SOAPP-CT O&M Cost Estimator

Updated product provides framework for estimating gas turbine plant O&M costs

Advancing combustion turbine and combined cycle technologies present a major challenge to those responsible for estimating O&M costs during the early stages of project development. In addition, project developers are faced with varying requirements between manufacturers and the impact of different operating modes. This software from EPRI provides a platform for users to work through many of the issues associated with the estimation of O&M costs.

The software tool is comprehensive in scope and can be used for a variety of purposes.  For instance, the type of operating duty has a significant impact on maintenance cost. For peaking service the number of starts generally controls the frequency of major maintenance activities while the maintenance frequency of base load units is governed by the number of fired hours. The type of service and the number of units on site also impact staffing decisions.

The SOAPP-CT O&M Cost Estimator provides the framework and cost items to determine O&M costs for specific plant equipment configurations and duty cycles. The user specifies key inputs such as CT manufacturer, cycle type, duty cycle, and plant net output, and then either accepts a series of default values or provides specific inputs for detailed cost categories. Maintenance costs for heavy-duty combustion turbines is based on a "bottoms up" approach, identifying components with repair and replacement costs and life estimates. Inspections/overhaul events are timed based on user-assigned operating scenarios. Maintenance intervals and costs for steam turbines and generators are also estimated but on a more generic basis.

Risk mitigation input options include original equipment manufacturer (OEM) extended warranty, maintenance contract (i.e. LTSA), boiler & machinery breakdown insurance, property insurance, and business interruption insurance.  The user may also choose from several optional Monte Carlo simulation options.

The spreadsheet generates a cash flow projection of O&M costs for use in a pro forma financial analysis, and provides both a present value and annualized analysis of costs, with and without risk mitigation alternatives. Scheduled maintenance outage rates and cost data for the heavy-duty models GE 7FA, 7F.04, 7F.05, 7EA, 6B, 6FA, 9FA, 9E, Alstom GT11N2, GT13E2, GT24, GT26, Siemens W501D5A, W501F, W501G, SGT6-5000F, SGT5-8000H, SGT6-8000H,V84.2, V94.2, V84.3A2, V94.3A, and Mitsubishi Hitachi M501F, M701F, M501G and M701G are included. A depot repair approach covers aero-derivative models General Electric LM2500, LM6000, LMS100, Pratt & Whitney FT8 and Rolls-Royce RB211 and Trent. The costing framework can be applied to any heavy-duty model using either Equivalent Operating Hours (EOH) maintenance intervals or those based on both starts and hours. Statistical unscheduled outage data is also incorporated. By considering outage and cost information probabil-istically, the user can quantify the degree to which risk mitigation alternatives decrease economic risks and change the average costs of a CT project. Estimates based on self-directed maintenance can then be compared with estimates incorporating risk mitigation options, including long-term maintenance contracts.

The SOAPP-CT O&M Cost Estimator is designed for use with the Windows® operating system (Win 7, 10). Microsoft® Excel (2010, 2013, 2016) is required to run the software. Adobe Acrobat Reader is required to read and print the electronic (pdf format) version of the manual. Oracle Crystal Ball®, an optional add-in program for use with Excel provides the additional statistical capabilities that are needed in order to take full advantage of the SOAPP-CT O&M Cost Estimator's features. The SOAPP-CT O&M Cost Estimator can be used as a standalone product or in conjunction with the SOAPP-CT WorkStation.

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