The Importance of Scheduled Maintenance Planning in Ensuring the Efficiency of Power Plants

In our previous article, we spoke about lifecycle costs to consider when choosing a power generation system, like temporary power plants. We said that the costs include fuel, maintenance, and labor, among others. In line with our previous discussions, in this article, we’ll take a closer look at the importance of scheduled maintenance planning in ensuring the efficiency of a power plant.

Scheduled maintenance planning is a vital part of a preventive strategy that allows engineers and power plant operators to effectively plan for repairs, maintenance costs, and system downtime. A proper maintenance program should identify maximum run hours for each component in the power plant system, and also consider maintenance intervals, required spare parts, manpower, routine analysis and inspection details.

Now, let us throw the spotlight on maintenance intervals.

Maintenance intervals are the time periods between system inspection or overhauls and should be scheduled in parallel with the component run hour lifetime and operating requirements. As some engine and auxiliary parts, like fuel injection nozzles, piston rings, and bearings, are designed to be wear components, they should be regularly checked and replaced. The schedule can vary from power plant to power plant, especially if a condition-based maintenance program is utilized. Bear in mind that under condition-based maintenance program, wear components are only replaced if wear limits are exceeded or if the components exceed other replacement criteria previously set. Thus, when following a condition-based maintenance program, the lifetime of components is adjusted in consideration of operating parameters and data harvested from regular inspections.

As part of a predictive maintenance program, engineers and power plant operators should assess the component wear as observed during regular scheduled inspections. They should also record operating data on a regular basis and trend data points to provide a clear picture of any necessary adjustments in order to maximize power plant efficiency and help foresee any possible failures. If this is successfully done, this can help power plant operators mitigate the risk of unscheduled outages.

One can never overstate the importance of electricity in our world today. In almost everything that we do, we require electricity, so a constant and reliable supply of power is non-negotiable. It is, therefore, paramount for a power services provider to have an effective and well-planned preventive maintenance strategy to preclude the occurrence of unplanned power outages and ensure the efficient and cost-effective operation of a power plant.

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Reference:
Steffens, David. “Lifecycle Cost Considerations when Choosing a Power Generation System”. Caterpillar Power Generation Systems. February 2013.


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Some Insights on Lifecycle Costs Related to Power Generation Systems

One cannot overstate the importance of electricity in people’s lives today. We all rely on electricity for a wide range of reasons, and we expect nothing but an uninterrupted supply of electricity that meets our power requirements. Thus, power utility providers strive to produce electricity not only consistently, but also efficiently in order to provide the most cost-effective solutions to their customers.

Even as power plants, temporary or permanent, differ according to several factors, they all need to be designed, operated and maintained properly, because even a minute irregularity in their operation will result in a dramatic change in their overall output. Poor power output, then, leads to lower efficiency, which in turn, brings higher lifecycle costs.

A close look at lifecycle costs

Any costs related to the operation and maintenance of the power plant during its lifetime are included in the lifecycle costs. Part of this are expenses related to fuel, scheduled and unscheduled maintenance, labor, and lubricant oil, among others. It is advisable to have a thorough upfront planning for the aforementioned costs in order to effectively mitigate the risk of the occurrence of any unplanned costs.

Several factors contribute to the lifecycle costs of a power generation system. Costs, like operation- and maintenance-related expenses, can be anticipated and, thus, must be taken into consideration at the nascent stages of the project. On the other hand, unanticipated costs are harder to predict, so proper planning is required to minimize their impact. Having a proper preventive maintenance program, conducting regular emergency training and setting solid contingency plans are vital to preparing for both anticipated and unanticipated costs of power generation systems.

Fuel Costs

Experts agree that even as fuel constitutes the highest lifecycle cost, it is the easiest to foresee and calculate. Fuel costs are related to the specific fuel oil consumption (SFOC) at different loads, the operating profile of the plant and the fuel price. Other factors that affect fuel costs include efficiency degradation and the wearing of engine components.

