power plant losses - examples from pakistan mansoor ali khan general manager hamid mukhtar &...
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Power Plant Losses -Examples from Pakistan
Mansoor Ali Khan
General Manager
Hamid Mukhtar & Company (Pvt) Ltd.
Karachi Insurance Institute
December 4th 2012
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Outline
1. Introduction to Power Plants
2. Common Types of Failures
3. Examples of PP Losses 2007-2012
4. Concluding remarks
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‘A good presentation should be like a mini skirt. Short enough
to arouse interest and long enough to cover the subject’
TED
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Accidents don’t happen – They are caused
That’s why loss adjusters have jobs!
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Power Plant Prime Movers
Steam Turbines
Gas Turbines
Hydro Turbines
Wind Turbines
Internal combustion engines
Solar Photovoltaic cells
Nuclear Reactors
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Common Causes of Failure
Gas, Steam & Hydro Turbines Ruptures, High Cycle Fatigue, Blade failures, Design failures
Wind turbines Lightning, Electrical Fires, Gearbox failures, Remote locations
IC Engines
Overheating, Lubrication failure, High speed equipment (Turbochargers), Fire
Generators Ruptures, Short circuits, Explosions, Fire
Transformers Explosion, Fire ,Insulation failures
Boilers Explosion , Fire
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Business Consequences
Reduces capacity available to Grid
Delays in construction
Loss of revenue
Delayed startup
Business Interruption
Losses to Insurers / Reinsurers
Impact on Renewal Premiums
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Power plant Losses in Pakistan 2007-2012
IPP Gas Turbine Compressor Blade & Shaft damage – MBD/ BI
Faulty design of air intake filter system. Blade fouling and damage to 9 stages
Property damage & BI Claim US$ 10.5 m
IPP HFO Diesel Generator – Alternator Damages – EAR/ DSU
Design fault in Alternator Base foot design
COD delayed 6 months
Loss paid under Warranty by OEM
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50 Mw Wind Power plant under construction
Turbine Rotor blade damaged due to sudden wind/ rainstorm.
Turbine Rotor assembly damaged during lifting operation for mating with Nacelle
on Mast
730 Mw Steam Turbine Plant
Plant site submerged due to overflow from breached irrigation canal during
heavy rains
Property damage and BI Claim US$ 50 m
Power plant Losses in Pakistan 2007-2012
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130 Mw Hydel Power Project - Flood Loss
2 Project sites – Weir Site and Power house
Connected by 9 tunnels
Loss occurred due to unprecedented rainfall and flooding in July 2010
Claimed loss Rs 2.3 billion (US$ 28.75 m)
Still not restored eg. Tunnels blocked with debris
Many Local and Chinese Workers buried under debris
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Weir Site
Power House Site
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Weir Site - before flood
Camp Site
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Weir Site, Stilling Basin and Campsite washed away
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Powerhouse building
Covered with debris
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Stilling basin Filled with debris
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Power House CampsiteBuried Under Debris
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Tunnel exit Exit blocked by Debris
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IPP CC Gas Turbine Rotor damage – EAR / DSU
Rotor blades, Stator Vanes, Rotor shaft damage
COD delayed 120 days
Property damage Claim US$ 17.5 m
DSU Claim US$ 3.1 m
Human Error during commissioning
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GT-1 Control Cabin GT-2 Control Cabin
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Thrust collar Rotor Blades
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Damaged Rotor blade tips
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Damaged Stator Vanes
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IPP Steam Turbine Rotor damage – MBD/ BI
Metal chipped off Bearing thrust collar journal
Property damage – Within deductible
Business Interruption Claim US$ 400 k
Out of service 95 days
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Chipped of metal from Steam turbine rotor bearing thrust collar
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Hydro Power Flood Loss
Run of the river Hydro Power project 96 MW being constructed on the
Indus River.
Overtopping of Coffer Dam
Turbines, Generators, LV and HV switchgear, Panels etc. were submerged
in Water for many days.
Property Damage claim is approx. USD 55 million
No DSU cover
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Unopened equipment submerged
Unopened equipment submerged
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CC Gas Turbine IPP
175 Mw IPP - 120.9 Mw Gas Turbine & 64.2 Mw steam turbine
Recurring combustion nozzle damages during commissioning
Cause was unsuitable specifications of Fuel gas
LEG 3/96 cover was available – Design faults covered
COD delayed by 13 months
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Burnt nozzle assembly Nozzle cover damaged
Damaged flow sleeve
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Lessons to be Learnt
Return period basis needs to be reviewed Safe Storage of equipment and materials during erection Periodic risk surveys during Construction & Operations Awareness of LEG coverage Awareness and understanding of DSU/BI basis for assessment Use of specialists to assist with complex losses Creating shared inventory pool of critical equipment Owners investing in HR training and development
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THANK YOU