cegco operation and maintenance strategy maintenance strategy 9. 2015 ... jordan, approximately 22...

IPS - 2017 24 FEB, 2017

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CEGCO Operation and

Maintenance strategy

Content

1. CEGCO history

2. Asset overview

3. Our mission

4. Main challenges and opportunities

5. Power plant general information

6. Historical Plant Availability Records

7. Historical Plant Reliability Issues

8. Optimized Maintenance Strategy

9. 2015 – 2017 Planned Outages

10. 2015 – 2017 Plant Availability

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• Central Electricity Generating Company (CEGCO) is considered the first generating

company in Jordan since 1999.

• From 1999 until 2004, CEGCO was the only commercial generator in Jordan with a

market share of more than 99% of 1,690 MW.

• Currently CEGCO running 1,075 MW of diversified fuels HFO, Diesel and Natural

Gas.

CEGCO was established 1999 separating power generating activities from transmission and distribution activities.

CEGCO History

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CEGCO Evolution

JEA 1967

NEPCO 1996

CEGCO 1999

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Saudi

Syria

JORDAN

Iraq

Egypt

Risha Power Station 60 MW

Aqaba Power Station 656 MW

Rehab Power Station 357 MW

Karak Power Station 20 MW(1)

Hussein Power Station 363 MW

Amman South Power Station 60 MW

Marka Power Station 80 MW (1)

Hofa Power Plant 1.12 MW

Ibrahimiya Power Plant 0.32 MW

(1) Decommissioned

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Governorates: 1. Ajloun 2. Amman 3. Aqaba 4. Balqa 5. Irbid 6. Jerash 7. Karak 8. Maan 9. Madaba 10. Mafraq 11. Tafileh 12. Zarqa

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Asset Overview – Installed Capacity of 1075 MW

Energy Arabia (Enara), a company established in 2007, owned 90% by ACWA Power and 10%

by Consolidated Contractors Co. (CCC)

CEGCO

Enara

(51%)

Government of Jordan

(40%)

Social Security Corporation

(9%)

Shareholders

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• Best practice

• Process Ownership

• Autonomy

• ERP platform

• Enhance connectivity

• EBIDTA monitoring

• Training & develop

• Performance objectives

• Recognition

•HSE •O&M focus •Learning Organization

Enterprise wide

People

Process Technology

Key Focus Areas

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Our Mission

To generate electrical power within the

various areas of the Kingdom by utilizing

any resources of primary, and renewable

energy delivering it with good quality,

optimum availability and least possible

cost .

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Improve Efficiencies

Improve Productivity

HSE

Increase Revenue

Plant Optimization

• Performance Optimization

Integration Plan Developed to address the performance optimization

Driving Operational Excellence

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• Hussein Thermal Power Station was entirely decommissioned by the end of 2015 Therefore, ACWA Power is building a new 485 MW CCGT in place.

• Aqaba Thermal Power Station will be decommissioned in two phases by the end of 2019 and 2025. Therefore, plans started to select the suitable option for repowering considering the grid limitations, diversification of fuel, efficiency and relatively lower tariff.

• CEGCO has been selected by the ACWA Power Zarqa Project Co. to be the O&M

contractor for the project being developed in Zarqa.

• CEGCO is selected as O&M contractor for ACWA Power Local Co. 50 MW PV in Mafraq.

• Business development to establish new streamlines for revenue and looking for new opportunities through:

Rehabilitation

Repowering

Invest in renewable energy projects

Investing in desalination projects.

Main Challenges and opportunities.

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Power Plants

The total generating capacity installed in the stations

equals (1075) (MW) distributed on several main plants in

the Kingdom and contributed of (33%) of the total

generated electricity in 2016:

• Aqaba Thermal Power Station

• Al-Hussein Thermal Power Station

• Rehab Station

• Risha Station

Using three types of fuel in these stations: Natural gas,

Heavy fuel Oil and Diesel Oil.

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Aqaba Thermal power plant

Aqaba power plant is located in the south-western border of

Jordan, approximately 22 km south of the town of Aqaba

and 1 km from the Red Sea.

The plant site located in the middle of an industrial area. It

consists of five steam turbines units, each nominally rated

at (130) ( MW) gross and two hydraulic turbines with total

capacity (6) (MW).

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General Information (ATPS)

Rated capacity (MW) 656

Fuel used Natural gas & Heavy Fuel oil

Cooling method By sea water

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Generating Units Information

Unit Rated

Capacity (MW)

Fuel (HFO, LFO,

NG)

Installation

(Year)

Manufacturer

Name

Unit 1 130 NG+HFO+LFO 1985 Mitsubishi

Unit 2 130 NG+HFO+LFO 1985 Mitsubishi

Unit 3 130 NG+HFO+LFO 1996 ABB



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Hussein Thermal Power Plant

Hussein power plant is located in the northern region

of Jordan, approximately 30 km northeast of the

capital Amman. The plant site is located within the

Zarqa Industrial area.