Maintenance Costs

Another important lifecycle cost is maintenance. It is helpful to note that some engine and auxiliary equipment parts, like fuel injection nozzles, piston rings, and bearings, are designed to be wear components. Thus, they need to be replaced based on the standard component life or, in some cases, if wear limits have already been exceeded. Therefore, close monitoring of such components is vital, because when a component’s useful life has been reached, the risk of system failure notably increases.

Equipment operators and maintenance specialists have to be aware of notorious contributors to premature component wear, which include dirty lubricant oil or fuel of inferior quality. In this light, it is important to have a proper predictive maintenance program to early detect problems.

Labor

Labor is another lifecycle cost to be considered. Labor costs vary according to local labor rates and regulations, operation profile, plant availability requirements and required skill level. Whoever is in-charge of plant staffing should take these factors in consideration in preparing a manpower strategy. Experts suggest that the planning team should keep abreast of current local standards and practices to correctly forecast labor costs.

While some costs are inevitable over the course of a power generation system’s lifecycle, an efficient predictive and preventive maintenance program is key to reducing unnecessary costs. But lower costs is not the only benefit of properly planned and implemented maintenance programs: They can also reduce the risk of a major system failure while increasing system efficiency. As the experts say, the goal of a power plant operator is simple: Operate effectively for as long as possible while reducing costs and maximizing profit over the duration of the power generation system’s lifecycle.

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Reference:
Steffens, David. “Lifecycle Cost Considerations when Choosing a Power Generation System”. Caterpillar Power Generation Systems. February 2013.


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Altaaqa Global
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rbagatsing@altaaqaglobal.com

The Benefits of Turning to Temporary Power from a Tenant’s Perspective

Owning a home has always been my lifelong goal, but unfortunately, personal and economic circumstances have not yet made that possible. So at present, I am renting a midsize house near my place of work. Through this experience, however, I realized that renting is a real viable alternative to having my own place – especially in a recuperating economy.

Working for a temporary power provider, I reckon that the benefits afforded to me by renting a home, compared to buying my own place, are parallel to the merits of turning to temporary power solutions, instead of building new or maintaining old permanent power plants. So for those who are having a hard time wrapping their heads around the concept of hiring electricity, here are 5 advantages of renting power explained through the perspective of a tenant.

1. Availability

When one chooses to rent, he will not have to wait for when the house is constructed or when the property is handed over, after all the legalities are fulfilled and relevant papers are signed. This can take years! Where will one stay, then? Under a tree? When one rents, he just has to pay the first month’s rent and move in. Simple. The same thing in turning to temporary power solutions. A city, a region or a country does not have to wait till the permanent power facilities are built to have electricity. The utilities can simply hire the services of a temporary power provider, the equipment and the engineering team will arrive at the site, and the power plant can be installed and powered on in a matter of days. Not years, but days.

2. Flexibility
One does not know what the future holds. One can get married and have children, and thus require a bigger home. On the flip side, one can lose his job or, touch wood, one of his loved ones, and decide to downgrade. Power requirements show a similar pattern. There are times, like during summer, when electricity requirement spikes, and there are seasons when it relaxes. With temporary power solutions, power utilities can choose to add or subtract power modules to increase or decrease the output of the power plants. There will be no need to build an additional permanent power facility when the power demand goes up, and there will be no need to run existing permanent power plants at part-load when electricity requirements go down.

3. No need to think of maintenance
Another definitive advantage of renting a home is that tenants do not have to think about maintenance and repair of household equipment and amenities. When you rent a property, the landlord should be responsible for all maintenance and repair jobs. It is the same case in hiring the services of temporary power providers. Part of their service is ensuring that generators run smoothly and efficiently at all times. So, clients can leave the maintenance services to the expert and highly trained engineers at site, and concentrate on activities that matters most to them.

