5. I MPROVEMENT MEASURES RELATING TO OPERATION...

The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia

5. IMPROVEMENT MEASURES RELATING TO OPERATION, MAINTENANCE AND INSPECTION

5.1. Toward Improvement of Operation Performance 5.1.1. PLN and North American Reliability Council (NERC)

In the course of the site visit to objective sixteen (16) power stations in Java-Bali region, all power stations use the common indicators to evaluate the performance of operation. Table 5.1-1 shows some of examples of common indicators.

Table 5.1-1 Examples of Common Indicators

Symbol Explanation Definition

GCF Gross Capacity Factor = {GAC/(PH × GMC)} × 100 %

GOF Gross Output Factor ={GAC/(SH × GMC)} × 100 %

AF Available Factor ={AH/PH} × 100 %

EAF Equivalent Availability Factor ={AH-(EUDH+EPDH+ESDH)} × 100 %

SF Service Factor ={SH/PH} × 100 %

FOR Forced Outage Rate ={FOH/(FOH+SH)} × 100 %

EFOR Equivalent Forced Outage Rate ={(FOH+EFDH)/(FOH+SH+EFDHRS)} × 100 %

SOF Scheduled Outage Factor ={SOH/PH} × 100 %

EUDH Equivalent Unplanned Derating Hours ={EDH × MW derating }/NMC

The above common indicators were developed by PLN in the middle of 1990s based on the NERC (North American Electric Reliability Council; Generating Availability Report). NERC1 was established in 1968 to ensure that the bulk electric system in North America is reliable, adequate and secure. NERC is a nonprofit organization and engaged in development of reliability standard through an American National Standards Institute (ANSI) working with the North American Energy Standard Board (NAESB). The power entities in United States, Canada and Mexico are members. Figure 5.1-1 is the quoted figure from the presentation material of Gresik power station. As shown in Figure 5.1-1, the operation performance of Gresik was compared with NERC’s value by using Equivalent Availability Factor (EAF). Some of above indicators are used in the contract between each power station and PJB / IP

1 NERC Home Page is http://www.nerc.com

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head office which is signed at the beginning of the year and each power station makes every effort to achieve the target values calculated by indicators in the relevant year.

0.00

10.00

20.00

30.00

40.00

50.00

60.00

70.00

80.00

90.00

100.00

MW

1992/ 1993 1993/1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 s/ dOkt

PLTU PLTGU

NERC PLTGU = 85,80 %NERC PLTGU = 85,80 %

NERC PLTU = 82,00 %NERC PLTU = 82,00 %

GRAFIK EAF PLTU & PLTGU GRESIK

Figure 5.1-1 Comparison with NERC for EAF (Gresik power station)

5.1.2. Maintenance Optimization Program (MOP)

Besides the development of performance indicators, PJB has developed Maintenance Optimization Program (MOP) with assistance of PT. MTS (Maintenance Total Solution) Indonesia and applied to Gresik power station firstly. Figure 5.1-2 shows the flowchart of MOP. In MOP, performance of operation and maintenance is expressed as Key Performance Indicator (KPI) consisting of ten (10) fields finally as shown in Figure 5.1-3. Relating to the Reliability Management, the following KPI are used as shown in Table 5.1-2.

Table 5.1-2 Key Performance Indicators for Reliability Management KPI Definition

Equipment breakdown rate

(Number of hours lost due to breakdowns/planned production hours) calculated as a percentage

Maintenance tactics profile Ratio tactical to non tactical maintenance

Availability EAF = Equivalent Available Factor = { AH - (EUDH + EPDH + ESDH) } / PH × 100 %

Schedule review rate (Number of schedules review or updated/ Total number of schedules) calculated as a percentage

Failure analysis (Number of failures analysed to identify root causes / Total failures) calculated as a percentage

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Figure 5.1-2 Flowchart of Maintenance Optimization Program at PJB

External Auditor (PT. TMS Indonesia) conducts the audit annually and submitted the Assessment Report. Figure 5.1-4 shows the overall finding of assessment rate for Gresik reported by the external auditor.

Figure 5.1-3 Result of the Assessment (quoted from P17-Plant Assessment Gresik)

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100%

50%

75%

25%

World Class > 80%

Target 12 Months 60%

Gresik May 2005 46%

Asset Management Performance MeterAsset Management Performance Meter

Gresik May 2004 (estimate)

Figure 5.1-4 Asset Management Performance Meter for Gresik

For Gresik power station, the management performance in the year 2005 is 46 % and the target performance for the year 2006 is 60 %. MOP is applied to Muara Kanrang and Paiton power stations. As described above, each power station tackles the scheme of Improvement of Operation and Maintenance Performance.

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5.2. Thermal Power Station

Based on the current status and tasks in the operation and maintenance management of the existing thermal power generation facilities under Section 3.2, the following improvements from operation and maintenance aspects are recommended to achieve effective power supply.

(1) Measures to promptly cope with unexpected accidents:

<Operational aspect> ① Education and training of troubleshooting of the unit utilizing a compact type simulator

(new installation), which is also useful for the development of instructors and maintenance personnel.

② Education and training of troubleshooting of the unit, by modifying the existing onsite simulators.

< Maintenance aspect > ① Establishment of material management system utilizing IT to promptly cope with

accidents, etc. by IT utilizing. (2) Measures to prevent deterioration of facilities: Promotion of Predictive and Preventive

Maintenance.

① Enhancement of CBM (Condition based Monitoring). Expansion of not only the exclusive diagnosing technique but the definition of CBM.

② Promotion of facility assessment to prevent serious accidents. A. Conduct trials of pipe thickness inspection work for power generation at a typical unit of

a typical power station. B. Reinforcement of efforts to perform equipment-based maintenance to cope with

increasing unexpected troubles due to deterioration of the equipment. (3) Improvements of education and training of Indonesia Power and PJB

① Improvements of education of newcomers ② Prevention of lessons gained from accidents and troubles from fading with time, prevention

of recurrence of similar accidents and passing on of skills to next generation ③Implementation of OJT on quality and safety management in Japan

(4) Arrangement in order and expansion of technical base jobs to ensure quality and safe. －Preparation of Manuals and development of Data Base－ (5) Promotion of information sharing. Holding information exchange meetings on operation and maintenance management.

< 1. Improvements to prevent routine accidents and troubles >

(2) Improvements toward reduction of the work period to rationalize the scheduled inspection work.

< 2. Improvements of Scheduled Inspection Work from operational aspect >

(1) Restructuring of scheduled inspection system and establishment of (Draft) guideline for implementation procedure.

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5.2.1. Improvements to prevent Routine Accidents and Troubles

(1) Measures to promptly cope with unexpected accidents

< Operational aspect >

① Education and training of troubleshooting of the unit utilizing a compact type simulator (new installation), which is also useful for the development of instructors and maintenance personnel

It is recommended that simulated training with a training simulator (a conventional and combined type of a typical unit) be provided to cope with an emergency of the unit as it is most effective in improving skills of operators in “normal starts and stops of the unit” and “troubleshooting of the unit.”

Outline of the Recommended Training Simulator

A compact type simulator in which the operation training effects can be expected from the simplified desk panel and not only training by an instructor can be provided but also selection of an effective training menu can be made without an instructor.

1) Standard specifications: ・Model accuracy: static property errors :less than 0.5% dynamic property errors :less than 2% (main process) :less than 10% (other process) ・Number of malfunctions :200 pieces

2) Merits of introducing operation training simulator ・ Operation can be easily learned individually or by group ・ Operators’ skills can be improved through simulated operation assuming various

troubles such as machinery failure and system fluctuation. ・ Maintenance personnel’s understanding of maintenance technique can be increased

through training of the control logic changes and control parameter adjustments.

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< Image > Operator Console for Training / Instructor Console

Instructor Console

Operation StationLarge Wide Screen

Panorama Vision Controller

Fast Ethernet

Maintenance Tool

Model Computer

Controller

Hard Wired

Plumb Window

Operation Station

Operator Console for Training

(Draft) Installation Schedule of a Simplified Simulator Work Schedule (month) -16 -15 -14 -13 -12 -11 -10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0

1. Proposal & Explanation of System

2. Adjustment of Basic Specifications

3. Study of Detailed Specifications

4. System Production

5. Onsite Installation & Adjustment

6. Verification Tests & Explanation

Receive Order DeliverCarry-in to Site

Main Items

The duration necessary for the simulation system structuring is approximately 16 months.

