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Gas Turbine
Maintenance
Strategy
OEM LTSA, In House, or Hybrid?
PETER SOUTH, WORKSTREAM LEAD GTSO AND GENOPS
16TH AUSTRALIAN GAS TURBINES CONFERENCE
25 – 26 NOVEMBER 2015
MENZIES HOTEL, SYDNEY
Gas Turbine Overview
KALGOORLIE GAS TURBINE STATION – 63MW
WKGT2: 38MW, distillate fuel only, synchronous
condenser.
WKGT3: 25MW, distillate fuel only, synchronous
condenser, black start.
KWINANA POWER STATION
KwGT: 20MW, dual fuel, black
start.
KWGT2&3: 2xLMS100 dual fuel
100MW
Cockburn: 1 Alstom GT13E2
Combined Cycle, gas only, 240MW
GERALDTON GAS
TURBINE STATION
GGT: 20MW, distillate fuel
only, black start.PINJAR GAS TURBINE STATION – 584MW
PJ1: 38MW, dual fuel, synchronous condenser
PJ2: 38MW, dual fuel, synchronous condenser
PJ3: 38MW, dual fuel, synchronous condenser, inlet fogging, black start
PJ4: 38MW, dual fuel, synchronous condenser, inlet fogging
PJ5: 38MW, dual fuel, synchronous condenser, inlet fogging, black star.
PJ7: 38MW, dual fuel, synchronous condenser, inlet fogging
PJ9: 116MW, gas fuel only, inlet fogging
PJ10: 116MW, gas fuel only, inlet fogging
PJ11: 124MW, gas fuel only, inlet fogging
MUNGARRA GAS TURBINE STATION – 114MW
MN1: 38MW, gas fuel only, synchronous
condenser.
MN2: 38MW, gas fuel only, synchronous
condenser.
MN3: 38MW, gas fuel only, synchronous
condenser.
G
Kw
KalP
M
Synergy Strategy
Maintenance
StrategySpares Supply
Industrial OCGTS (F5, F6, F9)
Totally in house
Competitive supply from OEM and proven 3rd
party suppliers
HEGTs(LMS100)
Hybrid: Gas Turbine/Generator:-OEMBalance of Plant (BOP):- in house
OEM
CCGT(GT13E2)
Routine maintenance in houseOutages OEM LTSA
Exclusive OEM
Synergy Strategy
– Industrial OCGT
Rationale
GE Frame type gas turbines
are well established mature
technology with decades
of operating history
Synergy has been
operating and maintaining
the fleet since late 1980s
We have maintained
continuity of technical staff,
and have succession
planning in place
Competent, proven 3rd
party suppliers are plentiful
Synergy Strategy – Industrial OCGTMaintenance Practice
OEM recommendations adjusted in view of operating
experience
Small, highly experienced technical team
Contract labour for peak work
Condition monitoring
Oil and water sampling
Monthly, quarterly and annual checks
Vibration surveys
Themography
On-line PD monitoring
Implementing reliability centred maintenance
Synergy Strategy
– HEGT (LMS100)
Rationale
New technology; first
commercial operation in
Australia
Synergy has limited experience
in aero derivatives, and no
experience in LMS100
Synergy has extensive
experience with BOP or similar
plant
3rd party suppliers are non
existent
Synergy Strategy – LMS100Maintenance Practice
OEM Contract Service Agreement (CSA) for ‘covered
unit’
Turbine
Intercooler
Generator
CSA covers routine maintenance, scheduled
borescope inspections and scheduled hot section
exchange
Balance of Plant (BOP) maintained ‘in house’ with
contractor support for trade labour during outages
Synergy Strategy
– CCGT (GT13E2)
Rationale
Little internal expertise for
outage work
Experienced operators and
maintenance staff available for
training
3rd party component suppliers
are emerging but not yet
widely established
Synergy Strategy – GT13E2Maintenance Practice
OEM Long Term Service Agreement(LTSA) for outages
and spares supply
Local contract labour for outage support
Operator/Maintainer model for routine maintenance
and breakdown response
In house engineering expertise for outage quality
assurance and coordination
Actively exploring alternatives for end of LTSA term
Gas Turbines Users Forum (GTUF)
Development of third party spares supply
Developing in house capability
Ideal:
Involve technicians and engineers in construction and
commissioning
Work beside OEM during initial maintenance period
Succession planning and traineeships
Or:
Direct recruit experienced staff from market
Succession planning and traineeships
Outcomes: - Reliability
Spike YTD in 2014/15 due to a F5 on
extended outage pending retirement
decision; rest of fleet below 1%
There is no significant difference in reliability
between GT13E2 (LTSA) and OCGT fleet (in
house). Both below 1% since 2010.
Cost
Comparison
For Frame machines, in house
outage cost about half OEM
Start cost (maintenance) for
GT13E2 about 6 times that of F9
(but comparing OCGT with
CCGT)
Competitive supply
dramatically reduces
component and refurbishment
cost
There is a fixed cost in
maintaining internal expertise
Other things
to think
about
In house expertise guarantees
undivided attention
In house expertise makes you
an informed operator
Is your fleet big enough?
What is the OEM ‘list price’ of a
component?
LTSA/CSA gets better response
from OEM
Be careful about incentives
and penalties
Sometimes, the OEM will be as
baffled as you are
Maintaining relationship with OEM
Put yourself in the shoes of your local OEM rep
Look for win/wins
Take advantage of upgrade opportunities if they fit your business
drivers
Keep your door open
SOWhat is the
best strategy???
I Don’t Know
It all depends
The size of your fleet
The diversity of your fleet
New technology or mature technology
Your business drivers
Your in house capability, and your appetite to develop it
Where you live
Your workforce stability/turnover ratio
Peter’s O&M Strategy Ready Reckoner
Technology Maturity
In house capability
In house
OEM LTSA or CSA
In house/ OEM hybrid
IIn house/ third party
hybrid
Third party or OEM LTSA/CSA
Thank You
After November 2015
