Document Number: ZE10027-KP1501

Zamunda Energy (ZE)

KURUTSI POWERPLANT
Technical Report on Diesel Power Unit EX-20
Engineer Chiviya Fariku 10/10/2012

This Document is a technical review and report of the existing Diesel Power Unit EX-20 and recommendations are made based on expertise.

Abstract
Zamunda Energy has engaged in a technical study of the Kurutsi Power Plant and its facilities with a focus on the Diesel Power Unit EX-20. The objective of the report is to analyze the current state of the diesel power unit, test the individual components and measure the efficiency of the power unit. New Zamunda Energy Patented mobile diagnostic technology is used for the testing. The results of the testing are then used to recommend a change of the model to a zero-waste ZE Power Unit.

Table of Contents
Executive Summary....................................................................................................................................... 3 Introduction/Background ............................................................................................................................. 3 Design Overview ........................................................................................................................................... 5 Problem Identification .................................................................................................................................. 6 Solutions ....................................................................................................................................................... 8 Recommendation.......................................................................................................................................... 9 Conclusion ................................................................................................................................................... 11 References .................................................................................................................................................. 11

Executive Summary
The Diesel Power Unit EX-20 located in the Kurutsi Powerplant started to malfunction in September 2012. The Power Unit has been on and off and has forced the power plant as well as all the national branches of Zamunda Energy to engage the use of its auxiliary power units as well as buy power from other regional and international branches of the company. This prompted the need for the technical review and evaluation that is the basis of this report. The purpose of the technical review and the report is to outline the design of the power unit, identify the problems with the power unit as well as cause of the initial breakdown and make recommendations. The review will first outline the general design of the power unit. It will identify the problems with the power unit by analyzing each part of it. The root causes of the first breakdown and how to prevent it from happening again will be identified. It will then recommend that the power unit be changed for the newer model zero-waste ZE power unit and then outline the advantages of the new model over the old model.

Introduction/Background

The Diesel Power Unit EX-20 is not a typical Diesel Power Generating Unit. The Unit is actually a 50mw section of the bigger 5,000 MW Kurutsi Power Plant Mega complex. It was the first of a kind combined biogas, diesel fuel and steam combined power plant used to run the processes of the whole plant as well as provide power to all the branches of Zamunda Energy (ZE) using the wireless transmission and distribution technology. The unit was commissioned in 1991 and was seen as far ahead of its time.

Figure 1: Diesel Power Unit EX-20 (GE, 2010)

Design Overview
The schematic of the diesel power unit EX-20 is shown below

Figure 2: Schematic of Cycle for Diesel Power Unit EX-20 (M Wakil, 1983) In this schematic the biogas goes in through the compressor where it is pressurized and then it is passed through a combustion chamber where it is combusted with diesel as the fuel. It then proceeds to turn the gas turbine and passes through some more combustion to increase its heat. It goes out through a chimney after passing through a heat exchanger where it heats the water that becomes steam which runs the steam turbine. Both the gas and the steam turbine which make up the unit are connected to diesel generators that convert the shaft work to electrical energy.

Gas Turbine

Steam Turbine

Diesel Generator

Boiler (Steam Generator)

Problem Identification
To identify the problem with the diesel power unit ex-20, the mobile diagnostic unit was inserted into the unit and it took reading an analyzed each part of the power unit.

Figure 3: Mobile Diagnostic Unit (MDU) The measurements garnered from the unit are shown below
Instrument FM 026 a Reading 108715 lb/hr Notes Over pressurized

FM 026 b FM 058 FM 174 FM 175 FM 201 FM 211 P 006 P 2003 P 2004 P 2005 PV 169A T 010 T 2003 T 2004 T 2005 Condenser Outlet Feed Water Input Work (TG-0102)

103201

lb/hr Valve at less than 10%

Negligible 73400 7000 lb/hr lb/hr

Not enough pressure

Negligible 49371 lb/hr 651 130.99 PSIG PSIG

No Flow 0.81 PSIA Valve at -3%

Closed 752 467 Degree F Degree F

No Flow 95.43 183 15.38 11.3 Degree F GPM GPM MW Overheating Contaminated Not Enough Far Less than 50MW

Table 1: Mobile Diagnostic Unit Measurements The measurements confirmed that the Diesel Power Unit was not working properly. It also showed that the unit was operating at less than 25% efficiency as opposed to its normal 75% efficiency. It also showed an increase in the amount of waste released, higher pressures than expected in many units as well as overheating of the turbines. When broken down into parts the turbines were damaged beyond repair as well as the boilers, the pipe system and valves as well as controls.

The cause of the breakdown from analyzing the results is the age of the unit as well as a failure to undertake regular maintenance of the unit or to upgrade parts of the unit as technology was improving which led to overworking of the machine.

Solutions
There are several potential solutions to the problems facing the diesel power unit EX-20. One of the solutions would be to replace the parts that are damaged. This includes the boiler, turbines, pipe

systems and controls. Considering that the parts are 21 years old it means that the parts would be hard to find. Currently such parts when found and shipped to location could cost the company almost 2 million dollars. Another alternative would be to buy and assemble another diesel unit which would cost 2.5 million dollars. The final alternative is to replace the diesel power unit with a different type of unit. In addition to the alternatives to the current machine it is key to design a regular maintenance schedule and inculcate a sense of ownership of the machines by the workers by selling machine bonds to the company workers as well as machine training.

Recommendation

My expert opinion would be to convert the parts of the current diesel power unit into metal scrap and exchange it with a steel mill for some currency and then add about 500,000 dollars to get a zero-waste ZE Power Unit which combines wind, solar and biogas to provide a cleaner alternative to diesel. It also gives an unprecedented 95% efficiency.

Plant type

Current Diesel Power Unit

Zero-Waste ZE Power Unit

Nominal power (MWe, net)

50

50

Plant type

Current Diesel Power Unit

Zero-Waste ZE Power Unit

field size (m2)

270,320

427,280

Fuel type

Diesel

Natural gas

Thermal energy storage (MWht)

839

Fossil back-up system

Duct Burner Duct Burner

BU thermal output (MWt)

50

50

Gas turbine power (MWe, gr) 162.0

162.0

Steam turbine power (MWe, 148.0 gr)

148.0

Plant efficiency, net

75.1%

94.9%

Total parasitics (MWe)

6.14

8.61

Cooling system

Wet

Wet

Table 2: Comparison of Current Diesel Power Unit with Zero-Waste ZE Power Unit ( Source: Energy Volume 29 Issues 5-6 April-May 2004)

Conclusion
The Diesel Power Unit EX-20 has several malfunctioning parts, replacing them would be costlier than getting a new technology which is the zero-waste ZE Power Unit. The new unit will exceed the performance of the current unit.

References

Wakil, M. M. (1984). Powerplant technology (International ed.). New York: McGraw-Hill Book.

GE Energy Overview: Solar Energy, Wind Energy, Nuclear Energy. (n.d.). GE | Technology | Services | Finance | Innovation | General Electric. Retrieved December 16, 2011, from http://www.ge.com/products_services/energy.html

Shin Nippon Machinery Co. LTD, Instruction manual for 14.5MW Steam Turbine Generator Set. 12/24/92. Conference Room and Reference Library (pp. A-3, A-4, A-9, A-10).