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Insurance companies expect power plant owners to follow preventive maintenance best practices to limit risk exposure. Implementing such practices for critical components not only keeps insurance premiums down, but also avoids costly downtime and equipment failure. By implementing best practices for preventive maintenance, power plants can head off equipment failure, avoid costly downtime and reduce corrective maintenance costs. Effective preventive maintenance is also an essential tool in keeping insurance rates down. This article discusses several critical power plant components and the operating and maintenance practices that insurance companies expect to be implemented to reduce their risk exposure. Because of their use in the majority of large-scale power plants, steam turbines are the focus of this article, spanning lube oil analysis, high-energy piping, vibration monitoring and turbine overhauls, with particular emphasis on the turbine overspeed testing process. A proper steam turbine maintenance program will include all OEM recommendations and suggestions specific to the turbines at each insured location. How these recommendations are implemented is very important to the turbines well being. Not fulfilling OEM recommendations, particularly the critical ones, can affect the insurability of a turbine and trigger unpleasant insurance penalties as well.
Most bearing or gear failures occur after their condition has slowly deteriorated over the course of months or even years. Quarterly sampling can provide a more subtle indication of oil or component deterioration, or the slow beginning of oil contamination. Long-term monitoring of oil condition (over several months or quarters) can reveal improper repair or maintenance practices, such as the failure to conduct effective system flushes after repairs, or the improper handling of lubricants, which can introduce dirt or even water to the oil.
Bearing vibrations can be monitored using one of several methods. Displacement probes measure shaft movement directly. Some models contact the shaft directly, using shaft riders; others are non-contacting types, called proximity probes. Conversely, velocity pick-ups do not measure shaft displacement directly, but quantify the energy transferred from the shaft to the bearing housing. To measure absolute shaft vibration, a proximity probe and a velocity pick-up are generally installed together at the bearing housing. This arrangement provides both absolute shaft vibration levels as well as vibrations relative to the bearing measurement. Displacement probes are usually used on turbines and generators that have a high rotor-to-casing weight ratio, or on turbine generators greater than 100 MW. Rotating equipment that has a high casing-to-rotor weight ratio can use velocity pickups with success.
Some original equipment manufacturers (OEMs) have relaxed their requirements for testing overspeed trip devices. In direct contrast with the insurance carriers, at least one OEM has allowed the testing interval of the overspeed trip device to be extended to the units major inspections. For some units, this could mean more than 10 years between tests.
James R. Peterson is president of High Energy Consulting, LLC. After more than 23 years with HSB, mostly as a B&M Power Generation Specialist inspecting power plants of every variety in the United States and Canada, Peterson started a consulting company to continue this work. He has a BA degree in print journalism from the University of Montana and engineering course work at Iowa State University. Peterson also spent eight years in the U.S. Nuclear Navy as a submarine nuclear operator, supervisor and instructor at the A1W prototype, and as a nuclear-qualified Navy scuba diver. T. Keith Schafer, Jr. is a vice president with Marsh Risk Consulting. He has more than 35 years of experience in power generation, in the Navy Nuclear Power Program as an operator, supervisor and instructor, and with Hartford Steam Boiler as a senior utility specialist at numerous power facilities around the world. Schafer currently works with Marsh Risk Consulting providing services to various utilities in the United States and abroad.
Setting a reasonable maintenance period while maintaining the availability, reliability and insurability of a critical generation asset is a necessary but difficult task. Overhauls are generally a contentious topic, especially when applying overhaul guidelines to equipment that is infrequently operated, such as prime movers in emergency, cold standby or peaking service, or units about to be retired or sold
Overhaul frequencies for power generating equipment have historically been set by the OEMs. These calendar or operating hour-based intervals have worked well, provided the equipment to be serviced is baseloaded, operated two shifts/day or in peaking service that approximates either of these operating modes. For generating units that are in peaking service or that operate less than 1,000 hours/year, however, these OEM guidelines do not provide realistic maintenance targets. Service class differentiation can be used to explain the operating modes of generating equipment regarding component maintenance planning. Service Class 2 refers to units that are in peaking, standby and/or emergency service that operate less than 1,000 hours/year. For example, a unit that operates 2 to 3 hours/day in peaking service would accumulate about 1,000 hours/year and would fit into this class. Service Class 1 encompasses unit components in all other operating modes.
Service Class 2
For peaking, standby and emergency service units that operate less than 1,000 hours/year, dismantled inspection frequency is a controversial subject with insurers. Each insurer determines peaking service overhaul intervals using similar engineering considerations, but each may reach differing conclusions depending on its loss history, market tolerance, or even its loss ratios or profitability. In some cases the carrier may opt out of the risk using reinsurance. Equipment owners view dismantled inspections of peaking or standby units from a more pragmatic perspective. Though budget considerations will likely be involved, the owners are most concerned with reliability and availability in the event a unit is returned to operation described under Service Class 1. OEM time guidelines for dismantled inspection frequencies will be exceeded if they are followed for units in this service. There are cases of units that operate only two or three hours a month and, even with severe penalties for cold starts, could go 50 years or more without approaching the OEM-recommended overhaul frequencies. This is particularly true with emergency diesel generators. So, what is a reasonable way to keep the equipment available and properly maintained within a practical overhaul period? If each unit is evaluated on a case-by-case basis, its operating and maintenance history can be compared to industry standards and best practices. Several factors must be considered when assessing the viability of
an extended turbine overhaul interval (see table). Satisfying the insurance carrier should also be a consideration. If the above can be accomplished using good procedures and documentation, the carriers concerns can be met. Nevertheless, the inconsistencies between insurers standards, guidelines and even personalities can complicate this process. Using sound engineering judgment and principles in critical component operations and maintenance should be the most important owner concerns. To access this Article, go to: http://www.pennenergy.com/pennenergy-2/en-us/index/articles/pearticle-tools-template.articles.power-engineering.volume-109.issue6.features.insuring-best-practices.html