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Step I, II

Simulator Training Course

OJT Step Up

Beginners’ Course

Middle Class Course

Pre-Advanced Course

Advanced Course

Standard Target: 5 yrs

Basic Education 3 yrs Applied Education (2-4 yrs)

Step I, II, III

Step IV, V

Control

Patrol

Control

Image of Upgrading of High School Graduates

Step I, IV : Learning of knowledge at Power Station … to be checked by paper testsStep II : Learning of skills … to be checked by simulated operation tests Step III, V : Learning of skills which are common

・

・

・

Beginners’ course : Learning of start-up/Shutdown of normal units. Learning of easy troubleshooting.

Middle class course : Learning of exact troubleshooting for frequently occurring accidents and troubles of facilities.

Advanced course : Learning of exact troubleshooting for unexpectedly occurring accidents and troubles of facilities.

Simulation Training Course: Learning of Knowledge & Technique in Standard Target of 5 Years

② Modification of the existing onsite simulator of PLN Suralaya Unit and providing troubleshooting education and training.

In order to enhance operators’ knowledge and ability, we think it very effective to provide troubleshooting education and training of units by additionally modifying software logics to promptly cope with recently occurring unexpected facility accidents and troubles on the existing onsite simulator at Suralaya P/S.

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< Maintenance aspect >

At several power stations, it takes several months before receiving the parts after placing order for them with the manufacturer and this has been affecting the work schedule. We presume that this is a system which the current material management cannot promptly cope with.

① Establishment of material management system to promptly cope with accidents, etc. by IT utilization. －Effective material management can be conducted－

JICA Study Team suggests that a material management system be established which would enable prompt search or diversion of items in case of an emergency, unified management by a small number of persons of inventory information on such as a variety of spare parts in large quantities and efficient conducting of facility maintenance work by sharing information company-wide.

< Main use > ・ Prompt checking of materials in case of an accident; Prompt recovery by

diversion. ・ Unified management and sharing of a variety of materials (spare parts, stores,

accessories, maker’s information on stocks, etc.) kept in store. ・ Study on the postponement of the timing of the facility renewal.

< System structuring duration > The duration necessary for the material management system structuring is approximately 10 months.

< Example of utilization > In case No.1 bearing is damaged, whereabouts of the spare parts will be promptly grasped.

Image of Countermeasure against incidents by utilizing the system

Material Management

System Data Base

Reference and search of information on materials

Display of common spare parts

Display of detailed specifications of facilities

Display of spots which can be converted for other purposes

Occurrence of an incident

Each Power Station

●Search the same kinds of spare parts ・Confirm specifications ・Confirm inventory status (quantity & quality)

System Operation

Inquiry of inventory status of spare parts and stores (used for replacements in case of an incident) can be made. Inter P/S exchanges of spare parts can be made as necessary

Items can be identified by detailed specifications data and drawings, etc.

Systematization of information non receiving and delivery has enabled timely inquiry of inventory status.

Display of drawings and photos

(In case the system is not possessed by P/S)

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(2) Measures against deterioration of facilities: Promotion of Predictive and Preventive Maintenance

A. Enhancement of CBM (Condition Based Monitoring).

The inspection of equipment which is less important is conducted on the basis of CBM; however, it is important for us to tackle equipment maintenance and management in an attempt to expand the definition of CBM which covers not only exclusive diagnosing technique but also routine inspection.

1. 2.

Utilization of five senses at the time of routine inspection by operators Early detection of abnormality by regular functional confirmation tests and issuing of alarms.

Expansion of the definition of CBM which covers not only exclusive diagnosing technique but also routine inspection.

Test Items of Security Devices conducted by the Japanese Electric Power

Companies (once a month)

Electricity-related 1. Seal oil back up activation tests and ANN tests 2. Stator cooling water pump automatic start tests

Main turbine-related

1. Main steam stop valve stem free tests 2. Governor valve stem free tests 3. Reheating valve stem free tests 4. Main turbine security device tests (central remote control) 5. Main turbine’s main oil pump discharge pressure low trip tests 6. Condenser vacuum low trip tests 7. Main turbine shaft bearing oil pressure low trip tests 8. Main turbine thrust protection device activation tests 9. EH oil pump automatic start tests 10. Main turbine suction oil pump (SOP) automatic start tests 11. Main turbine turning oil pump (TOP) automatic start tests 12. Main turbine emergency oil pump (EOP) automatic start tests 13. Bleeder check valve activation tests

BFP-T-related

1. BFP-T High and low pressure steam stop valve stem free tests 2. BFP-T Security device tests

① Thrust protection system activation tests ② Emergency trip system activation tests ③ Shaft bearing pressure low trip tests ④ Main oil pump automatic start tests ⑤ Emergency oil pump automatic start tests

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B. Promotion of facility assessment to prevent serious accidents

a. Conduct trials of pipe thickness inspection work for power generation at a typical unit of a typical power station In August 2004, a pipeline breakage accident (a condenser pipe and a drain pipe of feed water heater) occurred due to reduction of pipe thickness caused by erosion and corrosion at two Japanese power stations, which resulted in a socially major problem. As a result of the pipeline thickness inspection at each power station of electric companies, IPP and private power stations soon after these accidents, many pipelines which did not meet TSR* (Thickness Shell Requirement) were found.

* “TSR” is the thickness required to maintain pipeline strength which is obtained by calculation.

IP and PJB are recommended to establish a pipeline management policy of thermal power facilities as well as pipeline inspection plans and conduct trials of the following contents at early stages in a typical unit of a typical power station because there seems to be the possibility of occurrence of the same accident in Indonesia as well as Japan.

1. Facilities subject to investigation: Thermal power generation facilities using steam turbines with output of 1 MW or more.

Contents of Inspection

2. Pipelines subject to investigation: Pipelines made of materials which have a potential to suffer thickness reduction caused by

water and steam. Each pipeline of the following: ①Main steam system ②Reheat steam system ③Condenser system ④Feed water system ⑤Bleeder system ⑥Drain system 3. Portions subject to investigation (See Figure 5.2-1) : Portions which have a potential for thickness reduction due to erosion and corrosion. ①Control valve downstream ②Glove type check valve downstream ③Elbow ④T pipe ⑤Orifice downstream ⑥Swing type check valve downstream ⑦Reducer ⑧Bent pipe ⑨Glove type valve downstream 4. Inspection (test) method Inspection (test) method should be the following: ①Thickness measurement method with ultrasonic waves pulse reflection ②Test method by radioactive penetration image inspection ③Screening test method using pulse vortex ④Test method utilizing potential difference ⑤Test method with three-dimensional ultrasonic inspection 5. Inspection period: While the unit is shutdown during the scheduled inspection work period.

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Figure 5.2-1 Measurement Points

Figure 5.2-2 Measurement Flow for Key Inspecting System

Decision standard thickness;

less than (tm)?

Decision of measuring points by shape of the measuring parts

Conduct measurements at each measuring point

Yes Detailed measurement around the measuring points

(20mm pitch)

No

Evaluation of the Remaining Life

Pipe thickness evaluation at each measuring point

Preparation of skeleton of pipe thickness inspection range

(Source: “Standard for thermal equipment for power generation”)

(Negative difference)

2/3(tn-tsr)

tsr

tm

tn

T

pipe thickness

Decision standard thickness for detailed measurement (tm) = Required pipe thickness by calculation +2/3 (minimum thickness - required pipe thickness by calculation) ＝ tsr + 2/3 (tn-tsr)

T : Pipe thickness tn : Minimum pipe thickness (Pipe thickness - Required

pipe thickness by calculation) tm : Decision standard thickness for detailed measurements tsr : Required pipe thickness by calculation

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b. Reinforcement of efforts to perform equipment-based maintenance to cope with increasing unexpected troubles due to deterioration of the equipment

The following reinforcing measures are recommended for the equipment- based maintenance from the viewpoint of maintaining reliability.

a) Inspection activities focusing on investigation of deterioration of the whole equipment

Weak points inherent to the equipment should be presumed from the past cases of accidents and maintenance and repair records, and based on such presumption, the inspection menu should be prepared. Then, we should devote ourselves to close inspection on site.

b) Visual inspection by maintenance personnel who are familiar with the worksite facilities of their power station

In order to prevent degradation of accuracy by slipup of critical parts in inspection menu or oversight during inspection, maintenance should be performed by the system reflecting the experience level in facility maintenance.