4. Access to modern amenities/technology
Imagine building a state-of-the-art swimming pool and fully equipped gym in your own home. Nice to have, isn’t it? But they represent a colossal expense, and can be prohibitive to most of us. Temporary power solution providers deploy and install cutting-edge power generation technologies that are highly reliable and tremendously fuel efficient. Because such equipment can be rented, clients do not have to spend a fortune on capital expenditure, and can simply pay for the hired equipment and electricity from their operating revenues.

5. Freedom from worries of decreasing values
Property values go up or down. While this may be a huge factor for homeowners, it does not affect tenants. Hired temporary power plants can simply be demobilized when the requirement for supplemental electricity has sailed. This means that there will be no depreciating permanent equipment or facility left behind, which may sit idle and/or may need constant service and maintenance through the years. So those who turn to temporary power solutions do not have to worry about escalating expenses and dwindling values of permanent power facilities.

Bottom Line
Renting or buying is one’s own choice. Both have their advantages and disadvantages. Personally, the trump card of renting is the availability, affordability and flexibility it provides. It may be a different case for you. But, this one is true: before deciding to rent or to buy, look at all the available choices, review the details and make the decision that fits your needs and your pocket.

To know more about how temporary power solutions can work for you, visit www.altaaqaglobal.com

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Quick Facts: How can rental power plants support utility companies?

Rental power plants can replicate or supplement permanent power plants. They are fully able to provide reliable electricity in times of:

• Power plant failure
• Hydropower shortage
• Natural disasters
• Peak demand
• Maintenance or upgrade of power infrastructure

Temporary power plants prove highly beneficial in:

• Overcoming transmission and distribution limitations
• Powering remote locations
• Electrifying areas without grid connection
• Providing electricity ahead of transmission line construction

Modern rental power plants utilize generators with:

• Outstanding fuel efficiency
• Low noise
• Low exhaust emissions

Owing to the advancements in rental power technologies, temporary power plants guarantee exceptional performance and considerable operating cost reduction for end-users. Utility companies can reap the benefits of high reliability and cost-savings as they turn to renting power, in times when permanent power plants have stopped working or when they become increasingly expensive to run as they age.

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How Has Eskom Handled Power Crises Through the Years?

South Africa has been facing a power supply challenge since 2008. Regular power outages have become part of the lives of the residents of the country, owing to decreased generation capacity and ongoing planned and unplanned maintenance. Add to this the ever-increasing demand for electricity spurred by rapid population growth and lifestyle changes, as well as seasonal requirements.

Eskom said that it needed to complete scheduled maintenance works on the power infrastructure to minimize the chances of unplanned power cuts. It further claimed that it only implemented load shedding to protect the power system from suffering a complete failure.

This, however, is not the first time that Eskom has encountered such challenging circumstances. It would be interesting to have a look at how the power utility approached the same scenario in the 50s and 70s compared to today.

World War II

After the Second World War, the then Escom had to deal with an escalated demand for electricity. Thus, electricity consumption had to be restricted to avoid a consequent damage to the economy of South Africa, and key power stakeholders worked to gain access to additional power generation and transmission equipment.

Between 1945 and 1955, Escom reported that the capacity of its power plants grew twofold, and estimated that it would double again in the decade that followed. In the decade beginning in 1950, Escom commissioned 10 new power stations, among which were the small coal power plant in Hex River and the Taaibos and Kelvin stations.

1960s and 1970s

When South Africa faced another power crisis in the 60s and 70s, Eskom’s response was to build myriad power stations till the 80s. To support Eskom’s effort, the government of South Africa intervened at the policy level, creating special action committees and introducing new regulatory systems.

Today

Experts believe that the South African government and Eskom have to show more resolve in dealing with the present energy crisis.

When load shedding was re-implemented earlier this year, the government said that the foremost reason for the supply insufficiency was the growing energy demand brought about by an expanding economy.