Hussein power plant comprises 7 generating units, 3

of which are steam turbines, nominally rated at 33

(MW), 4 are steam turbines rated at 66 (MW)

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General Information (HTPS)


Fuel used Heavy fuel oil & diesel oil

Steam condensing & cooling method Air condenser fans

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Unit

Rated

Capacity

(MW)

Fuel (HFO,

LFO, NG)

Installation

(Year)

Manufacturer

Name

Unit 1 33 HFO 1977 Breda



Unit 4 66 HFO 1980 Kawasaki




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Rehab

Rehab power plant is located in the northern region of Jordan,

approximately 70 km north of the capital Amman. The plant site

is approximately 835 meters above sea level and located within a

rural area surrounded by extensive agricultural land.

Rehab power plant comprises 2 simple cycle gas turbines which

are nominally rated at 30 (MW) gross and a 297 (MW)

combined-cycle gas turbine which comprises 2 gas turbines with

100 (MW) and 1 steam turbine with 97 MW.

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General Information Rehab


Fuel used Natural gas & Diesel oil

Cooling Dry cooling fans

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Unit Rated Capacity

(MW )

Fuel

(HFO, LFO, NG)

Installation

(Year)

Manufacturer

Name Type Name

GT 10 30 NG+LFO 1994 EGT PG6541 B

GT 11 30 NG+LFO 1995 EGT PG6541 B

GT 12 100 NG+LFO 1996 EGT PG9171 E

GT 13 100 NG+LFO 2002 GE PG9171 E

ST 14 97 - 2005 MHI

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Risha Power Plant

Risha power plant is located in the eastern region

of Jordan, approximately 350 km from Amman.

Risha power plant comprises 5 simple cycle

generating units, each nominally rated at 30

(MW) The power station began producing

electric energy by burning natural gas since 1989.

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General Information Risha


Fuel used Natural gas & Diesel oil as back up fuel

Cooling method Dry cooling fans

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Unit Rated Capacity

(MW)

Fuel

(HFO, LFO, NG)

Installation

(Year)

Manufacturer

Name Type Name

GT 1 30 NG+LFO 1989 GE MS6001 B

GT 2 30 NG+LFO 1989 GE MS6001 B

GT 3 30 NG+LFO 1984 Hitachi MS6001 B

GT 4 30 NG+LFO 1994 GEC Alsthom PG6541 B

GT 5 30 NG+LFO 2005 GE PG6581 B

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Available Energy Resources for

Producing Electricity

The company continues to use the available

energy resources in the kingdom for generating

electrical energy such as Wind, Natural Gas in

Risha and Bio Gas.

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Wind Plants ( Ibrahimyah & Hofa)

The company is using wind for producing electrical energy form Hofa

and Al Ebrahemya electricity generating stations:

Ebrahimyah power plant is located in the north of Jordan,

approximately 80 km north of Amman. Ibrahimyah power plant

consists of 4 wind turbines with capacity 0.08 (MW) for each.

Hofa power plant is located in the north of Jordan, approximately 92

km north of Amman. Hofa power plant consists of 5 wind turbines with

capacity 0.225 (MW) for each.

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Bio Gas Jordan Biogas Company (equally owned by the Central Electricity Generating Company

and the Greater Amman Municipality) has continued implementation of its plans and

programs of 2016 that aimed to achieve the highest levels of production services of the

electric energy and environmental services through extracting the greater possible

quantity of the gas resulting from processing of the organic wastes.

The company could extract (3661754) cubic meters of Methane in 2016 which

contributed to reduction of its emission. The total hours of operation of operating units in

the company were (7084) working hours. The amount of energy generated in 2016 was

(4133) MW/H.

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Operation & Maintenance

Strategy

And Availability Forecast

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Background • In view of a series of unit forced outages experienced by CEGCO in the period between

2011 and 2014 which has significantly impacted CEGCO business performance, the plant

operations and maintenance policies and procedures for the various types of plant are

being reviewed by CEGCO technical team

• The following key information have been considered as inputs to the review process

Original Equipment Manufacturer (OEM) Recommendation

Plant and Equipment Past Historical Reliability and Availability Records

Past Inspection and Major Overhaul Reports and Recommendation

Types of fuel used

Plant Decommissioning Date

Equipment Obsolescence

Other Recommendations by third parties such as technical audit reports and insurance

survey reports

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Historical Plant Availability Records CEGCO level

Year Availability

(%)

Planned

Outage

(%)

Forced Outage

(%)

Availability

Target

(%)

2009 88.45 4.69 6.86 89.60

2010 95.69 1.54 2.77 93.20

2011 93.97 3.01 3.02 93.90

2012 93.52 2.85 3.64 92.06

2013 90.26 3.42 6.32 94.69

2014 92.20 4.84 2.96 95.55

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Historical Plant Availability Records - Aqaba Thermal Power Station

Year Availability

(%)

Planned

Outage

(%)

Forced Outage

(%)

Availability Target

(%)

