Managing National Resources

Transcription

1 Managing National Resources the role of technology in steam field and surface plant life extension Siemens Energy, Inc. James R Beverly September 11, 2013 Nairobi, Kenya

2 Steam Field Sustainability Designing for Decreased Pressure, Increased Flow Multiple Smaller Units Vs. Large Central Plants - Risk Smaller Units Vs. Larger Units - Logistics What happens when people do not listen... Summary

3 Steam Field Sustainability The economics sustained profits require suspension of greed. Sustainability requires NOT over utilizing the resource. Sustainability requires adequate injection reinjection or additional injection

4 Steam Field Sustainability Redesigning for Decreased Pressure, Increased Flow Multiple Smaller Units Vs. Large Central Plants - Risk Smaller Units Vs. Larger Units - Logistics What happens when people do not listen... Summary

5 Green Field Steam Path Seven Stages, 2 Inlets

6 Steam Path after 24 Yrs Service Six Stages, 4 Inlets

7 Re-rating for Sustainability Original Unit: Inlet pressure: 7.79 bara Inlet steam flow: 375,450 kg/hr Generator output: 55,108 kw After 24 Years of Service: Inlet pressure: 4.34 bara Inlet steam flow: 442,000 kg/hr Generator output: 29,000 kw Re-Rated Unit: Inlet pressure: 4.34 bara Inlet steam flow: 412,100 kg/hr Generator output: 54,500 kw plus 3 MW saved on parasitic load

8 Steam Field Sustainability Redesigning for Decreased Pressure, Increased Flow Multiple Smaller Units Vs. Large Central Plants - Risk Smaller Units Vs. Larger Units - Logistics What happens when people do not listen... Summary

9 Successful Multi-Unit Fleets Alterra Soda Lake 6 X 3.5 MW units Ormat Puna 10 X 3.5 MW units Ormat Mammoth 8 X 5 MW units ENEL Larderello 16 X 20 MW units TerraGen Coso 8 X 30 MW units Orkuveita Reykjavicur Hellisheidi - 3 X 35 MW units; 2 X 45 MW units Calpine Geysers 6 X 55 MW units

10 Advantages of Multi-Unit Fleets Commonality of spare parts Economical major spares rotors, diaphragms, blade carriers Reduction in forced outage time Reduction in planned outage time Empowers capital spending, reduces O&M spending Improves reliability, availability, capacity

11 Size Does Matter Sometimes Smaller is Better 110 MW Unit in Indonesia

12 110 MW Unit in Indonesia Rotor Requires Replacement after only 6 years

13 Steam Field Sustainability Redesigning for Decreased Pressure, Increased Flow Multiple Smaller Units Vs. Large Central Plants - Risk Smaller Units Vs. Larger Units - Logistics What happens when people do not listen... Summary

14 Additional Challenges for African Rift Region Re-injection still inexact, makeup water not available Infrastructure inadequate for large components Remote site locations Conclusion: African geothermal plants must be efficient, water-neutral and can benefit from small, modular designs 241 Metric Tons

15 Requirements for Maintenance 60 X 25 meter high bay 75 ton engine lathe 75 ton low speed balance machine 4 meter VTL 150 mm HBM TIG, MIG, SubArc Welding Weld Repair Bay Siemens, NC

16 Steam Field Sustainability Redesigning for Decreased Pressure, Increased Flow Multiple Smaller Units Vs. Large Central Plants - Risk Smaller Units Vs. Larger Units - Logistics What happens when people do not listen... Summary

17 Geothermal Challenges & Industry Solutions Every site is different: flow rate, NCG content, pressure, ph, prevalence of solids Improper materials selection results in early deterioration of equipment Poor damping and corrosion attack lead to corrosion-fatigue in geothermal blades Reduced material endurance strength can lead to catastrophic rotor failures. Material selection for harsh geothermal environment is critical for reliability 12Cr Cladding Erosion/Corrosion Corrosion-Fatigue Cracking IN625 Cladding

18 Geothermal Challenges & Industry Solutions Materials selection optimization is resource and turbine stage specific LP blades must be continuously coupled; HP blades must be integrally shrouded Where required, rotor surfaces must be HVOF coated or clad with 12Cr or IN625 Low stress designs in all configurations Advanced moisture removal systems throughout the turbine Proper design is critical for reliability in the geothermal environment Erosion/Corrosion Corrosion-Fatigue Cracking Continuous-coupled Blades

19 Corrosion Related Failures Prevention is the first key to availability Development of critical infrastructure and repair capability must parallel unit size the larger the generation unit, the more capital intensive repair facilities become Maintaining water treatment facilities is critical to geothermal equipment survival Corrosion related failures are often catastrophic Sophisticated repair capabilities are often half way around the globe

20 Corrosion Related Failures The first priority is always safety Missile generation is a real threat and it does not always happen to other people Low pressure turbine casings are not designed to contain internals during catastrophic failure Failure such as shown here often take years to repair this MUST be prevented

21 Steam Field Sustainability Redesigning for Decreased Pressure, Increased Flow Multiple Smaller Units Vs. Large Central Plants - Risk Smaller Units Vs. Larger Units - Logistics What happens when people do not listen... Summary

22 Summary Sustainability means cautious development, smaller units and developing maintenance capabilities in lock-step with generation development James Beverly Phone

23 Questions?

24 Disclaimer This document contains forward-looking statements and information that is, statements related to future, not past, events. These statements may be identified either orally or in writing by words as expects, anticipates, intends, plans, believes, seeks, estimates, will or words of similar meaning. Such statements are based on our current expectations and certain assumptions, and are, therefore, subject to certain risks and uncertainties. A variety of factors, many of which are beyond Siemens control, affect its operations, performance, business strategy and results and could cause the actual results, performance or achievements of Siemens worldwide to be materially different from any future results, performance or achievements that may be expressed or implied by such forward-looking statements. For us, particular uncertainties arise, among others, from changes in general economic and business conditions, changes in currency exchange rates and interest rates, introduction of competing products or technologies by other companies, lack of acceptance of new products or services by customers targeted by Siemens worldwide, changes in business strategy and various other factors. More detailed information about certain of these factors is contained in Siemens filings with the SEC, which are available on the Siemens website, and on the SEC s website, Should one or more of these risks or uncertainties materialize, or should underlying assumptions prove incorrect, actual results may vary materially from those described in the relevant forward-looking statement as anticipated, believed, estimated, expected, intended, planned or projected. Siemens does not intend or assume any obligation to update or revise these forward-looking statements in light of developments which differ from those anticipated. Trademarks mentioned in this document are the property of Siemens AG, it's affiliates or their respective owners.