・ In these maintenance activities, deteriorated parts of facilities should be extracted in a couple of years and the facility inspection points (know-how) should be arranged by job category and device in order to prepare “Manual for Facility Inspection Standards.”

・ Troubles collected in the inspection activities and recent large scale plant disaster cases should be incorporated into the manual from time to time so that the enrichment of the inspection manual can be achieved.

c. Study on the adoption of new exclusive diagnosing tools as measures to prevent facility deterioration

Since unexpected troubles due to deterioration of facilities are expected to increase in the future, it is necessary to study adoption of new exclusive diagnosing tools as measures to prevent deterioration of facilities.

(3) Improvements of education and training at IP and PJB

In order to enhance and maintain reliability of the thermal power stations of IP and PJB, education and training of the power station personnel is one of the vital items, we think it necessary to make improvements of the current education and training.

① Improvements of education of newcomers

A. It appears that same as in IP and PJB power stations, once the jobs of newcomers

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are fixed, their jobs rarely change. Since experience in the operation is very important, technicians (including Engineering, Environmental and chemical personnel) of the newcomers should all be assigned to the operation of power stations for a certain period of time (one year or two) after finishing the common education, and then after that the newcomers should be re-assigned to new jobs. It is also important to rotate subsequent assignments among them.

B. Since not only accidents of power station facilities but also plant trips due to the system failure often occur, it is essential to provide training to the operators to cope with emergency cases. It is suggested that new simulators be installed for such training. The electric power companies in Japan also provide simulator training to operators a couple of years after joining the companies.

C. Along with the above, it is also considered necessary to establish a new Training Center to cope with the increasing necessity of various education and training in the future.

D. As the improvement of facilities is the main purpose of this survey, we have not conducted detailed survey of education and training. However, needless to say, because this issue is vital, we would like to recommend that IP and PJB power stations conduct detailed survey of the other countries’ cases to study better ways.

E. It is also very important to acquire the basic knowledge concerning the operation of environmental facilities as one of the common education.

For example; 1) Outline of environmental issues, such as “Background of environmental

regulations” and “Relations between environmental issues and power station management”,

2) Air pollution and its measures relating to power station management, 3) Water pollution and its measures relating to power station management, 4) Noise and its measures relating to power station management, 5) Concept of air pollution, 6) Concept of water pollution, 7) Concept of noise, 8) Outline of capabilities of environmental preservation facilities, and 9) Way of thinking about capabilities of environmental facilities and methods to

grasp their capabilities.

The Study Team recommend the OJT at power utility companies in Japan, which consists of about two months and two people from IP and PJB respectively, to acquire the practical skills for daily and periodical managements and response to abnormal circumstances, concerning the following issues; - Water quality test and Water supply management,

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- Waste water analysis and Waste management, - Emissions testing and Exhaust gas management, and - Operational management of environmental facilities.

② Prevention of lessons gained from accidents and troubles from fading with time, prevention of recurrence of similar accidents and passing on of skills to next

generation －Preparation of cases of troubles and entry of Data Base－

A. “A collection of unexpected or unusual trouble cases” - Min. 20 cases For example, ・A trip due to boiler “low drum level” ・Steam turbine trip while turbines are gaining speed ・Steam Adjusting Valve spring tightening bolts, etc. ・Inability to start units due to BFP trip while the units are being started up

B. “A collection of damage cases of equipment suffering aged deterioration” - Min. 20 cases

For example, ・Corrosion on exterior surface of pipeline ・Expansion damage (HRSG exhaust gas damper) ・Tube rupture due to surface corrosion ・System shutdown due to malfunction of sequencer, etc.

C. “A collection of facility trouble cases due to human errors” - Min. 20 cases For example, ・ Emergency shutdown of boilers due to erroneous operation of DCS (Digital

Control System) ・ Erroneous activation of Gland Steam Pressure Adjusting Valve due to erroneous

connection of the signal wires ・ Delay in startup due to failure of steam turbine startup conditions ・ Lowering of condenser vacuum

③ Implementation of OJT on quality and safety control in Japan

Purpose : To acquire through OJT the actual status of quality and safety control in scheduled inspection work of the Japanese electric powercompanies in order to enhance skills of maintenance personnel inquality and safety control and make horizontal development of suchskills in Indonesia.

Number of participants

: 4 to 5 persons (Supervisor class in charge of boilers, turbines, generators, instrumentation and electricity)

Implementing Place

: Existing coal-fired or gas-fired thermal power station and such a power station under construction

Duration : about 6 months × 2 times or so

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(4) Arrangement in order and expansion of technical base jobs to ensure quality and safety

< Operation >

① Arrangement in order and development of the data base for “Manual for Measures to be taken in case ANN (Alarm) is issued”

It is important to routinely provide training so that in case of any abnormality in operation, operators can take prompt measures. Therefore, it is very important for us to enhance operators’ knowledge and ability as well as to arrange in order and post the data base of “Manual for Measures to be taken in case ANN is issued” drawing upon the equipment incidents and trouble cases which have occurred at each power station. Meanwhile, we would suggest to utilize paper tests to confirm how much operators have learned required knowledge at each power station.

② “Preparation of new patrol inspection standards and development of the Data Base”

There has been frequent occurrence of unit trips, shutdowns and derating due to turbine vibration troubles, boiler gas leaks, tube leaks, valve leaks, HRSG exhaust gas damper troubles, etc. Under such circumstances, it is important that in the routine patrol inspection, the maintenance personnel not only make a tour of inspection of the equipment using check sheets of the patrol inspection records specifying the operation standard figures of each equipment but also organize the damage mechanism of the equipment experiencing trouble. It is, therefore, important that based on this the operators prepare “New patrol inspection standards” and register the data base specifying the inspection points for each unit. It is also important for the maintenance personnel to prevent patrol inspection oversight and show the patrolling routes for reasonable inspection.

< Maintenance >

① Preparation of the “Manual for repairs of equipment”, “Work standard book”, etc. and development of the Data Base

Great efforts have been made for the maintenance work at each power station. However, it can well be considered that in the future there will be cases where non-delivery of spare parts and tools will cause problems because the relevant equipment cannot be repaired. Therefore, it is necessary to pay full attention to the following points and think of further enhancing reliability of each power station.

・ While the maintenance work is performed by utilizing the Manual for handling each equipment submitted by a manufacturer, it is recommended that in the future, the “Manual for handling each equipment” and “Work standard book” be prepared taking into consideration the experience of power stations.

・ It is also recommended that the important “Repair records,” “Summary of changes

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with time, etc. such as measurement records” be kept or managed by computer.

② Preparation for Manual for basic design and development of Data Base

It is also very important to tackle reorganization of intra-office standards and design standards such as the design manual aiming at arranging and expanding the design technology base and have review meetings of knowledgeable people.

(5) Promotion of information sharing －Holding of operation and maintenance management information exchange meetings－

It is recommended that operation and maintenance management information exchange meetings be held so that information sharing can be promoted.

[ Purpose ] ① To mutually exchange information on challenges tackled by other power stations as

well as know-how which are useful in continuing safe and stable operation of power stations so that the spiraling of the entire power station can be conducted.

② To provide opportunity for company-wide exchanges of chief level personnel who are

in charge of boilers, turbines, electricity, instrumentation and operation and help them to create environment in which routine information exchanges are made.

<Frequency of meetings> Information Exchange Meeting shall be held once a year. ※Time should be taken by each power station for mutual discussions.

<Tasks common to all functions> Information which is useful for safe and stable operation of power stations. ① Prevention of serious disaster ② Prevention of incidents causing supply disruption

<Cases of themes for specific information exchanges> ① Operation management aspect A. Information on efforts made to prevent human errors in operations. B. Information on challenges tackled to achieve early detection of any sign of

Items to be reflected for the improvement and expansion of the manual for designing

2. Since some items which require measures against troubles such as incidents at the existing power stations to reflected in “designing,” such items should be taken in positively.

3. Photos and image figures should be incorporated into the manual for designing so that it can become a visual manual for designing which even beginners can immediately understand.

1. When it comes to the preparation of manuals, they tend to take the textbook style of explaining the design method. However, the design manual should specify “conditions necessary at the time of designing” so that when such conditions are taken in, it should consequently lead to such and such design specifications.

