Harvey Jairaj, Engineering Manager, Eskom Holdings Limited, South Africa

18 - 22 May 2009CTICC, Cape Town,

SOUTH AFRICA

Smart power choicesfor Africa

18 – 22 May 2009, CTICC, Cape Town, SOUTH AFRICA

CONTENTS

•Introduction•Mothballed durations of Units•Camden Vote•Highlights•Lowlights•Lessons learnt•Questions

18 – 22 May 2009, CTICC, Cape Town, SOUTH AFRICA

Camden Power Station is situated near Ermelo in South East MpumalangaStation was commissioned in April 1967 and the last of eight units was commissioned in 1969 The plant was mothballed during 1985 to 1989 and returned to service (RTS) over the period March 2005 to September 2008 in order to satisfy future electrical energy demands

Introduction

18 – 22 May 2009, CTICC, Cape Town, SOUTH AFRICA

Eskom has set itself the target of achieving for Camden Power Station an availability of91% in the long term, based on 6% outage for planned maintenance and 3% for unscheduled outage. The planned RTS Station overall performance parameters are stated as:•98 x 200MW capacity Units (190MW S/out)•9Minimum annual load factor 25%•9Operating Regime is Load Following•9Unit Capability Factor (UCF) Winter 90%•9Unit Capability Factor (UCF) Overall 85%

Intro Cont.

18 – 22 May 2009, CTICC, Cape Town, SOUTH AFRICA

Camden Power Station (1600 MW)Consist of 8 x 200 MW units First unit commissioned in 1967Last unit commissioned in 1969Mothballed during 1990’s

Return To Service (RTS)Capacity constraints Engineering phase on site started mid 2002First unit 6 successfully RTS on 16 July 2005

Intro Cont.

18 – 22 May 2009, CTICC, Cape Town, SOUTH AFRICA

Mothballed Periods of Units

15.518-May-0605-Dec-908Camden

14.931-Oct-0505-Dec-907Camden

14.331-Mar-0501-Dec-906Camden

15.803-Sep-0604-Dec-905Camden

17.022-Jan-0701-Feb-904Camden

17.016-Jul-0727-Jul-903Camden

18.031-Jan-0801-Feb-902Camden

18.303-Jun-0801-Feb-901Camden

Years off loadRTS synch

dateActual Start

DateUnitStation

15.518-May-0605-Dec-908Camden

14.931-Oct-0505-Dec-907Camden

14.331-Mar-0501-Dec-906Camden

15.803-Sep-0604-Dec-905Camden

17.022-Jan-0701-Feb-904Camden

17.016-Jul-0727-Jul-903Camden

18.031-Jan-0801-Feb-902Camden

18.303-Jun-0801-Feb-901Camden

Years off loadRTS synch

dateActual Start

DateUnitStation

18 – 22 May 2009, CTICC, Cape Town, SOUTH AFRICA

Original Vote2003 was R4,029 Billion

Revised Vote 1June 2006 was R5,204 Billion

Current revised vote 2December 2007 is R6,061Billion

Camden Vote

18 – 22 May 2009, CTICC, Cape Town, SOUTH AFRICA

Successfully commissioned all 8 units. 8 units are out of its defects period Availability and reliability of commissioned units have improvedUnit 8 broke all previous non commercial and post commercial run records without tripping. (97 days)Relationship between CED and GX has improved and is good

Highlights

18 – 22 May 2009, CTICC, Cape Town, SOUTH AFRICA

Highlights Cont.

No fatalities recorded on the whole project Better understanding of the Grid Code requirementsHighly skilled and experienced staff available for other CED projectsCED and contractors achieved 2m DI free man hoursNo major incidents recorded

18 – 22 May 2009, CTICC, Cape Town, SOUTH AFRICA

Work stoppage from Inspector Of Machinery High percentage of rework in certain areasNot meeting contractual key dates on all unitsLP rotor resonance problemsToo many unit trips and forced outagesPoor workmanship in certain areasWet coal, fines and poor qualityPoor Unit availability and reliability

Lowlights

18 – 22 May 2009, CTICC, Cape Town, SOUTH AFRICA

Lack of Quality ControlGood quality structures and processes are in place. However, the processes are not being followed due to:

• QC staff lack certain skills on Plant• Lack of supervision• Bad planning • Discipline issues• Poor housekeeping

Lessons Learnt

18 – 22 May 2009, CTICC, Cape Town, SOUTH AFRICA

Lack of Quality ControlToo many plans:

• Contractor• Project Management Plans• High Level Plans

Quality should not be sacrificed due to time constraintsBe very careful when selecting contractors -reference checks

Lessons Cont.

