Studying the effect of black powder on the production of the station

 

POWER PLANT

Studying the effect of black powder on the production of the station

Contributing factors to the increase in the cost of production of the unit of energy from the eighth station

The costs of having a blackboard problem can be summed up as follows

1. Replace the main filters.

The gas receiving station in the eighth station contains three main filter units. Each main filter unit consists of (17) filters, meaning in total (51) filters for all three main filter units. According to the manufacturer’s recommendations, one main filter unit is changed once a year, i.e. It is supposed to change (102) filters during the period from May (2002 AD) to May (2004 AD), however, in addition to the filters that were provided by the contractor, (653) filters was changed due to the presence of black powder in large quantities.

Through the previous figures, it is noted that (551) filters were changed in excess of the normal number recommended by the manufacturer. The cost of increasing the number of filters changes was calculated as follows:

Number of filters changed 551 filters

The value of one filter is 3.420 riyals

The labor cost for changing one filter is 9.8 riyals

The total increase in the cost of replacing the main filters is 1,889,821 riyals

2. Clean the main filters.

As a result of the high consumption of filters during the last period, the station worked to re-clean (5100) filters and use them again. The cost of dismantling, cleaning, and reinstalling the filters was calculated as follows:

Number of filters cleaned 5100 filters

The labor cost for dismantling, cleaning, and reinstalling the filter is 19.6 riyals

The total increase in the cost of cleaning the main filters is 99,960 riyals

3. Repair of isolating valves for the main filter units.

The black powder associated with the gas causes corrosion of some parts of the isolation valves of the main filter units and damages the gaskets, and thus the lack of sealing seals at the insulation, which made the station contract with an external company to repair the valves.

The total cost of repairing isolating valves for the main filter units is 47,550 riyals

4. The increase in the cost of fuel when operating on crude oil instead of gas.

It is noted that the cost of producing the energy unit when operating the units on gas is lower if the units are run on raw fuel, and one of the most important reasons for the high cost is the need to inject fuel additives, and this material is considered high in price, as this material reduces the impact of vanadium in the oil Raw, which has a significant effect on the hot parts of the unit.

The cost of fuel when operating on gas is 35.16 riyals / mWh

The cost of fuel when operating on crude oil is 38.15 riyals / mWh

Energy generated using crude oil 3,651,652 MWh

Fuel value when operating on gas 128,392,084 riyals

The value of the fuel when operating on crude oil 139.310.524 riyals

The total increase in fuel cost as a result of operating on crude oil 10,918,440 riyals

5. Maintenance of units when operating on crude oil instead of gas.

It is known that when the generating units are operated on gas, the inter-periods of periodic maintenance work are 1.5 times more than the inter-periods of the same works in the case of operating on crude oil.

Maintenance cost when operating on gas 4.99 riyals / mWh

Maintenance cost when operating on crude oil 7.49 riyals / mWh

Energy generated using crude oil 3,651,652 MWh

The maintenance value when operating on gas is 18,221.743 riyals

Maintenance value when operating on crude oil 27,350,873 riyals

Total cost increase as a result of operating on crude oil 9,129,130 ​​riyals

It is noted that the cost difference will increase when calculating the maintenance costs of some other equipment that is affected when using crude oil.

6. Low capacity as a result of operating on crude oil fuel.

When operating the generating units using crude oil, the decrease in the capacity of the unit reaches (5%) of its original capacity, due to the presence of deposits on the hot parts of the unit. power output in general.

The increase in the cost of energy production as a result of the reduced capacity was calculated as follows:

The cost of producing the unit of energy in the eighth station is 40.16 riyals / mWh

The cost of producing the unit of energy in the fourth station is 41.02 riyals / mWh

The increase in the energy produced from the unit as a result of operating on gas 5%

Energy generated using crude oil 3,651,652 MW

The total energy produced from the fourth station, which is supposed to be produced from the eighth station, as a result of a decrease in capacity of 182.583 MW

The increase in operational cost due to a decrease in capacity by 5% 157,021 riyals

7. Washing the units when running on crude oil fuel.

The operation of generating units using crude oil leads to deposits on the hot parts, which causes a decrease in the capacity of the generating units by approximately (5%). Carrying out washing work, which requires the operation of other units that are less efficient and more expensive in the production of the energy unit, in order to compensate for the lost energy as a result of the exit of the units for washing.

The increase in energy output as a result of washing the units was calculated as follows:

The cost of producing the unit of energy in the eighth station is 40.16 riyals / mWh

The cost of producing the unit of energy in the fourth station is 41.02 riyals / mWh

Total extinguishing hours for washing 4722 hours

Average annual unit load 44.9 MW

The total energy produced from the fourth station, which is supposed to be produced from the eighth, as a result of the washing operation, is 212,018 MW

The cost as a result of washing the units when operating on crude oil fuel is 182.335 riyals

Etc.