1. Splash oil temperature monitoring: to eliminate crankpin failures
JOH-KGN JvW-X1
Splash oil temperature monitoring: to eliminate crankpin failures
Presented by: OMAR SALIM
AMANI KONDE
18th to 22nd June 2018

2. OMAR SALIM Ag. Chief Engineer KDP1 Qualifications: BE (Mechanical)
JOH-KGN JvW-X1
OMAR SALIM
Ag. Chief Engineer KDP1
Qualifications:
BE (Mechanical)
C.E.M & C.W.E.P
Responsibilities:
In charge of Kipevu 1 plant
Key milestones/achievements include:
Initiated a number of Innovative ideas from the G2G Transformation journey and G2G Forum
Participated in G2G Transformation journey and was Team Lead on Fuels
Functional team lead in the ERP journey
Member of the energy management team and carried a number of energy audits in KenGen installations.
Committee member in KenGen C Team

3. Outline
Introduction : Kipevu Plants, problem statement, Kipevu I Bearing & crankpin failures and its effect in Kipevu Availability and Loss of revenue.
Challenges/Current Situation : Kipevu I Availability over the last five years, major causes of low availability, number of bearings and crankpin failures and RCA of bearing and crankpin failures.
Opportunities from Splash oil system: The Splash oil system, expected benefits if the system was installed.
Cost Benefit Analysis : The total cost of the splash oil system, Annual savings from Improved Availability.
Conclusion & Way Forward :

4. Currently KENGEN operates two thermal plants at Kipevu
INTRODUCTION
Currently KENGEN operates two thermal plants at Kipevu
Kipevu I
75MW
Kipevu III
120MW
SOURCE : Google photos

5. KDP1 Last 5yrs Capacity Revenue

6. DG 6 Crankpin No. 2 Failure & Causes

7. ANNEALING PROCESS

8. Repaired Crankpin & Diameter sizes
Crankpin sizes (mm)
Standard size
420
416
412
 DG 5 Machined
To this point
410
De-loading to 70%
405
Condemning limit
400

9. Expensive foreign expertise involved
COST IMPLICATIONS
Specialized tools use in the repairs
Machine downtime: loss of revenue and penalties due to low plant availability
Expensive foreign expertise involved

10. Specialized tools use in the repairs
COST IMPLICATIONS
Specialized tools use in the repairs
Machine downtime: loss of revenue and penalties due to low plant availability
Expensive foreign expertise involved

11. COST IMPLICATIONS
Specialized tools use in the repairs
Machine downtime: loss of revenue and penalties due to low plant availability
Expensive foreign expertise involved

12. TOTAL COST KES 890M IN JUST 6 YEARS
BACKGROUND DATA
BEARING FAILURES: 2011 TO 2017
TOTAL COST KES 890M IN JUST 6 YEARS
60M PER YEAR
(EXCLUDING
DG 3)

13. CRANKSHAFT MAIN BEARING
TECHNICAL BACKGROUND
CRANKSHAFT MAIN BEARING
BIG END BEARING

14. AS THE ENGINE ROTATES OIL SPLASHES OUT OF THE BIG END BEARING
ENGINE ROTATES ABOUT 7 TIMES PER SECOND
WHEN BEARING FAILS, THE TEMPERATURE OF THE BEARING INCREASES
THE TEMPERATURE OF THE OIL SPLASHING OUT INCREASES
AS THE ENGINE ROTATES OIL SPLASHES OUT OF THE BIG END BEARING

15. WEAKNESSES OF OIL MIST DETECTION

16. OIL SPLASH TEMPERATURE SYSTEM
OIL SPLASHING
RTD TEMPERATURE DETECTOR
COLLECTION PAN
ENGINE ROTATION

18. INVESTMENT COSTS TOTAL Unit Cost No of Total Euro. Engines. Costs
Unit Cost
No of
Total
Euro.
Engines.
Costs
Complete Splash system
57,440.00 5
34,464,000.00
TOTAL

19. BENEFITS AVAILABILITY REDUCED O/M COST MONITORING
Improved availability increases revenue by around 62 Million annually
AVAILABILITY
Reduction of expensive maintenance works
REDUCED O/M COST
Improved monitoring parameters for better condition based maintenance
MONITORING

20. CONCLUSION & WAY FORWARD
Savings
Reduce revenue penalties by around 62 Million annually
Higher Availability increases maintenance allowances
Process
Approval granted.
Tender and evaluation done
PPO received, preparing purchase Order
Planning & Installation
Engine identification
Start Installation during major overhaul
Knowledge transfer and Install for the other engines internally.

21. THANK YOU