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an accident and prevent expansion of such an accident. C. Information on efforts to conduct educational and technical hand-down. D. Information on soundness of other facilities. ② Maintenance management aspect A. Quality enhancing information on the management status of pending issues. B. Accurate information on implementation of horizontal development of

incidents C. Information on improvement of facility management method (Condition

Monitoring Technician) D. Information on efforts to pass on education and technology E. Information on the soundness of other facilities

5.2.2. Improvement Plans of Scheduled Inspection Work from Operational Aspect

(1) Restructuring of scheduled inspection work and establishment of (Draft) guideline for implementation procedure

It is recommended that in order to prevent repetition of similar accidents due to overlooking, etc. during scheduled inspection and improve security and quality of power generation facilities, the Scheduled Inspection System specifying sharing of roles on user side be structured and the Guideline for Implementation Procedure be established to smoothly implement jobs.

① System for scheduled inspection and sharing of roles

A. Inspection System The inspection system for scheduled inspection shall be as follows:

Deputy Inspection Responsible Person

Effective Responsible Person

Deputy General Manager (Technical)

Adviser

General Manager

IP -Supervisor PJB-Specialist

Inspection Responsible Person

Supervisor

Deputy Inspection Responsible Person

Supervisor Supervisor

Operation Responsible Person

Operator

Inspection ( in charge) Inspection ( in charge)

※To No.1

m No.1

※Fro

Test staff

P/S: B/T/E/C

UBHAR, UHARB/T/E/C

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B. Sharing of Roles The sharing of roles played by members involved in the scheduled inspection between the Power Station and Maintenance Business Division (UBHAR & UHAR) shall be as shown in Table 5.2-2 “Sharing of Roles”.

② Securing of personnel in charge of scheduled inspection

The inspection responsible person shall make necessary confirmation for inspection before the scheduled inspection is started, and prepare an inspection system and after gaining approval from executive the post it in the scheduled inspection record data base. Meanwhile, as for the person in charge of operation and operators, the inspection responsible person shall individually establish the system before performing the activation tests and trial operation inspections.

③ Implementation Procedure for Scheduled Inspection

The sequence of the jobs from the start of scheduled inspection through its completion and the implementation procedure for each job are as follows:

Table 5.2-1 Implementation Procedure of Scheduled Inspection 1. Inspection

procedure The inspection procedure shall be as per Figure 5.2-3 “Flow of Inspection Procedure”.

2. Preparation for test and inspection

(1) Inspector shall confirm the following prior to the test

a. Confirmation of inspection and measurement Inspection and measurement device and testing device shall be calibrated and inspected at intervals specified by the “Guideline for measurement control device management” or before they are used and confirmation shall be made of required accuracy.

b. Confirmation of qualification The inspector shall make prior confirmation by a copy of Requirement Certificate or Work Engagement Career that the testing personnel have required qualification for the implementation of tests, and report to the inspector in charge.

(2) Inspector in charge shall confirm the following before inspection

a. Establishment of system for operating inspection and test operating inspection Operator in charge shall describe the names of Operator in charge and Operator and the day when he confirmed the operator’s qualification in Operating Inspection and Test Operating Inspection System Table (in arbitrary format). Inspector in charge shall confirm that the required items are described before the operating inspection and test operating inspection.

3. Implementation of tests

(1) Implementation procedure of tests Inspector shall confirm that tests are conducted by Test Staff in accordance with Inspection Manual by witnessing the tests each time of the tests. The items to be confirmed shall be as follows:

a. Test method b. Qualified person is conducting the tests c. Parts where the tests are conducted d. Inspection device used

(2) Handling of inspection device Inspector and Test Staff shall handle the inspection device in accordance with the manufacturer’s handling instruction book.

4. Test records (1) Record of test results prepared by Test Staff

a. Inspector shall instruct Test Staff to prepare test records and request him to promptly submit them.

b. Inspector shall confirm the test records submitted by Test Staff and confirm that there is no problem with the test results.

(2) Operating inspection and test records of test operating inspection Inspector shall output and print necessary data for inspection. If the data cannot be output or printed, the data shall be collected. In this case, the data collection may be entrusted with Assistant Inspector.

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5. Conducting of tests

(1) Scope of inspection In accordance with each Inspection Manual.

(2) Inspection method employed by Inspector

a. Inspector shall make a decision to pass or fail of the test results in light of the grading standards by witnessing on site or examining the test records. The date of inspection shall be the date when Inspector made the decision to pass or fail. (a) The kinds of inspection in which the acceptability is decided by witnessing on site shall be visual

inspection, appearance inspection, penetration test inspection, condenser leak inspection, operating inspection, and test operating inspection. However, as for the operating inspection of Gas Detector, the decision to pass or fail can be made by examining the test records.

(b) Regarding inspection other than those referred to in above (a), the decision to pass or fail can be made by examining the test records.

(c) In case inspection is made in factory, the decision to pass or fail can be made by examining the test records after obtaining confirmation by Inspection Responsible Person of the inspection manual prepared by the delivering maker meeting our requirements. (The inspection manual shall be limited to the one specified in advance.)

b. In case it is difficult to make a decision to pass or fail by visual inspection, etc., additional inspection such as PT inspection or technical evaluation confirming the soundness shall be conducted to make the decision to pass or fail. Meanwhile, in case the decision is made to pass or fail by technical evaluation, the approval date of such technical evaluation results shall be the date of inspection.

c. In case repairs are made based on the inspection results, re-inspection shall be conducted and an additional inspection conducted as necessary.

d. In case inspection other than those specified in the Inspection Manual is conducted, inspection manual shall be prepared and approval of Executive Responsible Person shall be obtained.

(3) Witness by Inspection Responsible Person and Deputy Inspection Responsible Person Deputy Inspection Responsible Person shall, in principle, witness on site the decision making on acceptance by Inspector and give appropriate instructions to Inspector and manage him.

6. Inspection records

(1) Recording of Inspection results

a. Inspector shall use “Inspection records” to describe necessary matters and prepare inspection records.Nothing shall be transcribed from the test records into the inspection records except minimum requirements. In case re-inspection is conducted or blank space of the inspection record format is insufficient due to additional inspection, inspection records shall be newly prepared. Each time inspection is conducted, the inspection results shall be confirmed by Deputy Inspection Responsible Person.

b. Deputy Inspection Responsible Person shall confirm that Inspector prepares appropriate records each time inspection is conducted and sign the inspection records. He shall also confirm completion of the inspection of all the facility items (name of inspection in the inspection records) and obtain approval of Inspection Responsible Person.

c. Inspection Responsible Person shall approve of the inspection records and conduct document registration and post in the scheduled inspection record data base inspection cover sheet, test records of operating inspection and test run inspection as well as inspection system table for operating inspection and test runs.

(2) Attachment to Inspection records

a. Materials used to make a decision to pass or fail shall be attached to the inspection records. The original test records prepared by the test staff shall be attached.

b. Description or supplement of the inspection results shall be attached.

c. As for operating inspection and test run inspection, the original of the test records and the actual records of inspection system including Operation Responsible Person and Operator shall be attached. In case it is difficult to make a decision to pass or fail in light of the judgment standards, a list of the test records may be prepared. In that case, the original of the test records shall always be attached.

7. Measures against failure

If Inspector decides that any item does not meet the requirement, the most appropriate measures shall be studied and described in the intra-office prompt report and confirmation of Inspection Responsible Person shall be obtained.

(1) In case repair is made After gaining approval from Inspection Responsible Person, retest shall be conducted after the repair or replacement and the series of actions taken shall be recorded in the inspection records.

(2) In case repair is not made

a. Technical evaluation (a) If technical evaluation method is specified in the intra-office standards, technical evaluation shall be

conducted in accordance with such standards. (b) If there is no prescription in the intra-office standards, Inspection Responsible Person shall coordinate

with the maker’s recommendations, operation records, etc, and if necessary, coordinate with the related parts and report to Executive Responsible Person on the result of the technical evaluation.

b. Special Employment If, as a result of the technical evaluation, Inspector decides that safe and stable operations can be continued until the next inspection, and Inspection Responsible Person approves of it, then it can be treated as Special Employment. The date when the special employment is approved shall be the date of inspection.

Final Report 5 - 20


8. Delivery to next process

If Inspection Responsible Person approves as “pass” or as “Special employment” in making a decision to pass or fail, the delivery to the next process is permissible. If Deputy Inspection Responsible Person approves any item as “pass,” he is allowed to give permission to the assembly or restoration.

