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
Tel: +971 56 1749505
rbagatsing@altaaqaglobal.com

How much does it cost to operate and maintain a permanent power plant?

Whatever the energy source, be it fossil fuel, nuclear or renewable, expenses for operation and maintenance (O&M) form a vital part of the life cycle cost of power plants. Though O&M cost differs among various forms of power generation, it plays an important part of any power plant’s business case. Guided by the information provided by the International Energy Agency’s World Energy Investment Outlook 2014, we present an overview of the estimated average O&M costs for six of the most common power generation methods.

1. Gas Turbine (USD 20 per kW)

Gas-fired power generation is popular for having a relatively low O&M cost compared to other power generation procedures. For instance, power plants installed with simple-cycle combustion turbines have been shown to have an average annual O&M cost of just around USD 20 per kW, making such technology the most economical O&M option in the power industry. The maintenance of an effective lubrication system for gas turbines plays an integral component of O&M expenditure in gas-fired power plants.

2. Large-scale solar photovoltaic (USD 25 per kW)

Thanks to the ongoing development of solar photovoltaic (PV) technology, large-scale PV installations are among the most economical power generation technologies for O&M, at just about USD 25 per kW. Because solar PV is a relatively simple technology, maintaining it often only involves cleaning and removing debris from PV cells, together with monitoring of inverter units and AC subsystems.
Concentrated solar power (CSP), on the other hand, being a more sophisticated and complex technology, demands a much higher O&M cost, estimated at USD 290 per kW.

3. Subcritical coal power (USD 43 per kW)

O&M costs for coal vary depending on the type of plant. For instance, the cheapest subcritical plant has an O&M cost of approximately USD 43 per kW, even higher for supercritical and ultrasupercritical coal combustion technologies, and about USD 88 per kW in the case of integrated gasification combined cycle plants. A major component of the O&M costs of coal-fired power plants is monitoring and servicing the numerous moving parts involved in the generation process, including turbines and generating sets, coal yard conveyors and handling systems.

4. On-shore wind power (USD 46 per kW)

There is a notable disparity between O&M costs for onshore and offshore wind farms, mainly owing to access-related issues. While O&M costs for onshore wind power sites are almost at part with those of the simplest coal technologies, and are even expected to fall below those of coal by 2020, O&M expenditure for offshore wind technologies are approximately four times as much, sitting at around USD 181 per kW.

5. Large-scale hydropower (USD 53 per kW)

Large-scale hydroelectric power is considerably cheaper to operate and maintain compared to smaller-scale projects. However, the O&M costs for maintaining large installations like dams and barrages are predicted to increase in the future, matching those of small-scale hydro by 2035. At present, the O&M costs for small hydro projects stands at USD 70 per kW. According to IEA, ageing equipment in need of replacement at hydroelectric dams, on top of the complexity of running and maintaining new equipment along with dated components may be factors that contribute to the predicted increase.

6. Nuclear power (USD 198 per kW)

Nuclear power plants do not only command a hefty capital expenditure, they are a long shot from being cheap to operate and maintain. Major contributors to the steep O&M cost include the processing, enrichment and fabrication of uranium into fuel elements; waste disposal; and maintenance of a large number of pumps, valves, cables, circuit breakers and other mechanical and electrical components.

When permanent power plants become less efficient and less reliable...

Naturally, O&M costs, as illustrated in our discussion on large-scale hydropower facilities, are expected to increase as power plants age and become less efficient and less reliable. When old power plants continually shut down or become increasingly expensive to operate and maintain as they age, power utilities may be compelled to do a major refurbishment on existing power plants or build new ones as they rest the old ones.

While permanent power plants are being optimized or new ones are being constructed, power utility providers can turn to reliable and fuel-efficient temporary power solutions for supplemental electricity.

Temporary power plants can be swiftly transported from and to anywhere in the world, and can be installed in a matter of days as soon as the power equipment arrived at the site. Rental power plants do not require a huge capital expenditure and major civil works before they can be installed, and have been proven to deliver exceptional performance and outstanding fuel efficiency. Power utilities can pay for the “hired” electricity from their OPEX,

Rental power plants are scalable in that power utilities can choose to increase or decrease the power plants’ power output depending on the existing requirement. This means that in case the power requirement rises, they do not have to build another permanent power plant to satiate the demand. Once the need for additional electricity passes, power utilities can simply end the contract, and the temporary power plants will be demobilized, leaving no permanent facility idle or requiring continuous maintenance.

Temporary power plants are operated and managed by a team of certified and expert engineers, so clients can rest assured that the power plants will be running smoothly and will be providing sufficient electricity anytime it is needed.

For more information on temporary power solutions, visit www.altaaqaglobal.com

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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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