MEBM

MRSE2563

PROF. MADYA SALLEHUDDIN BIN MUHAMAD

Dr. Abdelgadir Mohamed Mahmoud

abdgadir@gmail.com
abdgadir.kl@utm.my
0162658594
 Objective of this Course

To provide an understanding of:

Maintenance Engineering/Management
Principals & Practices used in the
Industries.
Where Applicable….

• Petrochemical
• Power Generation
• Water Treatment
• Engineering Plants
(Steel, Paper Mills,
Cement, etc.)
• Oleo-chemical
• Assembly plants,
• Ships, transport
• Building Services…
But before going into the details of the
Course….. Why is good maintenance
practices so important?

An Appetizer……
High Impact to Industry

Blades replacement
RM 1M per row

Revenue Loss

Base Load
500MW Generator
RM 4M/day

Peak load
100 MW Generator
RM 0.5M/day

Offshore Platform
US$ 4M /day
RM 12 M/day
5
Equipment and Plant Failures

Some Examples from the Industry….

and the Insurance Perspective
 Background

• Gas turbines are high value critical machines used

in oil & gas and power industry.
• Oil & Gas X group of companies are the largest
user / operator of industrial gas turbines in the
region.

*2009 data
 Some Statistics

• Typical gas turbine costs USD 1 million to USD 50 million

each.
• Company X has 167 units*. Estimated value of gas
turbines RM 2 billion (assuming RM 12 million each)
• Cost of maintenance and repairs for gas turbines for
example in one company is more than RM 100 million per
year.

*2009 data
 Gas Turbine Examples

Stages of Compressor Blades

Turbine Section

Combustion
Chamber

Compressor Section

Turbine Blades
 Cost of Failures

• Turbine blade cost US$15,000 to USD30,00

each. Turbine blade row may costs >RM 1
million per row.
• Blade failures account for 42% of gas turbine
failures.
• Cost of downtime not included: in offshore
platform >US$ 1 million per day,
• Power generation RM 0.5 million per day per
100 MW gas turbine.
 Gas Turbine Failure Statistics

45
40 Blades
35
Combustion
30 chambers
25 Hot Casing
20 Parts
15 Rotor and
wheel discs
10
Other
5
0

Source: Munich Re-Insurer Company (Allianz)

 Gas Turbine Failure Statistics
Distribution of 147 cases of damage versus operating hours

0-10.000
10.000-20000
20.000-30.000
30.000-40.000
40.000 - ...

Source: Munich Re-Insurer Company

Note: Typical OEM major inspection every 16,000 Equivalent Operating Hours
 Message …..

Equipment do not survive as

long as they ought to….
 Combustion Turbine Failures

7FA Failure

(Ian Barnard, AIG 2006)

501-D5A Failure
 GE Frame 6 Eastern Kalimantan

Source: Ian Barnard, AIG 2006

Air Filter Configuration
 GE7FA Turbine

Source: Ian Barnard, AIG 2006

R-0 Blade with P-Cut
R-0 Blade Miss
R-0 Blade with P-Cut
R-0 Blade with P-Cut
Steam Turbines – Broken Blades
 Lost Parts

Lost part in compressor blades in 110 MW gas turbines, ABB Gas Turbines, Malaysian
Power Plants. Source: M Salman 2000
 Blade Rubs

Rub marks on rotor from

stator blades, 110 MW ABB
gas turbines
 Cracks and Looseness at Blade Roots
and Intermediate Packing Pieces

• ABB gas turbine with 21 stages axial flow compressor on single composite welded
shaft.
• Fitted using intermediate packing pieces.
 Thermal Induced Shaft Failure

600 MW Steam Turbine

Wind Turbine Hydraulic Oil Fire
Wind Turbine Drive Shaft Failure
Major Loss Examples

Plant wide destruction

 Steam Turbine Incident
in South Africa

Pictures of a damaged 600 MW Turbine

Generator.

Source: Ray Beebe 2006

Australian Power Generation / Monash Univ Melbourne
➢ On start-up, a Low Pressure Blade (1m in length)
broke off while the turbine was turning at 3000 rpm.

➢ The blade went through the casing, through the roof

(20 meters higher up) and landed outside.
➢ The blade that broke wrecked another 15 blades.

