Power is fundamental to many projects / areas and knowing its requirement is only the start of a process. Feasibility studies are conducted to develop plant designs that meet the requirements of not only the load but also the environment, fuel source, water supply and any other government requirements. This information is used to determine a best fit solution which is then be engineered in to a budgeted feasibility study. This feasibility process is typically performed in house and with consultation with OEM’s, government bodies and the client. The end result from this may be the non-viability of the project. Typical outputs from the study would be a concept plant design, project plan, budget, water balance, electrical model and environmental footprint. This information would then be used to commence environmental approval for the project if moving forward.

Key to Gensrv’s success is its ability to start with a blank sheet of paper. With as little as a fuel specification and a desired output / availability, Gensrv are able to develop process and electrical models to specify the best fit generation solution. This work commences with the thermal modelling of the process based on the fuel composition. Either based on output or limited by the quantity of fuel the cycle conditions and main machine baselines can be determined. The data from the process model is used to create Process Flow Diagrams (PFD’s) which will later evolve to Piping and Instrument Diagrams (P&ID’s). The data from the PFD’s and Process Thermal model allow the determination of base electrical loads. When supported by best asset design practice and our IP Gensrv are able to generate the base load lists for the design. Using ETAP electrical software the Single Line Diagram’s (SLD’s) are developed to specify scope of electrical switchboards and base cable data. All of the above descried items therefore go to specify the base level of equipment and scope to meet the clients fuel and output brief.

The Gensrv team work with multiple equipment providers and vendors to establish procurement and shipping contracts that exceed the project QA standards. These sub supplier contracts will include such documentation and require such inspection to ensure the project technical and quality standards are achieved. Each equipment providers lead times are then factored in to the project plan to determine the ideal time to specify, design, procure manufacture and ship each sub system to ensure seamless cost effective construction at site.

Gensrv’s construction model utilises the minimum of subcontractors to reduce interface risk, yet provide sufficient diversity so as to not increase delivery risk. Typically works are split between Civil, Mechanical and Electrical. A detailed Division of Works (DOW) is produce to clearly define work scope. Construction is then assessed, reviewed and managed daily by engineering and contracts managers. Each sub-contracting group has its own safety representatives reporting to the overall HSE representative and site manager. Where possible the same manager is used for construction and commissioning to provide continuity through the phases to operation. All works are managed under a Project execution plan and master delivery schedule.

The team at Gensrv is always seeking new opportunity to achieve more with what is given. Our motto is that we must add value to all services we provide. Since the cost of fuel is the highest significant contributor to operation costing (OPEX). Fuel optimisation and energy waste are key areas to be addressed when looking at plant performance improvement. In some cases, the basics such as mill maintenance and condition along with PF fineness can have significant cost impacts on base fossil plants. Indicators such as stack and ash analysis assist in the determination of poor combustion and therefore fuel / cost loss. For reciprocating plants conditions such as poor atomisation of fuel through bad injectors may be a contributing factor or in gas turbines compressor cleanliness and filter condition. In all cases Gensrv will assess and monitor your asset to determine areas for improvement to give reduced costs or improvements in availability. Paramount to the process is the effective use of the maintenance dollar. GenSrv is competent with most modern Enterprise Resource Planning (ERP) packages such as SAP, Mincon MINS, MEX and can utilise these IP and history tools to streamline maintenance effort and cost. The group has Thermal and electrical modelling tools which allow the determination of optimum conditions and therefore determination of loss. Why not add these impacts to your Human Machine Interface (HMI) so that staff see the real impact of operating off design.

In some cases, the method of operation by the grid system and the application of spinning reserve has a detrimental impact to heat rate and therefore cost. It is therefore imperative the spinning reserve is best managed to utilise the most cost effective assets to provide such service. In short know your Short Run Marginal Cost (SRMC).

Understanding what it takes to construct and operate each type of power plant places Gensrv in an ideal position to develop long term financial models to assist our clients in determining suitability of assets or identify areas of concern. Data is collected and managed for each area of revenue and expense and a revenue is conducted of plant condition along with expected costs likely to be incurred in the future. This can all then be placed in a financial model for long term.