2009 91.98 7.24 0.77 90.15

2010 96.72 0.85 2.43 92.67

2011 90.83 4.43 4.74 92.36

2012 95.00 3.63 1.36 90.81

2013 92.17 5.44 2.38 94.24

2014 90.68 6.11 3.20 95.41

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Historical Plant Availability Records - Gas Turbine & CC (Rehab)

Year Availability

(%)

Planned

Outage

(%)

Forced Outage

(%)

Availability

Target

(%)

2009 72.59 5.98 21.43 78.96

2010 89.62 4.12 6.26 91.42

2011 94.92 2.74 2.34 94.88

2012 92.98 2.11 4.91 90.92

2013 82.26 3.27 14.47 94.36

2014 93.28 5.31 1.39 95.15

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Historical Plant Availability Records - Gas Turbine (Risha)

Year Availability

(%)

Planned

Outage

(%)

Forced

Outage

(%)

Availability

Target

(%)

2009 89.51 2.02 8.47 96.50

2010 96.84 2.10 1.05 93.93

2011 98.72 0.20 1.08 92.63

2012 97.67 2.00 0.33 94.65

2013 95.19 0.83 3.97 97.24

2014 93.88 1.12 4.99 98.18

PLAN VS ACTUAL - CEGCO

Year

Availability (%) Planned Outage (%) Forced Outage (%)

budget actual budget actual budget actual

2014 95.55 92.20 3.77 4.84 0.68 2.96

2015 95.43 93.36 3.51 3.91 1.06 2.73

2016 94.23 93.91 5.01 3.96 0.75 2.13

2017 93.32 * 5.58 * 1.10 *

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PLAN VS ACTUAL - ATPS

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Year



2014 95.41 90.68 3.75 6.11 0.85 3.20

2015 95.49 92.57 3.43 2.90 1.08 4.53

2016 93.44 93.68 5.83 4.14 0.74 2.19

2017 90.99 * 7.88 * 1.12 *

-PLAN VS ACTUAL REHAB

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Year



2014 95.15 93.28 4.30 5.32 0.55 1.40

2015 95.57 91.16 3.56 7.59 0.87 1.25

2016 93.90 93.34 5.21 5.20 0.89 1.46

2017 97.28 * 1.61 * 1.12 *

PLAN VS ACTUAL - RISHA

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Year



2014 98.18 93.88 1.37 1.13 0.45 4.99

2015 97.24 97.95 2.19 1.64 0.57 0.40

2016 98.57 95.34 0.97 0.38 0.45 4.28

2017 98.08 * 1.37 * 0.55 *

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Optimized Maintenance Strategy

The maintenance policy and plan for all CEGCO Generating units will be according to the

following:

Units which are due for decommissioning in next two years, scheduled inspection will be

undertaken, but any major replacement/refurbishment will be done only after considering the

operational risk and cost benefit analysis.

For all other Units, CEGCO will adopt a condition-based program focused on critical systems

that need periodic evaluations in order to maintain high levels of reliability while optimizing

maintenance costs.

Critical systems are equipment which can lead to loss of availability in case of failures or can

jeopardize the plant until its replacement.

Systems not identified as critical, will be maintained through a combination of scheduled

inspection and failure based replacement.

A list of SPOF equipment / parts has been agreed to be purchased and to store it in order to

reduce the outage period in case of failure occurs.

To standardize best practices within CEGCO in relations to preventive, corrective and predictive

maintenance.


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Upgrade the system with equipment Obsolescence.

Intending to introduce CMMS along with the ERP system.

The maintenance for all steam generating units will be according to CEGCO maintenance practice

and past long experience

The maintenance for all Gas Turbine Generating units will be according to the OEM recommendation.

Avoid stopping more than one unit at the same period in the same power plant.

Avoid stopping Rehab gas turbine frame 9E units with any steam unit in ATPS at the same period due

to Grid demand constrains.

Avoid stopping more than one units of gas turbine at the same power plant or with gas turbine unit at

other power plants.

Generator Transformer

• 6 monthly DGA transformer oil analysis shall be carried out to determine the condition of the oil

• To implement OEM recommendation as an when required

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Maintenance type ATPS unit 1,2,3,4,&5 Rehab steam unit

interval Duration interval Duration

Ordinary inspection 12 months 30 day Yearly 10 days

Major inspection ~50000 EOH 60 day for stage one

50 day for stage two

4 years 35 day


for Steam Generating Unit

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Maintenance

type

Frame 9 E units Frame 6 B units

Interval Duration Interval Duration

CI 8000 EOH or 400 E.

start

10 days 8000 EOH or 400 E.

start

5 days

HGPI 24000 EOH or1200

E. start

22 day 24000 EOH or1200 E.

start

19 day

MI 48000 EOH or 2400

E. start

35 day 48000 EOH or 2400 E.

start

22 day


for Gas Turbine Generating Units (as per OEM)

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2015 – 2017 CEGCO Availability

Financial Year Availability Forecast

%

2015 97%

2016 97%

2017 96%

Thank You!

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cegco operation and maintenance strategy maintenance strategy 9. 2015 ... jordan, approximately 22...

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