➢ The turbine went from 3000 rpm to standstill in a

couple of seconds. The turbine/generator shaft
broke clean at two different places.

➢ The resultant fire was so hot that some of the

roof's steel beams bent.
To take the phrase from NASA, these are
photos of a "BAD DAY" at the power station. . .
 BP AMOCO EXPLOSION MARCH ‘05

15 DEAD
100 INJURED
30 PUBLIC INJURED
8 IN CRITICAL CONDITION
➢ Location was Texas City, about 35 miles southeast of Houston.

➢ BP AMOCO Refinery is on 1,200 acres with 30 refinery units and is

71 years old. It is the USA’s third largest refinery.

➢ It is BP’s largest plant, and the USA’s third largest.

Explosion was a believed to be the result of an Unconfined

Vapour Cloud Explosion from a release of
Benzene/Heptane from a Raffinate Splitter on a 180 kL/hr
Isomerisation Unit.

Source: Ian Barnard 2006

Most of the damage to the process unit was thermal (from the fire which
ensued after the explosion).
It is believed that a car being started may have provided the
source of ignition for the explosive vapour cloud
Of interest are the following incidents which occurred at the
same plant.

❑ The day prior to the explosion, a furnace valve caught fire.

❑ March 2004 a similar explosion on the same plant had occurred,

requiring evacuation of the entire facility. Afterwards BP were fined
$US63,000 for 14 safety violations including problems with its
Emergency Shutdown System and Employee Training.

❑ In 2002 at the same plant 2 maintenance employees were killed when

scalding hot water (260°C) was released from a pump seal – only a
check valve was used as isolation for the pump.

In addition, the Alaska Oil and Gas Conservation Commission fined BP

$US700,000 for a well head explosion in 2002 in Prudhoe Bay.
The total cost of this incident is
expected to reach $US 1 Billion
 Typical Losses
Power Generation

Source: Ian Barnard 2006

US$200M and 30 Months to Repair
Boiler/Plant Furnace Explosion
Hydrogen Fire ESCOM – South Africa
Hydrogen Explosion- Tampa E
Steam Turbine Generator - Overspeed
Transformer Fire After Turbine Blade Went Through Wall
Source: Ian Barnard, AIG
1st World Congress on Asset Management, 2006 Keynote Paper
 The Lessons…..

• Equipment and machinery failures can be very

catastrophic, and expensive.
• Failures do result in deaths & loss of valuable assets.
• Condition monitoring can make a difference.
• The Insurance Industry are insisting on it.
 Other Examples…………

• Aviation
• Public Transport
• Water Supply
A Qantas jet was forced to turn back to San Francisco after a hole was
blown in the shell of the engine.
Photo: Channel Ten

Source: http://www.smh.com.au/travel/travel-news/exploding-qantas-engine-turbines-broke-off-
20101025-170b3.html#ixzz2Kw86Tn81
Technicians inspect the damaged engine of the Qantas A380 forced to make
an emergency landing in Singapore after an engine exploded soon after take-
off. Photo: Reuters

Source: http://www.smh.com.au/travel/travel-news/faulty-oil-pipe-to-blame-for-qantas-incident-says-report-
20101203-18itw.html#ixzz2Kw9rnlRT
No 2 engine from QF32 being removed from aircraft.
Photo: Australian Transport Safety Bureau

Source: http://www.smh.com.au/travel/travel-news/faulty-oil-pipe-to-blame-for-qantas-incident-
says-report-20101203-18itw.html#ixzz2Kw9wIkHC
Low Pressure Turbine module removed from the No. 2 engine.
Photo: Australian Transport Safety Bureau

Source: http://www.smh.com.au/travel/travel-news/faulty-oil-pipe-to-blame-for-qantas-incident-says-report-
20101203-18itw.html#ixzz2KwA00hUB
Misaligned counter-bore.
Photo: Australian Transport Safety Bureau
 The Real Cause of Failure
- the Software Element !

THE BIG 4
Didn’t install correctly Didn’t operate correctly
Didn’t maintain correctly Didn’t design correctly

= BROKEN EQUIPMENT !
Question and Answers…..