O&M Annual Report

2014
 Contents
1. Operation Report............................................................................... 2
1.1 Executive Statistic ........................................................................................ 2
1.2 Operation Summary ..................................................................................... 2
2. Maintenance Report .......................................................................... 3
1) Mechanical Maintenance ...............................................................................................................3
2) I&C Maintenance ..........................................................................................................................8
3) Electrical Maintenance ..................................................................................................................9

3. HSE Report ...................................................................................... 11

3.1 HSE Statistics ............................................................................................. 11
3.2 HSE Summary ............................................................................................ 11
a) HSE Inspection ........................................................................................... 11
b) Environment Inspection ............................................................................. 11
c) Emission Analysis Results ......................................................................... 11
d) Evaporation Pond Analysis Results ........................................................... 11
4. Administration Report .................................................................... 12
4.1 Document Status ............................................................................................ 12
4.2 Unattended Document Management Plan. .................................................... 12
4.3 Budget Execution: .......................................................................................... 12
4.4 Spare Part and Procurement ........................................................................... 12
4.5 Staff Organization: ......................................................................................... 12
5. Plans of 2015 .................................................................................... 12
<Attachments> ...................................................................................... 13

1
1. Operation Report
1.1 Executive Statistic
During 2014 the facility had been operating on combined cycle mode. Almost of
operation was on fuel oil 81.93% FO and 18.07% NG (Based on exported energy
percentage).

The Facility exported 1,491,194.125 MWh, wherein the utilization factor was
45.63% with 9,487.36 kJ/kWh heat rate comparing with 9,782.58 kJ/kWh
guaranteed heat rate.

The Facility outage were 242,071.837 MWh. The weighted availability was
92.593% comparing with 92.01% planned availability for this year in accordance
with 2014 O&M plan submitted (ref: AQPP-KOSPO-QSO-14-0031).

1.2 Operation Summary

Operation Summary Report includes primary operational parameters. Which were
calculated for the facility during this year. Then evaluated using comparisons with
the 2014 accumulative similar parameters. The major operational parameters
obtained during this year are summarized as follows.

Summary of major operation parameters

Parameter Value Reference

Facility Availability * 92.593 %
Table 2: Summary - Operation
NG Running Hours 1,616.35 hr
Regime
DO Running Hours 7,810.69 hr
Exported Energy 1,491,194.125 MWh
Imported Energy 7,333.10 MWh Table 1: Energy and Utilization
Consumed Energy 28,209.00 MWh Factor
Consumption Rate 1.89 %
NG Consumption 2,489,148.45 GJ
FO Consumption 10,523,838.08 GJ
Raw Water Consumption 44,972 m3 Table 3: Efficiency & Heat Rate
Demi Water Consumption 20,487 m3
Heat Rate 9,487.36 kJ/kWh
* Facility Availability is calculated in accordance with EOE concepts rather than hours concepts

Detailed Operation events are shown in the tables and charts included in the
attachment #1. These are classified according generation unit number CTG11,
CTG12, STG and the facility with consideration that some items are common that
couldnt be connected with a certain unit such as natural gas consumption.

HRSG chemical analysis listed in attachment #1 page 20.

Attachment # 1: Operational Detailed Report.

2
2. Maintenance Report

1) Mechanical Maintenance
During the year 2014, Mechanical Section performed mainly the following tasks:

a) Major Activities:

[1] CTG11 HGPI (July 5, 2014 ~ July 29, 2014)

a) CTG11 HGPI was performed during (July 5, 2014 ~ July 29, 2014);
The following items were performed on the CTG#11 and auxiliaries:
1. Replace the Turbine blades 1st &2nd stage.
2. Replace the Turbine vanes 1st &2nd stage.
3. Sandblasting and NDT for turbine blades and vanes last stage.
4. Cleaning and NDT for turbine blades and vanes 3rd stage.
5. Made sandblasting and welding and repair for the mixing chamber and
Flame tube.
6. Made cleaning and inspection for the fuel oil and fuel gas burners
(diffusion and premix nozzles).
7. Change the defected ceramic tiles.
8. Made inspection and leaking test for the fuel oil and fuel gas ball cock
valves.
9. Made inspection and repair for the fuel oil and fuel gas control valves.
10. Made inspection for the inlet guide vanes and compressor 1st stage.
11. Replace all coalescer filter of Air intake system (1004EA).
12. Cleaning all Air intake pre-filters.
13. Made inspection for lube oil pumps.
14. Change the lube oil and jacking oil and mist eliminator filters.
15. Clean the heat exchanger of the lube oil and generator system.

b) CTG#11 (Aug23, 2014~Aug29, 2014).