18 – 22 May 2009, CTICC, Cape Town, SOUTH AFRICA

Project PlansCreate one realistic fully integrated planCommercial process to be geared for project planProject Plan should be centered around P&ID and Single Line DiagramsProject Plan must be inter-phased between different disciplinesPlan needs to be accepted by Project

Lessons Cont.

18 – 22 May 2009, CTICC, Cape Town, SOUTH AFRICA

Project PlansManagers, Commissioning and PlannersMechanical should be leading discipline per system and co-ordinate all inter-phasingInter-phasing meetings should take place between the different Project Managers and Commercial DepartmentRisk assessments to be done for changes in scope of work

Lessons Cont.

18 – 22 May 2009, CTICC, Cape Town, SOUTH AFRICA

Procurement ProcessNot quick enough for project environmentProject plan to be aligned to commercial processPoor quality of reports due to a lack of trained buyers and bad planningAppoint experienced and skilled buyers A.S.A.P to overcome shortage

Lessons Cont.

18 – 22 May 2009, CTICC, Cape Town, SOUTH AFRICA

Scope of WorkScope of work to be determined ASAP for contractingContractors should come to the party right from the start to assist in drawing up scopesPoor scopes of work due to costsChange in SOW to be officially documented

Lessons Cont.

18 – 22 May 2009, CTICC, Cape Town, SOUTH AFRICA

Lessons Cont.

TeamworkCED and Generation to have common objectivesShared performance appraisals (CED)-Reliability issueCelebrate milestones togetherMixed workgroups CED & CamdenMulti-disciplinary groups

18 – 22 May 2009, CTICC, Cape Town, SOUTH AFRICA

Lessons Cont.

InterfacingProject managers to ensure proper co-ordination between departments, disciplines and contractorsLack of co-ordination between project planning, contract planning and commissioning planning

18 – 22 May 2009, CTICC, Cape Town, SOUTH AFRICA

Lessons Cont.

LEADERSHIP (PROBLEMS)Encourage interdepartmental teamworkLeadership to capitalize on opportunities to develop staffEnforce basic disciplineLate for meetingsNo commitmentNon compliance to proceduresDevelop strategies to prevent high staff turnover

18 – 22 May 2009, CTICC, Cape Town, SOUTH AFRICA

Lessons Cont.

Lack of Philosophies, Operating Procedures, Maintenance & Technical StandardsProduction and technical services to be involved in developing philosophies, operating procedures, maintenance & technical standardsPoor interpretation of above due to a lack of training/experienced operatorsOperating and maintenance manuals to be available before Commercial operation of unit

18 – 22 May 2009, CTICC, Cape Town, SOUTH AFRICA

Lessons Cont.

SAFETYEnforce discipline amongst contractors to ensure good housekeepingDeal harshly with non conformanceMake provision for adequate lighting when boards are worked onImprove quality of safety inductionEnsure adequate persons are authorized in terms of Plant Safety RegulationsAuthorizations in terms of RP and AP to be part of performance contracts

18 – 22 May 2009, CTICC, Cape Town, SOUTH AFRICA

Lessons Cont.

CommunicationEncourage one to one communication –not E -mailsJoint communication to respective organizations ( CED & GEN)User Requirement SpecificationURS to be interpreted and used in the spirit that both divisions are part of Eskom HoldingsBoth parties to make an effort to understand the URSUse URS as a minimum guide

18 – 22 May 2009, CTICC, Cape Town, SOUTH AFRICA

Lessons Cont.

Configuration management vs. document managementPreservation of documents during the next mothballingLack of documents ( history) during the start –up of projectsInclusion of design Review process in design phaseGrid code compliance process and interface with key playersEngineering change management

18 – 22 May 2009, CTICC, Cape Town, SOUTH AFRICA

Lessons Cont.

Scope creep, cost creep and engineering costs Quality control early in the projectCommunication ( Interface) with all stakeholders – interdepartmental and external partiesEverybody should be involved in the scope freezeMods close out processElectro – mechanical interface

18 – 22 May 2009, CTICC, Cape Town, SOUTH AFRICA

Questions

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