Having a vast experience in plant design, delivery operation and compliance puts Gensrv in an ideal position to perform due diligence studies on existing assets to ensure our client’s financial positions are protected. The team will look closely at the plant design, current operation and maintenance strategies and off takes and commitments to determine any adverse impact in the known financial modelling. We are also able to determine net worth of assets to assist procurement and construction based on similar strategies to those detailed above. of generation cost and viability.

In the majority of cases power facilities are financial entities to earn their shareholders a return on investment. Initial cost and return is done as part of the assets capital cost model calculations. Post-delivery of the asset it is paramount that the facility is transitioned to an operational asset at minimum cost and in the fastest time. Key drivers in the early life of the project are warranty tracing and works along with OEM recommendation and compliance to protect such warranties. As time moves on these practices need to be modified to reflect the actual requirements of the system as a whole. For that reason, maintenance often moves to being condition based. Key equipment in this process are plant ERP maintenance management systems. Gensrv has installed and set up a number of these software packages to track not only preventative and defect works but also manage spares holdings and capital upgrades.

Other aspects of business optimisation focus on system requirements. For example, grid system and island system are quite different in both operating dynamics and revenue return. Gensrv strives to understand a client’s entire business and ensures value addition by focusing on the areas of loss, inefficiency or waste.

With years of experience Gensrv can take a green field asset and develop all the plans, procedures and policies required for its operation over the proposed lifecycle and supply, customise and propagate the plants ERP system. We are also able to supply skilled staff to manage assets of different designs and are always keen to negotiate performance based O&M contracts with our clients. Gensrv uses methodologies such as condition based assessment, incluiding borescope investigation to ensure our maintenance costs are reduced year to year excluding known CAPEX expenditure. With regard to brownfield assets and following due diligence the existing methodologies can be reviewed and any improvements identified and ratified then implemented. In all cases the key drivers are O&M cost in relation to delivering the facility generation warranties to clients and their upstream commitments.

Key to any group is the staff within that group. All Gensrv staff are used to working with local teams and where required transferring knowledge and know how. Underpinning this is the ability to hold training and education courses for asset owners on all aspects of operation and maintenance as well as asset management and business process. With courses based on engineering / business foundations we are able to tailor each subject to a client’s specific hardware or system.

For our Operation and Maintenance contract Gensrv employs a system of “Competency Management” as experience has dictated that multiple short courses with written and oral exam serve much better to impart knowledge than one of block sessions. The Gensrv “Power Competency” suite of training modules is tailored to advance most staff in the areas of power facility business and engineering / operations management.

On some occasions Gensrv acts as the clients or EPC’s local engineering and project delivery provider. Such cases occur where large international firms are not 100% conversant with Australia and PNG’s codes / Standards. Or sometimes they require a local company to manage the local content of the job or project. In these cases, Gensrv works with bespoke project execution plans accompanied by Primavera scheduling and EPC delivery reporting. Supporting system include Human Resources, HSE and Quality management and supply.

Gensrv has also at times acted as an owner’s engineer or banks engineer to ensure the EPC contract documents requirements are achieved. This work often extends beyond the written EPC contract to best practice HAZOP study development and solutions engineering / delivery. For example, verification of maintainability at a client’s asset or simple items like commonality of parts.

Our primary goal is to ensure the wellbeing of our employees, third parties and the environment. Everybody has the right to work and return safely at the end of each day. Gensrv has a set of established Health and Safety policies forming a framework to ensure the company strives to achieve zero hard to everybody directly and indirectly impacted by its operations. Safety starts from when we wake and is the responsibility of everybody. Gensrv’s health and safety framework of documents sets the minimum standard for Gensrv and its employees to work under. This HSE framework is continually reviewed and improved and forms the backbone for all new projects. On every occasion Gensrv embarks on a new project the risks specific to that project are evaluated and extended in to the deliverable project health and safety plans.

As part of project development environmental constraints are set by the governing body’s which determine the impact during the life stages of the project ranging from construction through to decommissioning. These standards form the minimum for all parties working on the project and their reporting is performed in accordance with government requirements. Environmental concern and sustainability is a further mandatory compliance that the Gensrv team lead to promote. When developing asset plans for new equipment there impact on the environment is critical to project success and permitting. Even the smallest polluting droplet of oil needs to be cleaned and managed. Housekeeping goes a long way to ensuring a safe and environmentally friendly workplace. Each project undertaken has a specific environmental policy written to capture the unique challenges for each aspect of that project.