1. Due to hybrid burner alarm and fuel oil premix nozzle tag weld lose.
2. We perform more tag welding on fuel oil premix nozzle.

c) CTG#11 (Nov29, 2014~Dec5, 2014).

1. Due to continuous hybrid burner alarms we made seal weld for all fuel oil
Premix nozzles.

[2] CTG11 HGPI (July 28, 2014 ~ August 25, 2014)

a) CTG11 HGPI was performed during (July 28, 2014 ~ August 25, 2014);
The following items were performed on the CTG#11 and auxiliaries:
3
 1. Replace the Turbine blades 1st &2nd stage.
2. Replace the Turbine vanes 1st &2nd stage.
3. Sandblasting and NDT for turbine blades and vanes last stage.
4. Cleaning and NDT for turbine blades and vanes 3rd stage.
5. Made sandblasting and welding and repair for the mixing chamber and
Flame tube.
6. Made cleaning and inspection for the fuel oil and fuel gas burners
(diffusion and premix nozzles).
7. Change the defected ceramic tiles.
8. Made inspection and leaking test for the fuel oil and fuel gas ball cock
valves.
9. Made inspection and repair for the fuel oil and fuel gas control valves.
10. Made inspection for the inlet guide vanes and compressor 1st stage.
11. Replace all coalescer filter of Air intake system (1004EA).
12. Cleaning all Air intake pre-filters.
13. Made inspection for lube oil pumps.
14. Change the lube oil and jacking oil and mist eliminator filters.
15. Clean the heat exchanger of the lube oil and generator system.

b) CTG#11 (Aug26, 2014~Aug29, 2014).

1. Due to hybrid burner alarm and fuel oil premix nozzle tag weld lose.
2. We perform more tag welding on fuel oil premix nozzle.

c) CTG#11 (Dec4, 2014~Dec12, 2014).

1. Due to continuous hybrid burner alarms we made seal weld for all fuel oil
Premix nozzles. And we changed all diffusion fuel oil burners (16EA).

[3] STG Grade (B) inspection (July28, 2014 ~ Aug14, 2014)

STG Grade (B) was performed during (July 28, 2014 ~ August 14, 2014); the
following items were performed on the STG and auxiliaries:
a) STG and Generator bearing front and rear inspected (oil gap check, twist
check, contact check, NDT check).
b) Oil Deflector clearance check and cleaning.
c) Rotor lifting check.
d) Couplings run out check.
e) Alignment.
f) Main steam turbine valves were dismantled and inspected (Dismantle all
valves, make cleaning for all internal part, make NDT for seat and disk and
stem, change seal ring and packing, make sand blasting for strainer of the
valve).

4
 g) STG lube oil pumps (A,B,C) were dismantled and inspected (bearings
were replaced by new, bearing gasket and casing gasket were replaced,
shaft and impeller and wearing rings inspected, suction strainer of the
pumps cleaned, check valves inspected).
h) Lube oil filters: New filters changed.
i) Jacking oil filters: New filters changed.
j) Oil vapor fan: gasket of the fan was changed by new.
k) Lube oil: four drums add to the lube oil system.
l) STG Hydraulic oil skid (change all the hydraulic oil: 3 drum, change
suction filters and discharge filters).
m) Condensate drains system (made inspection for the drain pumps A&B,
condensates drain pot welding point NDT check).
n) All STG drain valves and warming valves were inspected.