9. Inspection process management

Inspection Responsible Person shall prepare “Inspection Process Management Table” after receiving reports from Deputy Inspection Responsible Person and grasp each inspection process. After completion of the inspection, he shall make an interim report to Executive Responsible Person in general interlocking timing. (Such a report can be eliminated if the scheduled inspection does not include the general interlocking.) After making reports upon completion of the inspection, he shall post it on “Inspection Process Management Table” in Scheduled Inspection Record Data Base.”

10. Completion of scheduled inspection

When Inspection Responsible Person confirms the completion of all the scheduled inspections, the inspections shall be completed.

Table 5.2-2 Sharing of Roles

Title Contents of duty Executive Responsible Person / General Manager of Power Station

He shall exercise control over jobs on security at the power station. If Deputy Superintendent is posted, he can have him assist his duty.

Inspection Responsible Person: Representatives of Maintenance Divisions at P/S IP: Supervisor Senior PJB: Specialist

・ He shall be responsible for appropriate implementation of scheduled inspections.

・ He shall prepare Inspection Manual and establish inspection system.

・ He shall post inspectors who have knowledge and experience required to conduct scheduled inspections. On the basis that he shall be familiar and comply with the procedure necessary for inspection, he shall conduct inspection having sufficient contact and cooperation with parties concerned, and give appropriate instructions and make management of inspectors under his control performing their duty.

・ If there is any failure, he shall take measures in accordance with the guideline.

・ He shall confirm that there is no imperfection in the inspection records and attachment and if he finds any imperfection, he shall correct it.

・ He shall be authorized to give permission to the delivery to next process.

・ He shall conduct process management of scheduled inspections. Deputy Inspection Responsible

Person: ・IP/PJB Power Station: Supervisor (B/T/E/C) ・UBHAR/UHAR； Supervisor (B/T/E/C)

・ When Inspection Responsible Person is absent, he shall perform superior’s duty on his behalf.

・ If it is difficult for him to abide by the procedure necessary for the inspection in performing his duty, he shall seek Inspection Responsible Person’s judgment and take necessary measures.

・ He shall confirm that there is no imperfection in the inspection records and attachment, and if finds any imperfection, he shall correct it.

・ He is authorized to give permission to the assembly or restoration.

・ He shall grasp the inspection status and periodically report to Inspection Responsible Person.

・ Deputy Inspection Responsible Official who has qualification necessary for inspection can perform Inspector’s duty.

Inspector (Maintenance Div.) ・IP/PJB Power Station: Technician Senior (B/T/E/C) ・UBHAR/UHAR； Technician Senior (B/T/E/C)

・ On the basis of compliance with the procedure necessary for inspection, he shall conduct scheduled inspections.

・ If he finds it difficult to abide by the procedure necessary for inspection, he shall seek Inspection Responsible Person’s judgment and take necessary measures.

・ He shall decide to pass or fail in light of the judgment standards.

・ If he finds it difficult to decide to pass or fail, he shall seek guidance or advice from Deputy Inspection Responsible Person, Inspection Responsible Person or BT Chief Technician.

・ If any decision goes beyond the decision standards, he shall review the contents of measures to be taken in case of failure and after obtaining approval from Inspection Responsible Person, he shall take measures against failure.

Operation Responsible Person (IP/PJB)

・He shall select Operators necessary for inspection and give instructions on operations.

・If he finds any malfunction, he shall report to Inspection Responsible Person. Operator

(IP/PJB) ・He shall perform operations under the instructions given by Operation Responsible Person.

・If he finds any malfunction, he shall report to Inspection Responsible Person.

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*1 : If it is difficult to decide to pass or fail, decision shall be made after conducing additional inspection. (Example: Since an incident of a crack was suspected in visual inspection, penetration test was conducted as additional inspection).

Start

Preparation for test

Conducting of test

Permit delivery to next process

Complete inspection

Technical Assessment

Is technical assessment method

“standardized” ?

Maintenance Dept. confirms technical assessment and send the result to Inspection Responsible Person. It gives advice as necessary

StandardizationUBHAR

Use of equipment subject to inspection suspended

Yes Although the result is within the decision standards, if there is any minor incident, the contents of the incident should be recorded along with the reason for the decision to pass. If it is difficult to make such record, photos or sketches may be used.

Yes

Test

(Pass)

No

[ Contents of failure is reviewed ]

Yes

No

Yes

No

Yes

No

[ special employment ]

Technical Evaluation

(Fail)

Repair made

Is repair made ?

As a result of technical

assessment, is continued use possible?

Is the test

conducted appropriately ?

Within decision standards ? (*1)

Figure 5.2-3 Flow of Inspection Procedure

Final Report 5 - 22


(2) Improvements toward reduction of the work period to rationalize the scheduled inspection work

The work period reduction items are employed in Japan at each work process of the scheduled precision inspection of boilers and turbines. We investigated whether or not each power station of Indonesian Power/PT PJB also performed such work process reduction items in the form of questionnaire.

The results are shown in Table 5.2-3. Since these work period reduction items seem to greatly contribute to ensuring high operation performance of the equipment and reduction of the operation and maintenance and repair costs, IP and PJB are recommended to re-review the items of the shortening methods for scheduled inspection at each power station.

Meanwhile, with respect to the basic operation of the scheduled inspection work (disassembly inspection of turbines, etc.) and large size improvement work, we consider it very important to broadly make a study focusing on the review of the work contents, rearrangement of the procedures, improvement of construction methods, development of maintenance tools and temporary construction and utilization of new technology to achieve reduction of the work period.

(Reference) Employment status of Scheduled inspection shortening method in Japan.

(Boilers) The employment rates of boiler forced cooling and adoption of vacuum cars such as an ash handling system are very high. These are followed by enlargement of manholes for work and improvement of tube polishing method.

(Turbines) The employment rate of encapsulation of casing insulation materials is high. This is followed by forced cooling of gas/steam turbine, employment of cranes for accessories disassembly, adoption of a mass bolt heater and in-line type oil flushing equipment.

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Table 5.2-3 Scheduled Inspection Shortening Method (Questionnaire Result Summary Sheet)

○:Finishing[adoption] ×;un-adopting (Boiler) －: No response

shortening method Suralaya TanjungPriok Semarang Perak Muara

Tawar Gresik Grati Paiton

1 Boiler forced cooling × × ○ × × ○ × ×

2 Enlargement of a manhole × ○ × × ○ × ○ ○

3 Adoption of the scaffold in a lifting furnace ○ × × × ○ ○ × ×

4 An improvement and increase of a mechanic tool ○ ○ × － ○ ○ ○ ○

5 Increase of welding equipment ○ ○ × × ○ ○ × ○

6 Foundation of the scaffold work in a furnace ○ ○ ○ － ○ × × ×

7 Adoption of the scaffold in a sky station (gondola type) furnace ○ ○ × × ○ ○ － ○

9 Adoption of vacuum car, such as an ash handling system × －－－－－－ ×

10 An improvement and of the polish methods, such as a pipe and a tube ○ ○ × － ○ ○ ○ ○

(Turbine)

shortening method Suralaya Tanjung Priok Semarang Perak Pesang

-garan Pemaron Gilima- nuk

MuaraTawar Gresik Grati Paiton

1 Forced cooling of a gas/ steam turbine × × × × × × ○ ○ × × ×

2 Encapsulation of casing keeping-warm material ○ ○ × × ○ ○ ○ ○ × ○ ○

3 Adoption of a mass bolt heater ○ ○ ○ － ○ ○ ○ × ○ ○ ○

4 Increase of welding equipment ○ × －－－－－ ○ ○ × ○

5 Adoption of a high frequency bolt heater ○ ○ ○ － × × × ○ ○ ○ ○

7 Encapsulation of main steam entrance pipe flange part keeping-warm material

○ ○ × × －－－ ○ × ○ ○

8 The crane for accessories disassembly ○ ○ ○ × ○ ○ ○ ○ ○ ○ ○

9 Hydraulic coupling bolt ○ ○ ○ － ○ ○ ○ ○ × ○ ○

10 Adoption of turbine casing jack rise equipment ○ ○ ○ － ○ ○ ○ ○ × ○ ○

11 Adoption of turbine rotor slewing mechanism ○ ○ ○ － ○ ○ ○ ○ × ○ ○

12 Foundation of a diaphragm storage stand ○ ○ ○ － ○ ○ ○ ○ × ○ ○

13 Adoption of in-line type oil flushing equipment ○ × × × × × × × ○ ○ ○

14 Adoption of additional oil flushing equipment ○ × ○ × ○ ○ ○ × ○ ○ ○

Final Report 5 - 24


5.3. Hydropower Stations Based on the review and analysis as mentioned in Section 3, common issues to be studied for each power station are as follows at the moment. And selections of the items to be applied are recommended.

