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IPS - 2017 24 FEB, 2017
1
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
2
• 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
3
CEGCO Evolution
JEA 1967
NEPCO 1996
CEGCO 1999
4
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
2
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
12
10
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1 6
4
9
7
11
3
8
5
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
6
• 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
7
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
Improve Efficiencies
Improve Productivity
HSE
Increase Revenue
Plant Optimization
• Performance Optimization
Integration Plan Developed to address the performance optimization
Driving Operational Excellence
9
• 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.
10
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
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
General Information (ATPS)
Rated capacity (MW) 656
Fuel used Natural gas & Heavy Fuel oil
Cooling method By sea water
13
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
Unit 4 130 NG+HFO+LFO 1996 ABB
Unit 5 130 NG+HFO+LFO 1996 ABB
14
15
16
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
General Information (HTPS)
Rated capacity (MW) 363
Fuel used Heavy fuel oil & diesel oil
Steam condensing & cooling method Air condenser fans
18
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
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
General Information Rehab
Rated capacity (MW) 357
Fuel used Natural gas & Diesel oil
Cooling Dry cooling fans
21
Generating Units Information
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
22
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.
23
General Information Risha
Rated capacity (MW) 150
Fuel used Natural gas & Diesel oil as back up fuel
Cooling method Dry cooling fans
24
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
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
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.
27
28
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.
29
30
Operation & Maintenance
Strategy
And Availability Forecast
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
32
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
33
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
34
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
35
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 *
36
PLAN VS ACTUAL - ATPS
37
Year
Availability (%) Planned Outage (%) Forced Outage (%)
budget actual budget actual budget actual
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
38
Year
Availability (%) Planned Outage (%) Forced Outage (%)
budget actual budget actual budget actual
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
39
Year
Availability (%) Planned Outage (%) Forced Outage (%)
budget actual budget actual budget actual
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 *
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.
Optimized Maintenance Strategy
41
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
42
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
Optimized Maintenance Strategy
for Steam Generating Unit
43
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
Optimized Maintenance Strategy
for Gas Turbine Generating Units (as per OEM)
44
2015 – 2017 CEGCO Availability
Financial Year Availability Forecast
%
2015 97%
2016 97%
2017 96%
Thank You!
45