[4] Condensate system

We performed the following maintenance on the condensate system and
auxiliaries:
a) ACCU Gearbox and fans (Gearbox oil change, Lube oil filter change, Fan
blade angle check, Fan blade clearance check, Bolt tightens check).

b) Condensate tank inside clean and change the manhole gasket.

c) Control valves were inspected (HP Bypass 11&12, LP Bypass 11&12, HP
and LP Bypass spray 11&12, Gland steam valve, Ejector and hogging
valves).
d) Pipe rack valves (All high pressure valves were inspect and cleaned, all low
pressure valves were inspect and cleaned).

[5] HRSG# 11 overhaul maintenance (July5, 2014~July29, 2014).

HRSG#11 overhaul maintenance was performed during (July 5, 2014 ~ July29,
2014); the following items were performed on the HRSG#11 and auxiliaries:
a) Inspected HRSG inside from leakage or corrosion.
b) Replaced secondary S/H tube supports by new design.
c) Modified primary S/H drains.
d) Inspected inside main stack and cleaned it from sulfur oxide.
e) MOV valves (Dismantled all MOVs valves (inlet, outlet, drain, vent,
Inspected internals parts and replace the defective parts, made lapping if
necessary).
f) BFP #A &#B discharge MOVs valves (Dismantle valves and check
internal parts, Replaced gasket set, made lapping if necessary).

5
 g) Flow control valves (FCV) (HP drum FCVs 100%, 30% and CPH outlet,
LP drum FCVs (dismantle and check inside, Inspected internals parts and
replace the defective parts).
h) HP Drum (Open HP manholes, check inside and clean it )
i) LP Drum (Open manholes and check inside , Repaired weak points by
welding and grinding )
j) Dearetor Drum (Open manhole and check inside, Repaired metals trays
(baffle) made modification to reduce flow at metals trays).
k) Perform hydraulic test for HP, LP drums and systems.

[6] HRSG# 12 overhaul maintenance (July28, 2014~August25, 2014).

HRSG#12 overhaul maintenance was performed during (July 28, 2014 ~ August
25, 2014); the following items were performed on the HRSG#12 and auxiliaries:
a) Inspected HRSG inside from leakage or corrosion.
b) Replaced secondary S/H tube supports by new design.
c) Modified primary S/H drains.
d) Inspected inside main stack and cleaned it from sulfur oxide.
e) MOV valves (Dismantled all MOVs valves (inlet, outlet, drain, vent,
Inspected internals parts and replace the defective parts, made lapping if
necessary).
f) BFP #A &#B discharge MOVs valves (Dismantle valves and check
internal parts, Replaced gasket set, made lapping if necessary).
g) Flow control valves (FCV) (HP drum FCVs 100%, 30% and CPH outlet,
LP drum FCVs (dismantle and check inside, Inspected internals parts and
replace the defective parts).
h) HP Drum (Open HP manholes, check inside and clean it )
i) LP Drum (Open manholes and check inside , Repaired weak points by
welding and grinding )
j) Dearetor Drum (Open manhole and check inside, Repaired metals trays
(baffle) made modification to reduce flow at metals trays).
k) Perform hydraulic test for HP, LP drums and systems.

[7] Pumps overall maintenance.

Due to running hours operation for the pumps and OEM recommendation we
performed inspection and repairing and testing for the following equipments:
a) Inspection BFP#A,B at HRSG# 11&12
b) Inspect the Condensate Extraction Pumps (A,B,C)
c) Inspect the Generator Cooling water pumps of the CTG#11&12.
d) Inspect the Closed cycle cooling water pumps A, B.
e) Inspect the Forwarding pumps A, B, C.
6
 f) Inspect the Unloading pumps A, B, C, and E.
g) Inspect the CPH pumps A, B at HRSG11&12.

[8] Fin Fan coolers system.

a) Clean the heat exchanger.
b) Change the lube oil of gearbox.
c) Fan blade angle check
d) Fan clearance check.

[9] Replace NG press. Reduction station isolation valve.

As a pending item of passing valves 11/12EKD20AA401. LEC supplied one
new valve and one repair set. However, valve 11EKD20AA401was replaced by
new one and line was normalized.