(1) Periodical Personnel Exchange between Operation Staff and Maintenance Staff

Number of operation staff and maintenance staff seems to be enough at the all power stations. However, the periodical personnel exchange between operation staff and maintenance staff is seldom carried out basically. The periodical personnel exchange is advisable in view of further upgrading the existing skill of the relevant staff.

(2) Flexible operation of scheduled periodical inspection

The periodical inspection in Indonesia consists of “Annual Inspection (AI)”, “General Inspection (GI)” and “Major Overhaul (MO)” basically and a certain inspection is conducted for almost every year in keeping with the schedule. However, considering the current frequency level of accidents, the flexible operation of scheduled periodical inspection including the extension of interval is advisable like Soedirman, which once simplified Annual Inspection (AI) to 6-month maintenance inspection and reduced the inspection duration to 30 hours for an example.

Concerning the Major Overhaul, MO is scheduled to conduct for every 40,000 hours basically. However, MO has not been carried out up to now at Soedirman power station because the operation has been in good condition even though the first commercial operation was about twenty (20) years ago (1998.11). If the unit operation is in good condition, non Major Overhaul is advisable.

(3) Better operation and maintenance work

Indication of the equipment name or machine’s abbreviation number is quite important to prevent miss operation and/or miss judgment. Therefore it is desirable to indicate above mentioned indications for safety work.

For the meters, pressure gauges, level gauges, indication of standard value or normal range is desirable if possible.

Description of the criteria is important in the recording sheets for easier judgment during maintenance work.

Measurement and recording of the unit operation sequence time (for instance “preparation finished, inlet valve full open, start the machine, excitation, in parallel”, and vice versa) during

5 - 25 Final Report


starting and stopping is one of the useful check to judge the machine condition.

The machine’s temperature is recorded closely at this moment for every power station however long term trend management is advised to continue closely for bearing temperature, stator winding temperature, generator cooling air temperature, etc. Concerning the machine temperature management, comparison is quite important for actual gathered data and design data and/or commissioning test data.

In case that abnormal data is found out, urgent confirmation of machine condition and measurement system condition are needed. Also description of its cause is important to the recording sheets for the reference at long afterward maintenance. And it’s important the calibration of the detector if necessary.

(4) Better inspection work

It is considered, overhaul of the machine is not necessary only the reason that operation hours of the unit reach the scheduled period. (and also economical point of view)

Except the special case, it is considered that inspection of the bearing pad surface is not necessary at AI.

Detail description of repair work is desirable in the report for the reference at long afterward.

Polarity index (PI) test and Tan (δ) test are useful for the evaluation of stator winding. Therefore it its desired that both of test is carried out during general inspection. (according to the periodical inspection reports, these tests ware carried out some cases completely and some cases incompletely.)

It is desirable to add the some performance test items after inspection. Measurement of relation between guide vane opening and output is advised to confirm turbine performance. During GI, carrying out the load rejection test is desirable to confirm the governor performance if it is permitted both of the power grid side and power station facility side.

Any performance record is not described in the some periodical inspection report. Test result is important not only to confirm the machine performance but also to compare the previous time record. Therefore description of the performance test record is advised in the report.

Following items are advised individually for each power station. (5) Saguling

Recent year, the forced outages are increased caused by same reason. These may be malfunction of the detector or control module trouble. It is important to replace the related

Final Report 5 - 26


component as soon as possible.

(6) Cirata

The load factor of Cirata is approximately 60~65% every year. At the view point of turbine efficiency, unit operation is rather inefficient. Attempt is needed to improve of the turbine operating efficiency by higher load operation of the units. In this case, consideration is also needed of influence to LFC function.

Cirata office considers shortening the required days for AI to approximately half period. This effort is useful to improve the unit operation availability.

(7) Soedirman

Checking is needed cause of decreasing the average output and attempt is also needed improvement of turbine operating efficiency by higher load operation of the units.

(8) Sutami

Operating hours of Unit 3 is relatively shorter than other units. It is recommended to consider that balancing of operation hours is important for better maintenance.

Regarding the staff profile, average age is relatively high. Therefore assign and training of younger age group is probably needed. Concerning the experience, present condition is ideal. However considering the future, it is important to plan assign the younger age group staff step by step to prevent the age jumping.

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5.4. Regulations related to Power Utilities Companies in Japan This section introduces the related laws and regulations on Power Utilities Companies in Japan, especially on operation and maintenance, in order to serve MEMR, a control authority of Indonesia power sector, for her reference toward the improvement of her supervision and instruction.

5.4.1. Regulations Related to Electricity Utilities Industry Law Power utilities companies in Japan run their business in compliance with the following regulations and rules set by METI (Ministry of Economy, Trade and Industry). (1) Electricity Utilities Industry Law (National Law : enacted in 1964, revised in 2005)

(2) Enforcement Order for Electricity Utilities Industry Law (Ministerial Decree: enacted in 1965, revised finally in 1996)

(3) Rules for Enforcement of Electricity Utilities Industry Law (Ministerial Decree: enacted in 1965, revised finally in 2006)

(4) Ministerial Decree for Technical Standards on (a) Electrical Facilities (enacted in 1965, revised finally in 2006) (b) Thermal Power Facilities (enacted in 1965, revised finally in 2006) (c) Hydropower Facilities (enacted in 1965, revised finally in 2006)

(5) Regulation on Electricity Related Accident Report (Ministerial Decree: enacted in 1965, revised finally in 2004)

On the other hand, the current prevailed regulations and codes in Indonesia are as follows as far as we know. (a) The Law of Electricity2 (b) The Grid Code (ATURAN JARINGAN JAWA-MADURA-BALI) “The Law of Electricity” seems to correspond to “Electricity Utilities Industry Law” in Japan, which regulates the framework of power utility business. And “The Grid Code” seems to correspond to “Technical Standard on Electrical Facilities” in Japan which regulates the technical specification for power grid. The outline of the above regulations and rules relating to power generation facilities, and operation and maintenance in Japan are as follows.

2 The law of Electricity was sumitted to the perlimament on March 22, 2006 and has been under discussion. According to National

Legislative Program, the law of electricity will clear the Diet within this year.

Final Report 5 - 28


(1) Electricity Utilities Industry Law

The national law aiming at protecting the benefit of power consumers and developing the electricity utilities industry soundly by the appropriate and reasonable management of electricity utilities industry, and also aiming at secure the public safety and environmental conservation by regulating the engineering work, operation and maintenance of electric power facilities.

1) Conformance to Technical Standard (Clauses 39 & 40)

(a) The installation personnel of power utility facilities shall keep their facilities conformance to technical standards set by the METI............................... (Cause 39)

(b) If the power utility facilities are judged to be not matched with the relevant technical standard, the Minister of METI has the power to order the installation personnel to repair and modify, and/or to move those facilities, or to stop the operation for the meantime, or to restrict the operation. ......................... (Clause 40)

As shown in the above, Clause 40 stipulates the power of the control authority.

2) Establishment of Independent Safety Rule (Clause 42)

(a) The installation personnel of power utility facilities shall establish the safety rule on engineering works, operation and maintenance relating to power utility facilities by each organization in compliance with the relevant Ministerial Decrees and submit the notification to the Minister of METI prior to the commencement of service...................................................................................................(Clause 42-1)

(b) If safety rule is modified, the installation personnel shall submit the notification to the Minister of METI on modified issues without delay......................(Clause 42-2)

(c) The Minister of METI can order to modify the safety rule from the viewpoint of assurance of safety of power utility facilities, if necessary. .................(Clause 42-3)

(d) The installation personnel and his employees shall follow the safety rule. ..............................................................................................................(Clause 42-4)

The establishment of “Independent Safety Rule” for the installation personnel is guaranteed by Clause 42. Please notice, however, their safety rule should be in compliance with the relevant Ministerial Decrees.

