Wärtsilä engines at your plant? Learn from AES Levant’s experience – Combined Cycle Journal

Wärtsilä engines at your plant? Learn from AES Levant’s experience

AES Levant Power Plant

Owned by AES Corp, Mitsui, and Neberas Power
Operated by AES Levant Holdings BV Jordan
250 MW, tri-fuel peaking facility consisting of 16 Wärtsilä 18V50 diesel/generators located in Al Manakher, Jordan
Plant manager: Feras Hammad

Protect waste-gate actuator from heat damage

Challenge. Function of the waste gate is to control the air/fuel ratio when burning natural gas in the peaking plant’s diesel engines. Problem faced by plant staff: The waste-gate actuator (Fig 1) was prone to a controls failure caused by heat coming from a damaged bellows near where the waste gate is located.

Solution. Insulate the waste-gate actuator from the heat coming from the engine’s exhaust-gas system. Do this by designing and fabricating an insulation jacket designed for use at up to 500F. Final step: Cover the waste-gate device with the fabricated jacket (Fig 2).

Results. Project goals of reducing maintenance man-hours and cost, and improving plant availability and reliability, were achieved. The saving during 2022 was about $28,000.

Project participants:

Amer Manaseer
Mohammad Abu Hayja

Isolate SCR control-air system to prevent a plant trip

Challenge. The 100-psig control air system for Levant’s SCR is equipped with several leak-prone flexible rubber hoses. Should a leak occur, the plant could be at risk of tripping offline because of low control-air pressure.

Solution. Several possible solutions were evaluated for the effort involved in their implementation and effectiveness. The alternative selected: Install a shutoff valve with a pressure switch in the compressed-air pipe feeding the SCR system to cutoff air at the SCR if leaks occur in the system. Keep a sufficient amount of control air flowing to keep the plant running smoothly until permanent repairs can be made.

Results. Saving in 2022 was estimated at $16,000, more than twice the $7700 cost of the improvement.

Project participants:

Mazen Alamro
Mohammad Jaradat
Ibrahim Arori
Ahmad Bani Hani

No instructions for servicing fuel-oil injectors, no problem

Challenge. Fuel-oil injectors on Levant’s recip engines were failure-prone. There were several reasons for the poor performance, but the problem facing plant personnel was the absence of service instructions from the manufacturer. Undaunted, staff set about developing a project to reduce maintenance and shipping costs.

Solution. Several steps were involved: Dismantle the injectors with special tools designed and fabricated in-house, cleaning and servicing the solenoid with a special cleaner (Figs 3 and 4), bench testing the injectors more than 20 times, and verifying injector performance in the engine.

Results. All objectives were met: (1) Performance of serviced injectors was as good as that achieved with new injectors. (2) Maintenance saving in 2022 attributed to servicing injectors using plant personnel was about $170,000.

Project participants:

Dhanapalan Thangadurai
Ahmad Bani Hani
Abdullah Dabaybeh

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