[10] Repairing the HRSG#11 Drain pipes

Due to water leakage and crack on the two drains on the HRSG#11 primary
Super Heater the two pipes were welded after that we make Heat treatment and
NDT.

[11] Made Overall maintenance for HVAC system.

Made overall maintenance for facility HVAC, for CTGs, STG, FG, Admin,
workshop and WTP buildings, were cleaned of flat filters, replaced the bag
filters, replaced fan belt, and greasing for fans motors.

[12] Replace the coalescer filter (A&B ) : 25 times

Due to operation on DO, the coalescer filter #B differential pressure increased to
full scale. Dismantle coalescer filter and remove old filters and separators. Install
new filters elements and Clean separator elements and install.

[13] Cleaning of CTG11 & CTG 12 fuel oil injection filters

Due to operation on DO, fuel oil injection filters differential pressure increased
to alarm level. Cleaning of oil filter elements was performed.

b) Obstacles and Countermeasures

N/A

c) Preventive Maintenance Activity

Preventive maintenance actions were done completely according to Mechanical
Schedules.

7
2) I&C Maintenance
During the year 2014, I&C Section performed mainly the following tasks:

a) Major Activities
[1] Main gas valve (ESDV) pneumatic connections were modified to ensure
redundant operation of the solenoids

[2] CTG's #HGPI : I&C team performed all required maintenance for HGPI
including:
a) Calibrating all process transmitters and switches and control valves
b) Dismantling all needed instrumentation from control valves and
equipment, and installing again after mechanical maintenance was finished
c) Disconnect wiring from combustion chambers mainly to facilitate
mechanical maintenance, and connecting again.
[3] STG inspection:
a) I&C team performed the needed maintenance on STG and its related
equipment
b) Removed needed instrumentation from STG and its main equipment
c) Installed again STG monitoring Instrumentation and control valves insts
after mechanical work
d) Calibrated control valves, to ensure consistent operation

[4] DCS- Modifications:

a) I&C applied several logic modifications for the purpose of optimizing
control schemes, and facilitate easier operational actions for operators,
these included:
b) Added SGC illustrative charts and tables, on related DCS graphics. For the
purpose of making it easier for operators to analyze processes and faults
c) Setup LDC logic and graphic, tested changing CTG load from DCS
successfully.
d) Created logic for showing the period of NOx exceeding limits.

[5] CTG#12- Back purge valve:

a) 12MBN45AA402- Tested fuel oil drain valve opening to adjust feedback
limit switch (XG01), to give correct indication and reset alarm
b) Replaced the trip mechanism of the FO drain valve

b) Obstacles and Countermeasures:

NA

8
 c) Preventive Maintenance Activity.
Preventive maintenance actions were done completely according to I&C section
Schedules and procedures.
The preventive activities are included in attachment #2 (I&C Maintenance
Preventive Activities).

Attachment # 2 Corrective & Predictive maintenance and improvement

Actions.

3) Electrical Maintenance
During 2014 Electrical team Perform facility comprehensive maintenance (HGPI)
for CTG, STG and HRSG,

a) Major Activities

[1] Generator
Electrical team made full inspection and test for Generator and GCB as:
a) Inspect Stator insulation paper and wedges situation.
b) Insulation resistance test for Stator and rotor.
c) Inspect slip ring situation and Excitation brushes holder situation.
d) Inspect Generator Star point and NGR.
e) Generator bearing inspection (PT and UT).

[2] Transformer :
We made full inspection and test for GSUT and SAT as follow:
a) Inspect transformer Bushing situation.
b) Actual test for Transformer mechanical protection and test all tripping
signal with NEPCO.
c) Inspect OLTC and its mechanism.
d) Inspect the transformer cooling system (Fans and pumps).
e) Inspect the GSUT and SAT CTs.

[3] GCB :
We made full inspection and test for GCB as follow:
a) Functional test for GCB mechanism.
b) Inspect VTs and CTs in GCB and Generator.
c) Inspect SF6 chamber in GCB.
9
 d) Check flexible Joint for GCB and Generator.

