CEGCO Operation and Maintenance strategy IPS FEB, 2017

Transcription

1 CEGCO Operation and Maintenance strategy IPS FEB,

2 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 Planned Outages Plant Availability 2

3 CEGCO History CEGCO was established 1999 separating power generating activities from transmission and distribution activities. Central Electricity Generating Company (CEGCO) is considered the first generating company in Jordan since 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. 3

4 CEGCO Evolution JEA 1967 NEPCO 1996 CEGCO

5 Asset Overview Installed Capacity of 1075 MW Ibrahimiya Power Plant 0.32 MW Marka Power Station 80 MW (1) Hofa Power Plant 1.12 MW Syria Rehab Power Station 357 MW 10 Risha Power Station 60 MW Iraq Amman South Power Station 60 MW Hussein Power Station 363 MW (1) Decommissioned Karak Power Station 20 MW (1) Egypt JORDAN Aqaba Power Station 656 MW Saudi 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 5

6 Shareholders Enara (51%) CEGCO Social Security Corporation (9%) Government of Jordan (40%) Energy Arabia (Enara), a company established in 2007, owned 90% by ACWA Power and 10% by Consolidated Contractors Co. (CCC) 6

7 Key Focus Areas HSE O&M focus Learning Organization Training & develop Performance objectives Recognition Enterprise wide People Technology Process ERP platform Enhance connectivity EBIDTA monitoring Best practice Process Ownership Autonomy 7

8 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. 8

9 Driving Operational Excellence Performance Optimization Integration Plan Developed to address the performance optimization Plant Optimization Increase Revenue Improve Productivity HSE Improve Efficiencies 9

10 Main Challenges and opportunities. 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 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. 10

11 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. 11

12 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). 12

13 General Information (ATPS) Rated capacity (MW) 656 Fuel used Natural gas & Heavy Fuel oil Cooling method By sea water 13

14 Generating Units Information Unit Rated Capacity (MW) Fuel (HFO, LFO, NG) Installation (Year) Manufacturer Name Unit NG+HFO+LFO 1985 Mitsubishi Unit NG+HFO+LFO 1985 Mitsubishi Unit NG+HFO+LFO 1996 ABB Unit NG+HFO+LFO 1996 ABB Unit NG+HFO+LFO 1996 ABB 14

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17 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) 17

18 General Information (HTPS) Rated capacity (MW) 363 Fuel used Heavy fuel oil & diesel oil Steam condensing & cooling method Air condenser fans 18

19 Generating Units Information Unit Rated Capacity (MW) Fuel (HFO, LFO, NG) Installation (Year) Manufacturer Name Unit 1 33 HFO 1977 Breda Unit 2 33 HFO 1977 Breda Unit 3 33 HFO 1978 Breda Unit 4 66 HFO 1980 Kawasaki Unit 5 66 HFO 1980 Kawasaki Unit 6 66 HFO 1981 Kawasaki Unit 7 66 HFO 1984 Kawasaki 19

20 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. 20

21 General Information Rehab Rated capacity (MW) 357 Fuel used Natural gas & Diesel oil Cooling Dry cooling fans 21

22 Generating Units Information Unit Rated Capacity (MW ) Fuel (HFO, LFO, NG) Installation (Year) Manufacturer Name Type Name GT NG+LFO 1994 EGT PG6541 B GT NG+LFO 1995 EGT PG6541 B GT NG+LFO 1996 EGT PG9171 E GT NG+LFO 2002 GE PG9171 E ST MHI 22

23 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

24 General Information Risha Rated capacity (MW) 150 Fuel used Natural gas & Diesel oil as back up fuel Cooling method Dry cooling fans 24

25 Generating Units Information 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 25

26 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. 26

27 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 (MW) for each. 27

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29 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 ( ) 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. 29

30 Operation & Maintenance Strategy And Availability Forecast 30

31 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 31

32 Historical Plant Availability Records CEGCO level Year Availability (%) Planned Outage (%) Forced Outage (%) Availability Target (%)

33 Historical Plant Availability Records - Aqaba Thermal Power Station Year Availability (%) Planned Outage (%) Forced Outage (%) Availability Target (%) 33

34 Historical Plant Availability Records - Gas Turbine & CC (Rehab) Year Availability (%) Planned Outage (%) Forced Outage (%) Availability Target (%)

35 Historical Plant Availability Records - Gas Turbine (Risha) Year Availability (%) Planned Outage (%) Forced Outage (%) Availability Target (%) 35

36 PLAN VS ACTUAL - CEGCO Year Availability (%) Planned Outage (%) Forced Outage (%) budget actual budget actual budget actual * 5.58 * 1.10 * 36

37 PLAN VS ACTUAL - ATPS Year Availability (%) Planned Outage (%) Forced Outage (%) budget actual budget actual budget actual * 7.88 * 1.12 * 37

38 -PLAN VS ACTUAL REHAB Year Availability (%) Planned Outage (%) Forced Outage (%) budget actual budget actual budget actual * 1.61 * 1.12 * 38

39 PLAN VS ACTUAL - RISHA Year Availability (%) Planned Outage (%) Forced Outage (%) budget actual budget actual budget actual * 1.37 * 0.55 * 39

40 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. 40

41 Optimized Maintenance Strategy 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 41

42 Optimized Maintenance Strategy for Steam Generating Unit 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 42

43 Optimized Maintenance Strategy for Gas Turbine Generating Units (as per OEM) 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 EOH or1200 E. start 22 day EOH or1200 E. start 19 day MI EOH or 2400 E. start 35 day EOH or 2400 E. start 22 day 43

44 CEGCO Availability Financial Year Availability Forecast % % % % 44

45 Thank You! 45