3) Chief Engineer (Clause 43)

(a) The installation personnel of power utility facilities shall select the chief engineer among chief engineers certified by METI in order to supervise engineering work, operation and maintenance of power facilities. ..................................... (Cause 43.1)

(b) The installation personnel of power utility facilities shall submit the notification to

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the Minister of METI without delay, when the chief engineer is selected and discharged. ........................................................................................... (Clause 43-3)

(c) The chief engineer shall carry the supervision in good faith for engineering work, operation and maintenance relating to security..................................... (Cause 43-4)

(d) The personnel involved in engineering work, operation and maintenance shall follow the instruction of the chief engineer to keep the security. (Clause 43-5)

The more detailed relationship between the certified chief engineers and power facilities are stipulated in Clause 52 of “Rules for Enforcement of Electricity Utilities Industry Law” as follows:

Power facilities Certified Chief Engineers

Hydro Power Station (Dam height is 15 m more, or water pressure of headrace is 392 kPa more, or equipped with surge tank or tailrace)

The personnel who have the certifications of “1st Class Dam and Waterway Chief Engineer” or “2nd Class Dam and Waterway Chief Engineer”

Thermal Power Station (Except driving power is coming from internal-combustion power and driving power of turbine is less 10,000 kW )

The personnel who have the certification of “1st Boiler and Turbine Chief Engineer” or “2nd Boiler and Turbine Chief Engineer”

Business Place controlling power stations, substations, transmission line and distribution line

The personnel who have the certification of “1st Class Electric Chief Engineer” or “2nd Class Electric Chief Engineer” or “3rd Class Electric Chief Engineer”

To keep the security of power facilities relating to engineering work, operation and maintenance, the qualified chief engineer is assigned for every power facilities in Japan.

(2) Enforcement Order for Electricity Utilities Industry Law

1) Collection of Report (Clause 8)

(a) The Minister of METI can let the Electric Power Supplier report the following issues: - Issues relating to management of electric power supply business - Issues relating to engineering work, operation and maintenance in connection

with security of power utility facilities - Issues relating to financial status - Issues relating to management of research services

The control authority can get any information or data relating to electric power supply business according to need.

Final Report 5 - 30


(3) Rules for Enforcement of Electricity Utilities Industry Law

The Ministerial Decree of “Rules for Enforcement of Electricity Utilities Industry Law” gives the more detailed clauses to practice the “Electricity Utilities Industry Law”.

For example relating to Periodic Safety Control Inspection stipulated in Clause 55 in Electricity Utilities Industry Law, the following issues are stipulated3.

1) Steam turbine in a power station except a nuclear power station shall not exceed the four (4) years after the date of commencement of commercial operation, or the completion date of the last voluntary inspection, or the completion date of the last periodical inspection stipulated in Clause 54 of “Electric Utility Law”. ..... (Clause 59-i)

2) Gas Turbine of which output is less than 10,000 kW and Air Heater for operation of Gas Turbine of which output is less than 10,000 kW shall not exceed the three (3) years after the date of commencement of commercial operation, or the completion date of the last voluntary inspection, or the completion date of the last periodical inspection.

..................................................................................................................... (Clause 59-ii)

3) Boiler, Independent Re-heater, Steam Accumulator, Gas Turbine of which output is equal or more than 10,000 kW, and Air Heater for operation of Gas Turbine of which output is equal or more than 10,000 kW shall not exceed the two (2) years after the date of commencement of commercial operation, or the completion date of the last voluntary inspection, or the completion date of the last periodical inspection.

.................................................................................................................... (Clause 59-iii)

4) Regardless of the above articles, the voluntarily periodical inspection is conducted at the timing specified by the head of Regional Bureaus of Economy, Trade and Industry who controls power utility facilities in the relevant region for the following cases;

......................................................................................................................(Clause 59-2)

(a) The head of Regional Bureaus of Economy, Trade and Industry admits the execution of voluntarily periodical inspection at the stipulated timing is not necessary from the viewpoint of operation status, and sets the timing for voluntarily periodical inspection separately.

(b) The head of Regional Bureaus of Economy, Trade and Industry admits the execution of voluntarily periodical inspection is difficult due to the casualty and/or other emergency situation, and sets the timing for voluntarily periodical inspection separately

5) Voluntarily periodical inspection shall conduct for the following items;........ (Clause 60)

3 Clause 59, 60 and 61 are deleted in the final revision in September 2006 in line with the deregulation of power industry.

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(a) Release or overhaul inspection for partial damage, deformation and occurrence of abnormal condition

(b) Operational test inspection for function and actuation condition

6) The record of the voluntarily periodical inspection shall include the following items; ....................................................................................................................... (Clause: 61)

(a) Date of inspection (b) Inspection facilities and equipment (c) Method of inspection (d) Result of inspection (e) Name of the person conducting the inspection (f) Contents of the countermeasures and / or repairs, if any

7) The voluntarily periodical inspection record shall be stored for five (5) years. ..................................................................................................................... (Clause 61-2)

(4) Regulation on Electricity Related Accident Report4

The regulation defines the accidents to be reported to the head of Regional Bureaus of Economy, Trade and Industry or the Minister of METI including the definition of accidents.

1) Definition of accidents (Clauses 1-3, 4, 5)

(a) “Accident of damage” means the power facilities/equipment have stopped the operation immediately or are forced to stop the operation, or become un-operational condition, or to suspend their usage due to the decrease in function and/or loss of function caused by deformation, damage, breakdown, fire disaster, and/or insulation deterioration/breakdown

(b) “Accident of damage for main power facilities” means the main power facilities/equipment, which are given notice separately, have stopped the operation immediately or are forced to stop the operation, or become un-operational condition, or to suspend their usage due to the decrease in function and/or loss of function caused by deformation, damage, breakdown, fire disaster, and/or insulation deterioration/breakdown

(c) “Accident of delivery failure” means power supply to the power consumers are stopped or restricted immediately by the accident of damage, miss-operation of power facilities or non-operation of power facilities. However, the case which the cessation of power supply ends by the automatic close of cable run is excusive.

4 MEMR has no Ministerial Decree corresponding to “Regulation on Electricity Related Accident Report”, although an investigation prior

to the commencement of commercial operation is obligated by the decree.

Final Report 5 - 32


2) Accident Report (Clause 3-2)

(a) Electric power supplier shall report to the personnel specified in the following table, when the following accidents occur.

Table 5.4-1 Regulated Electricity related Accident Report

Accidents Reporting to whom

1 Accident causing injury or death due to the electrical shock or miss-operation of the power facilities or non-operation of the power facilities only for the cases of death, or hospital stay for curing.

The head of Regional Bureaus of Economy, Trade and Industry

2 Fire accident (Concerning the facilities, only for the case of more than 50 % loss by fire. Relating item 1 above and following items 3 to 5 are exclusive.)


3 Accident causing damage for their use relating to public properties and community facilities, such as a road, a park, a school, other facilities and causing serious social impact due to the accident of damage or miss-operation of power facilities or non-operation of power facilities (Relating to item 2 above is exclusive)


4 Accident of damage for main power facilities belonging to followings (Relating item 1 above and following items 8 to 10 are exclusive)

1) Hydropower station of which power output is less than 900,000 kW

2) Steam driving power or powers consisting of two (2) driving power units and more including a steam in a thermal power station, and power facilities which use a gas turbine with 1,000 kW and more or internal-combustion power with 10,000 kW and more as drive power

3) Steam driving power or powers consisting of two (2) driving power units and more including a steam in a thermal power, of which power output is less than 1,000 kW (Boiler related is exclusive)

4) Fuel battery power station (Omission)

5) Solar battery power station (Omission)

6) Wind power station (Omission)

7) Substations with 170,000 V and over to less than 300,000 V

8) Transmission line with 170,000 V and over to less than 300,000 V

9) Omission


5 Accident of damage for main power facilities belonging to followings (Relating to items 1 & 3 above and following items 8 to 10 are exclusive)

1) Hydropower station of which power output is 900,000 kW and over

2) Substation with 300,000 V and over, or substation of which capacity is 300,000 kVA and over, or which has a frequency converter with 300,000 kW output and over, or which has a rectifier with 100,000 kW and over

3) Transmission line with 300,000 V and over (170,000 V and over for direct currency line)

The Minister of METI

6 Accident of delivery failure of which delivery failure output is 7,000 kW more and 70,000 kW less and its delivery failure time is more than one (1) hours, or of which delivery failure output is 70,000 kW more and 100,000 kW less and its delivery failure time is more than ten (10) minutes (Relating to item 3 above and following item 8 are exclusive)