[4] PCC :
We made full inspection and test for PCC as follow:
a) Inspect the PCC SWGR ACB
b) Inspect PCC Load breaker mechanism
c) Inspect SFC system (Thyrestor, internal mechanism ,controller and
transformer)
d) Inspect SFC system (Thyrestor, internal mechanism , controller and
transformer
e) Inspect Protection panel and Synchro. Panel and its relay and CTs
f) Inspect Battery charger and Battery bank and Battery charger.

[5] MOVs :
We made full inspection for HRSG and STG MOVs and CTG combustion
chamber MOVs as follow:
a) Inspect control card and Adjustment switches.
b) Inspect MOV motor situation.
c) Full calibration for all STG and HRSG MOVs.

b) Electrical Modification.

[1] STG Protection Modification :

In generator protection system we have two independent protection relay with
different CTs and VTs so if fuse failure supervision alarm activated on one
relay (No voltage monitor in one channel) normal action should be blocked for
same protection relay and other protection relay will be in service and protect
our generator, But in our case fuse failure supervision alarm will trip directly
STG, which could strongly effect our system. So we made Modification for
our system, so in case one of VT fuse damage the protection relay will blocked
without trip and, made full supervision and protection to Backup relay as
attachment.

[2] Transfer the control power for STG MCC :

In Past STG MCC control power feed from emergency MCC , So during any
problem in Emergency MCC all main STG motors like lube oil system and
Main MOVs will trip directly because no control power , so we transfer the
Power source for STG MCC from Emergency MCC to AC UPS which more
stable and reliable.

10
 [3] HRSG #11 ,12 diverter damper LCP :
Diverter damper LCP its located in body of HRSG which have strong
vibration which could damage electrical equipment, so move the panel to be in
ground grid

c) Obstacles and Countermeasures:

N/A.

d) Preventive Maintenance Activity

Preventive maintenance actions were done completely according to Electrical
Section Schedules and plans.

3. HSE Report

3.1 HSE Statistics

During 2014 the major HSE detailed reports are attached as mentioned later.

3.2 HSE Summary

a) HSE Inspection
The site has been surveyed and the check list was prepared as the attachment #3
(Attachment #3 HSE Inspection Checklist)

b) Environment Inspection
The site has been surveyed and the check list was prepared as the attachment #3
(Attachment #3 Environment Inspection Checklist).

c) Emission Analysis Results

The average CEMS readings of NOx, Sox, and Dust were obtained as the
attachment #3.

d) Evaporation Pond Analysis Results

The chemical team has analyzed the evaporation pond frequently, and the monthly
average is calculated for PH, TDS, COD and conductivity as the attachment #3.

Attachment # 3: HSE Summary in Detail.

11
4. Administration Report
4.1 Document Status
The following table shows the status of official letters received from QEPC and
submitted by KOSPO to QEPC.

Document Statistics
Received Unattended
Division
(Total Yearly) (Total Yearly)
P&E 35 1
Electrical 1 0
Mechanical 8 0
I&C 6 2
Chemical 0 0
HSE 3 1
Admin 10 0

4.2 Unattended Document Management Plan.

With respect to official references received from QEPC, particularly those on
which KOSPO havent responded, KOSPO response plan and countermeasures are
planned as the attachment #6.

4.3 Budget Execution:

[1] Monthly Expenses (Attachment # 7).

4.4 Spare Part and Procurement

[1] Facility Spare Part Management (Attachment # 8).
[2] Procurement status (Attachment # 8).

4.5 Staff Organization:

[1] O&M organization chart (Attachment # 9).

5. Plans of 2015
5.1 Operation and maintenance plan for year 2015. (Attachment 12)

12
<Attachments>
[1] Operational Detailed Report.
[2] Attachment # 2 Corrective & Predictive maintenance and improvement Actions.
[3] HSE Annual Environmental report.
[4] Emergency Plan during Rainy and Snow.
[5] Organizational Chart.
[6] Employee in & out list for 2014.
[7] Budget Execution Statement for 2013
[8] Procurement Status.
[9] Facility Inventory Spare Part for 2014.
[10] Document Status in Details.
[11] Operation and maintenance plan for year 2015.

13