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Power – Challenges, difficulties and experiences

Power – Challenges, difficulties and experiences. November, 2012. CPO of Qatalum, Steve Davison. Qatalum power supply - in a nut shell. Design philosophy Captive power plant, designed for island operation Generating capacity according to smelter demand plus one generating unit in spare

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Power – Challenges, difficulties and experiences

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  1. Power – Challenges, difficulties and experiences November, 2012 CPO of Qatalum, Steve Davison

  2. Qatalum power supply - in a nut shell Design philosophy • Captive power plant, designed for island operation • Generating capacity according to smelter demand plus one generating unit in spare Operating philosophy • Power plant generates the power to the smelter and zero import • 99.95% of the time in grid connected mode • Summer operation with 6 generators, maintenance during winter Organisation • Operation and maintenance of Power Plant + HV: 100 employees • Administrative resources shared with the smelter Agreements • Grid and emergency agreements with the grid operator Kahramaa • Gas agreement with QP (Qatar Petroleum)

  3. Fuel Gas Steam Turbine 13 LP LP Genr Genr ~ ~ ~ ~ Genr Genr Genr HP HP GT GT GT GT HRSG HRSG HRSG HRSG ~ ~ Cooling Water System Condr Condr SW Make-Up SW Blow Down to Fume Treatment Steam Turbine 2 Cast House 220kV GIS 400kV Grid Interconnection Carbon Plant 33kV Distribution Rectifiers Qatalum Power Supply - Asset Overview GT11 GT12 Steam Turbine 23 Genr GT21 GT22

  4. 9th August 2010 incident Incident • Early morning of 9th August, a grid system detected earth fault lead to a complete black-out of the Qatalum facility • After approx. 3.5 hrs the smelter loading could commence • Long power outage and unstable smelter reasons for smelter freeze Effects on the power plant • Smelter ramp-up stopped • Power Group concentrates on rectification and commissioning of the steam cycle • End August 2011 power plant handed over to Power Group Improvements • Several investigations suggested improvements • Two large projects – 2nd ICT and 11kV modification

  5. Cooling Tower fire - early morning 17th March

  6. Cooling Tower rebuild Rebuild • Same cooling tower (SPIG) • Foundation and basin re-used • Fire protection will be implemented Status • Installation complete Nov 2012 • Fire protection to be installed 3Q 2013

  7. Reliability of the current power supply Gas Turbines Generators • Particular high reliability since CT fire • Dusting problems on two GT generators • Steam Turbines • Both successfully returned to service after cooling tower fire • Power Management System (PMS) • Improvements to be implemented • Interconnector, HV & Rectifiers • Second interconnector by April 2013 • First ICT so far no reliability issues • Strong focus on reliability and minimal downtime • Fuel Supply • Second gas supply pipeline commissioned 7 24 August 2014

  8. Thank you شـــكراً

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