ALL LINES
COMPETENCE CENTERS FOR CYBER AND ENERGY are located in Munich
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The fascinating world of EngineeringWho we are … and what we stand for
8
More than 100 Engineering experts with worldwide
experience
Working hand-in-hand with Contractors, Manufactures,
Governments, Business Owners, large
corporates to provide tailor-made insurance solutions
Strong playerwith significant net capacity
up to €300m
We are committed to
long-term relationship
Partner in sophisticated
Construction projects and all kind of
Operational Power plantsacross the globe
16 March 2021
Facultative Property / Engineering TeamMRoA
Daphne SitoleSenior Underwriter
Uwe KutscheraMR F&C APA / MR Singapore
Simon RobinsonManager Fac Underwriting
Irmgard BremSenior Underwriter
Munich
Philani MbathaSenior Underwriter
Teresa SardinhaUnderwriter
Linda WeleguelaUnderwriter
Falko SchwaetterSenior Underwriter
Munich
NNUnderwriter
Alice ShobaJunior Underwriter
Shannon-Lee Pires Junior Underwriter
Munich
Nyiku NkunaJunior Underwriter
Munich
Thomas KibetUnderwriter
Belhassen TonatHead of Non-Life MRoA
Nomxolisi SoloJunior Underwriter
Property Engineering
16 March 2021 9
Facultative Engineering TeamMRoA
10
Falko SchwaetterSenior Underwriter
+49 (89) 3891-3754 [email protected]
Philani MbathaSenior Underwriter
+27 11 242 [email protected]
Manager fac UnderwritingSimon Robinson
+27 72 397 [email protected]
Thomas KibetUnderwriter
+27 11 242 [email protected]
Nomxolisi SoloJunior
Underwriter+27 11 242 [email protected]
Nyiku NkunaJunior
Underwriter+49 (89) [email protected]
NNUnderwriter
16 March 2021
16 March 2021 12
Equipment600 MW Steam Turbine
HP : 30% (180MW)Pressure. inlet 160barTemp. inlet 535°C
IP : 50% (300MW)Pressure. inlet 37barTemp. inlet 535°C
LP : 20% (120MW)Pressure. in (37bar), exit (0,05bar)Temp. inlet (264°C), exit (45°C)
Source : Introduction to Steam Turbines, Abhimanyu Gupta, GE
1316 March 2021
Equipment600 MW Steam turbinePressure differential along the rotor shaftline Temperature differential along the rotor shaftline
Source : Introduction to Steam Turbines, Abhimanyu Gupta, GE
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Equipment600 MW Steam turbine
High centrifugal forces, high blade tip speed (510m/s) & wet steam flow (8 - 10% moisture)
LPT contributes 20% of MW output (could be increased)
Blade Length is 1,08 metre long
Source : Introduction to Steam Turbines, Abhimanyu Gupta, GE
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Equipment110 MW gas turbine (GE 9E.03)
17 stage compressor (atm to 17bar)Ambient temperature to 400°C
14 combustor cans firing at 1100 °C
3 stage turbineExhaust temperature (450°C)
Source : https://energyeducation.ca/encyclopedia/Gas_turbine
1616 March 2021
Equipment110 MW gas turbine (GE 9E.03)
Bellmouth direct air into the compressor inlet
64 variable (34°C - 84°C) inlet guide vanes controls amount of air into the compressor
Source : Gas turbine components and operation
16 March 2021
Equipment110 MW gas turbine (GE 9E.03)
17
Air is extracted from stage 5 & 11 of the compressor to cool the
Combustor casing
Turbine shaft (hollow)
Turbine casing
Nozzles (stator) & buckets : blades
Source : Gas turbine components and operation
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Equipment110 MW gas turbine (GE 9E.03)
Cross fire tubes
Spark plug
WLE (Water injection to reduce NOx)
Source : Gas turbine components and operation
1916 March 2021
Equipment110 MW gas turbineCooling & TBC
Thermal Barrier Coating (TBC) is applied on components exposed to excessive heat (combustor liner, 1st nozzles & buckets, turbine shaft)
Source : Gas turbine components and operation
Maintenance
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2216 March 2021
MaintenanceSA power : 49 000MW installed1. Deteriorating generation energy availability factor (EAF) to 33 000MW at 67%
2. Unplanned maintenance of 10 000MW exceeding 20%
3. Planned maintenance of 6 000MW at 13%
Why?
