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The Asset Integrity Journey of Uniper’s Grain CHP add energy’s partnership with Uniper’s Grain CHP in the pursuit of enhanced asset integrity and performance

add energy asset and integrity management partnered with Uniper’s Grain CHP site in 2010 in an ongoing asset integrity mission to help optimise the safety and performance of their assets . Uniper is one of the world’s largest power and gas companies spanning across Europe, Russia, and North America. Uniper’s diversified business consists of renewables, conventional and dezentralized power generation, natural gas, energy trading, retail and distribution; supplying 26 million customers with energy.

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With a strategy of cleaner & better energy Uniper aims to be a global provider of specialized energy solutions. To help achieve this, add energy have and continue to apply a number of Asset Integrity and Maintenance Optimisation Services that have enabled Uniper’s Grain CHP to enhance their asset’s efficiency and performance.

The initial contactUniper received a recommendation from another client following the successful Integrity Solutions that add energy had applied to their company. We were personally recommended on how we could assist the integrity, safety and performance of Uniper Grain’s Combined Heat and Power (CHP) Plant.

In December 2010, add energy successfully delivered its first integrity improvement project to Uniper’s Grain CHP - Identification of Safety Critical Equipment (SCE) and Equipment Criticality. This involved creating equipment types, identifying SCE’s and establishing a set of Performance Standards. The deliverable enabled Uniper’s team at Grain to measure reliability of equipment more efficiently, prioritize work and build equipment based maintenance strategies; all enhancing the plants integrity and performance.

Work that followedFollowing the success of the first project, in August 2011, add energy Asset and Integrity Management were chosen to do a Maintenance Build of the entire Grain CHP plant, this project was delivered within a short time span due to the pressure of an impending start up resulting from the expectation that the turn-key project would deliver maintenance for start-up. add energy utilised the maintenance library and incorporated the written scheme of examination and original equipment manufacturer documents to construct the maintenance build. This strategy enabled the planning and prioritization of maintenance strategies to be optimized and a maintenance system to be developed for the plant that could predict budget requirements two years in advance.

Over the next two years, Uniper’s Grain CHP mandated add energy for an additional four projects.

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Reviewing equipment A Spares Criticality Review was also executed alongside the Maintenance Build, this project consisted of reviewing data collection logging, identifying systems requiring critical spares, reviewing vendor documentation, conducting a risk assessment and removing systems with critical spares that did not require critical spares. Identifying critical spares gave Uniper’s Grain CHP additional efficiency in inventory management, storing only critical spares. Critically, periods of downtime were reduced as a result of spare part access.

In November 2011, add energy engaged in a lubrication review, this included a review of the lubrication schedule proposed by the lubrication manufacturer. The project team identified key areas for improvement and produced an optimised lubrication schedule based on a Failure Mode, Effects and Criticality Analysis (FMECA). This reduced the maintenance cost and intervention by one third, while insuring that all valves were exercised at optimal frequency.

A Verification of theAs Built PlantA Desktop Asset Verification and a Physical Asset Verification were conducted on Grain CHP in 2013. The findings gained through these projects provided Uniper with a clear snapshot of the current state of their Plant. Using the asset register to verify that what was in the Plant Drawings (P&IDs) were also on the Plant meant that add energy were able to optimise the asset register by identifying issues requiring correction, adding new pieces of equipment and grouping equipment based on object type or criticality. Optimising the asset register in this way means that it becomes more accurate and efficient, allowing maintenance activities to be prioritized, maintenance costs to be estimated more accurately and therefore budgeted for, and smarter and quicker decisions regarding maintenance to be made.

Uniper Grain CHP

Uniper Grain CCGT

Project: SCE Equipment Criticality and Data Improvement

Project: CHP Maintenance BuildCHP Spares Criticality

Dec 2010

Project: CHP Lubrication

Project: CHP SCE

andEquipment Criticality

Project: CHP DAV

Uniper CorporateProject: Maintenance Strategy and Development of Corporate Performance Standards

Uniper Ratcli e

Project: DAV and Criticality

FUTURE SCOPEProjects: AS Built, RCA and SAP Upload

Aug 2011 Nov 2011 Feb 2013 Sept 2013

2014

Dec 2011

InitialContact

Ratcli�e-on-Soar is one of the most e�cient coal �red power stations in the UK. With a total generation capacity of 2,000MW from four 500MW units, it produces enough electricity to meet the needs of approximately 2 million homes.

The CHP has the capacity to transfer up to 350MW of heat energy providing massive environmental bene�ts by reducing carbon dioxide from the LNG terminal by up to 300,000 tonnes per year. The CHP circuit raises the overall plant e�ciency from 58% to circa 73%, depending on the amount of heat exported.

Grain Power Station is located in North Kent on the eastern end of the Hoo peninsula, at the point where the Rivers Medway and Thames meet. Grain CCGT consists of three single shaft units which are capable of generating up to 455MW of electricity giving a combined total of 1365mw.

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Uniper Grain CHP

Uniper Grain CCGT

Project: SCE Equipment Criticality and Data Improvement

Project: CHP Maintenance BuildCHP Spares Criticality

Dec 2010

Project: CHP Lubrication

Project: CHP SCE

andEquipment Criticality

Project: CHP DAV

Uniper CorporateProject: Maintenance Strategy and Development of Corporate Performance Standards

Uniper Ratcli e

Project: DAV and Criticality

FUTURE SCOPEProjects: AS Built, RCA and SAP Upload

Aug 2011 Nov 2011 Feb 2013 Sept 2013

2014

Dec 2011

InitialContact

Ratcli�e-on-Soar is one of the most e�cient coal �red power stations in the UK. With a total generation capacity of 2,000MW from four 500MW units, it produces enough electricity to meet the needs of approximately 2 million homes.

The CHP has the capacity to transfer up to 350MW of heat energy providing massive environmental bene�ts by reducing carbon dioxide from the LNG terminal by up to 300,000 tonnes per year. The CHP circuit raises the overall plant e�ciency from 58% to circa 73%, depending on the amount of heat exported.

Grain Power Station is located in North Kent on the eastern end of the Hoo peninsula, at the point where the Rivers Medway and Thames meet. Grain CCGT consists of three single shaft units which are capable of generating up to 455MW of electricity giving a combined total of 1365mw.

What does 2014 hold for Uniper CHP? As part of the work that add energy do in

partnership with Uniper, we analyse their needs

and provide them with a bespoke selection of

services that we believe will better improve their

asset’s integrity along with its performance.

To achieve this objective, add energy have proposed three new scopes; a Root Cause

Analysis, SAP Upload and Red Line drawings that are due to commence during 2014.

Overall Value for UniperThe deliverables that add energy has provided Uniper’s Grain team with over the past three years have had a significant effect on Safety, Integrity and Performance. Most critically: safety and reputation through assurance of hardware barriers are being managed and controlled at an optimal level – allowing Uniper the permit to work system to be safely applied. Uniper now have Optimised Maintenance Strategies, increased budget clarity, the ability to predict future costs, contingency planning and reduced downtime due to unplanned maintenance. æ