Industry insiders, however, believe that Eskom should not have found itself in such a challenging predicament had it heeded the warning of the Department of Minerals and Energy (DME) in the late 90s, which said that at the rate of the annual growth in demand for electricity in the country, South Africa’s energy supply would be outstripped by 2007. It added that decisions about building additional electricity generation capacity should be taken by 1999, but instead, owing to a variety of reasons, Eskom waited until 2004 before making a resolution on constructing new power plants.

The Roadmap Ahead

Now, the onus is on the government, Eskom and key stakeholders to find a viable and sustainable solution to South Africa’s power supply challenges. Building additional electricity generation capacity through the construction of new power plants may be a permanent solution, but its completion may take several years, even decades.

Rental or temporary power plants may be able to help South Africa boosts its electricity supply now that it needs it. Rental power plants can be installed in a matter of days, and can provide the exact amount of power that South Africa requires. They can be shipped from and to anywhere in the world, and can be installed and commissioned in no time, as they do not require additional power infrastructure to be constructed to run. They come as packaged systems, so once they are plugged and played, they are good to go.

Moreover, since temporary power plants are hired, South Africa need not shell out a huge capital for their construction and subsequent maintenance.

The key to the resolution of South Africa’s energy woes may not lie on one single technology. To resolve the crisis, the country and its utility providers should tap the potential of all solutions on offer. In this way, South Africa will be provided with a reliable and sustainable source of electricity and avert future energy supply challenges from occurring.

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Robert Bagatsing
Altaaqa Global
Tel: +971 56 1749505
rbagatsing@altaaqaglobal.com

There is Power in Foresight

Electric utility providers in developing countries, where load shedding is common, may be able to gain valuable information on the health of their areas’ power systems through advanced analytical tools available today.

Though utility companies have always employed analytics to a certain degree, the data they gather from power plants, transformers, generators and other equipment only reflect those that have already happened. Industry experts agree that making operational decisions based on historical data is ineffective and may lead to false conclusions.

By relying on historical data, the decision-making process of utility companies becomes more reactive than proactive. Let’s take the health of power plants as an example. Many of the power plants operating in developing countries are well beyond their lifespans, and the constant increase in demand for electricity puts more pressure on these dated facilities. As a result of the overwhelming requirement, these power plants often break down, forcing utility companies to perform unplanned maintenance activities. However, because the unexpected breakdown is outside the maintenance cycle in vigor, utility companies usually choose to delay the operation and “sweat” the facilities even more. Professionals knowledgeable in power systems will agree that “sweating” assets will only increase the chances of breakage, higher maintenance costs and sub-par performance.

The latest technologies in advanced analytics allow utility providers to plug the gathered data into a statistical model, which is capable of scientifically predicting future scenarios based on operational events that have already occurred. This will, then, enable utility providers to make proactive decisions that will help regulate the electricity supply and plan maintenance schedules. Using the forecast, utility companies will be able to estimate the electricity demand and supply per area and per season. When, for example, they ascertain a potential gap in demand, they can take the proactive step of introducing other sources of electricity, like temporary power plants, into the energy mix.

If load shedding is really unavoidable, having advanced analytical tools will allow utilities to effectively manage and communicate planned outages. From the statistical information available, utility providers can determine critical operation times for industrial and commercial companies, so that they can work around the schedule in such a way that the planned power outage will have the least impact on these entities’ business operations. For instance, they can collaborate with rental power providers that will provide the necessary power to industrial and commercial zones during the hours when the permanent facilities aren't able to generate enough electricity.

Today’s advanced analytics systems are more accessible, because the latest technologies provide for plug-and-play operations, even for non-specialists. They use a considerable degree of artificial intelligence to meet the requirements of modern-day businesses and utilities. This allows them to make proactive decisions that will ultimately save them time and money, and optimise processes and resource allocation.

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PRESS INQUIRIES
Robert Bagatsing
Altaaqa Global
Tel: +971 56 1749505
rbagatsing@altaaqaglobal.com