1. Low availability of the 9 600MW delivered by new built stations due to inherent plant defects
2. Retiring of old fleet approx. 8 000MW to 10 000MW
3. Deferred maintenance of the operating units (anticipation of the new built stations + funding challenges)
Source : https://www.eskom.co.za/IR2020/Pages/default.aspx
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Maintenance600 MW Steam turbineActivity Cycle time
(years)Duration (days)
Scope
Inspection (IN) 1 – 1,5 14 LPT rotor Last Stage Blade (LSB) inspection
Mini General Overhaul 3 49 Emergency Stop Valves (ESVs) & Control Valves (CVs)
Life assessments (Inlet pipes & valve chests) Barring gear
Mini General Overhaul 6 63 LP blades change out (ESVs) & (CVs) are replaced and refurbished Overhaul of boiler feed pumps All oil pumps refurbishment
General Overhaul 9 84 Overhaul of HP/IP/LP cylinder, blades, rotor removal, rotor truth checks & balancing, distortion
All turbine valves Life assessments of all parts Perform mechanical overspeed
Components theoretical life. Approx. 200K hrs. (rotor, casings)
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Maintenance110 MW gas turbine
Activity (inspection)
Equivalent Operating Hours (Equivalent Starts)
Duration (Typical)
Combustion 8,000/16,000 (400/800)
3 - 5
Hot Gas Path Inspection
24,000 (1,200) 14
Combustion 32,000/40,000 (1,600/2,000)
3/5
Major Inspection 48,000 (2,400) 35
Source : Heavy-Duty Gas Turbine Operating and Maintenance Considerations GER-3620M (02/15)
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Combustion InspectionGas turbine
Component Inspect for Action
Combustion liners (TBC), transition pieces, spark plugs, fuel nozzles, flow sleeves, flame detectors, cross-fire tubes
FOD abnormal wearcrackinghot spots/burning corrosion/erosion
Strip & recoatCreep repairFlow test
Borescope inspection of compressor & turbine 1st stage nozzle & bucket
Criteria Inspection methods
O&M manualGE Field EngineerTIL’s
VisualBorescopeLiquid penetrant
Source : Heavy-Duty Gas Turbine Operating and Maintenance Considerations GER-3620M (02/15)
3016 March 2021
The Power Plant
XYZ Paris Electric, FranceSite Location : Lumbumbashi, DRC 80 MW Co Generation Plant 2 x 185 t/h Boilers steam at 525 degrees C
Bagasse + Coal
2 X 40 MW Steam Turbines
55MVA GSU transformer
Sums Insured MD – USD 300 mio
BI – USD 80 mio, IP 24 months
3116 March 2021
Annual Planned Maintenance
Off Crop SeasonOn Crop Season
1 Jan 1 August 31 December
Coal Bagasse
Annual Planned MaintenanceMaximum/ Peak capacity
On Crop Season
Maximum/ Peak capacity
Deferred Maintenance
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OEM recommendation
Cracked turbine rotor New one ordered
9 months lead time Manufacturer in France France under lockdown Unknown lead time
Power is reduced by 50% Sugar Milling is affected Import grid power Limit power to other operations
Machinery Breakdown loss
3316 March 2021
Loss Details
o Loss of the turbine due to cracked rotor
o Deductible EUR 150,000 each and every claim.
o Estimate (net of deductible) : EUR 4 561 583.
o 24 months IP
o 40 days time excess
o 50% reduced operation
o However, import additional power from the grid
o Reduced Power demand
o Off crop + On crop seasons
o BI Total Value ?
o Shipping to – 1 month
o Lockdown – 2 months
o Manufacturing + Testing - 4 months
o Failed Load Test additional - 4 months
o Shipping from – 1 month
o Installation + testing - 2 month
o Interrupted period - 14 months
Machinery Breakdown Interruption Business Interruption
3516 March 2021
Conclusion
Deferred maintenance leads to unreliable equipment performance
manifesting itself in frequent breakdowns
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