7 Accident of delivery failure of which delivery failure output is 100,000 kV and over, and its delivery failure time is ten (10) minutes and more (Relating to item 3 above and following item 9 are exclusive)


8 Accident causing other electricity power suppliers the delivery failure of which delivery failure output is 7,000 kW and over and less than 70,000 kW and their delivery failure time is one (1) hour and more, or of which delivery failure output is 100,000 kW and over, and their delivery failure time is ten (10) minutes and more due to the accident of damage or miss-operation of power facilities or non-operation of power facilities (Relating to item 3 above is exclusive)


9 Accident causing other electricity power suppliers the delivery failure of which delivery failure output is 100,000 kW and over, and their delivery failure time is ten (10) minutes and more (Relating to item 3 above is exclusive)


10 Omission

11 Omission

12 Accident caused by the abnormal discharge passing through a spillway of a dam (Relating to item 3 above is exclusive)


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(b) Prompt report of electric accidents stipulated in the preceding clause shall be made within forty-eight (48) hours from when the accident was found and informed in manner of telephone etc. concerning the date & time of accident, power facilities which occurred the accident, and brief of accident without delay, and detailed report of electric accidents shall be submitted by the reporting form 11th within thirty (30) days from when the accident was recognized. However, concerning the 7) or 8) in item 4, and 2) or 3) in item 5 in the above table, if the accident was caused by natural phenomena, the submission of reporting form 11th is not necessary. ............................................................................................... (Clause 3-3)

(c) Reporting form 11th.......................................................................(Clause 3 related)

Electricity Related Accident Report

1. Title :

2. Reporting enterprise 1) Name of enterprise (Name of the installation personal of power utility facilities) 2) Address

3. Date and time of accident occurrence

4. Power facilities of accident occurrence (Installed location, working voltage)

5. Status of accident

6. Cause of accident

7. Status of damage 1) Death or injured : yes / no

Status : 2) Firing : yes / no

Status : 3) Delivery failure : yes (Delivery failure output and time) / no

Status : 4) Others : Affection to others, if any

Status :

8. Date and time of recovery

9. Preventive countermeasures

10. Name and affiliation of the chief engineer

11. Confirmation by the installation personal : yes / no

Based on the above introduction of current regulations and rules in Japan, the following relationship between power utility companies and controlling authority (METI) is able to be drawn.

Final Report 5 - 34


Power Utility Companies METI

Operation and Maintenance

Establishment of Technical Standard

Establishment of Safety Rule

Establishment of Qualification System

Selection of Qualified Chief Engineer

Collection of any Data and Information

Submission of Accident Report

Issuance of Business Improvement Order, if any Power Utility Companies

METI Execution of necessary

countermeasures

Figure 5.4-1 Relationship between Power Utility Companies and METI in Japan

5.4.2. Other Related Regulations and Qualified Personnel in Japan

In the practical operation of a power plant, many related regulations not limited to the regulations in Section 5.4.1 shall be followed. The following table shows the regulations and personnel assignment related to operation of a thermal power plant including the regulations in Section 5.4.1.

Related Regulations Required Personnel

Electricity Utilities Industry Law; Clause 43.1 1st /2nd Class Electrical Chief Engineer

Electricity Utilities Industry Law; Clause 43.1 1st/2nd Class Boiler Turbine Chief Engineer

Law of Rationalization for the Use of Energy; Clause 7.1 Qualified person for Energy Management (Heat)

Law of Rationalization for the Use of Energy; Clause 7.1 Qualified person for Energy Management (Electricity)

Law of Development for Pollution Control Organization for Specific Factory; Clause 3 & 7

Non-qualified Engineer

Law of Development for Pollution Control Organization for Specific Factory; Clause 4 & 6

Qualified Manager in charge of Pollution Control

Waste Disposal and Public Cleaning Law; Clause 12.2.6 Qualified Chief Administrator for Industrial Waste (subject to) Special Control

Law of Digestion Tank; Clause 10.2 & 10.3 Non-qualified Engineer

Industrial Safety and Health Law; Clause 11.1 Non-qualified Person

Industrial Safety and Health Law; Clause 12.1 1st /2nd Class Health Administer

Industrial Safety and Health Law; Clause 14 Operation Chief for Specified Chemical Substance

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Related Regulations Required Personnel

Fire Service Law; Clause 8.1 Fire Marshal

Fire Service Law; Clause 12.7 Non-qualified person

Fire Service Law; Clause 13.1 1st/2nd Class Operator for Dangerous Article

Fire Service Law; Clause 14 Non-qualified person

Fire – Prevention Law; Clause 17.1 Non-qualified person

High Pressure Gas Safety Law; Clause 27.2 & 27.3 & Clause 33

Qualified Manager for High Pressure Fabrication Security

High Pressure Gas Safety Law; Clause 28.2 Non-qualified person

Port Regulation Law; Clause 24 Non-qualified person

Port Regulation Law; Clause 5 Non-qualified person

Road Traffic Law; Clause 74.2.1 Non-qualified person

Road Trucking Vehicle Law; Clause 50 & 52 Non-qualified person

Water Works Law; Clause 19 Person participating in Water-works Engineer Lecture

Final Report 5 - 36


5.5. Guideline and Management Plan for Thermal Power Station 5.5.1. System and Regulations on the Operation, Maintenance/ Inspection Management

As for the system and regulations for the operation, maintenance/inspection management to cope with short-term and mid-term power demand in the entire Java-Bali regions, we would recommend them on condition that the following requirements are met.

(1) Organization

A. The system for the operation, maintenance/Inspection management of the thermal power stations (hereinafter “Organization”) shall have clear description of the responsibility, authority and mutual relationships of the following departments (including the employees) and shall be documented. ① Department which manages the jobs on the operation and maintenance and safety

management. ② Department which implements the jobs on the operation and maintenance and

safety management. ③ Department which verifies the validity of the jobs on the operation and

maintenance and safety management.

(Remarks) “Safety management” means to make prior evaluation of safety when the condition of use such as for the modification of boilers, etc. and to utilize information on malfunctions and incidents inside and out of the company for the operation and maintenance management.

B. Especially, the responsibility, authority and mutual relationships shall be defined, documented and implemented in the departments which require decision making and authority for the following jobs: ① Actions which prevent all the nonconformity on the operation, maintenance and

safety management. ② Clarification and documentation of all the problems on the operation, maintenance

and safety management. ③ Commencement, recommendation or provision of solutions through specified

routes. ④ Verification of the implementation of solutions ⑤ Management until malfunctions or unsatisfactory conditions are corrected.

(2) Standards for the operation management and routine inspection

A. Table 5.5-1 of Boilers/Turbines, etc. Proper standards specifying operation management items shall be established and the operation management shall be implemented based on the standards and the results shall be recorded and kept.

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B. Table 5.5-2 of Boilers/Turbines, etc. Proper standards specifying routine inspection of equipment, inspection points, inspection items, inspection method, standards for adequacy, etc. shall be established and the routine inspection shall be conducted based on the standards and the results shall be recorded and kept.

(3) Measures to be taken in case of an emergency

A. Standards for measures to be taken to cope with abnormality and incidents of boilers/turbines, etc. shall be established.

B. Contact system in case of an emergency shall be established.

(4) Maintenance standards

A. Standards shall be established for making a decision on maintenance and repair, etc. B. Records including the details of maintenance and repair, etc. shall be managed and kept.

(5) Management of documents

A. Procedure for managing documents on the operation, maintenance and safety management shall be documented and maintained.

(Remarks) The documents may be hard copies, electronic media or any other media.

B. The authorized department shall examine and approve the adequacy of the documents.

C. In order to clarify the updated versions, the procedure for managing ledgers and the like shall be specified.

D. This procedure shall be available at all times to prevent any use of invalid documents or abolished documents.

E. Management of the following shall be ensured. ① Appropriate versions of documents shall be available at all the departments that

operate, conduct maintenance and safety management. ② Invalid or abolished documents shall be promptly removed from all the issuing

departments and using departments, or measures shall be taken to prevent use of documents for unintended purposes.

③ Appropriate identification shall be made for abolished documents which are kept for the purpose of preserving knowledge.

F. Unless expressly instructed, confirmation or approval of any modification shall be made by the same organization that first prepared the documents.

G. If expressly instructed, the procedure for giving instructions shall be clarified.

H. Expressly instructed organization or department shall be able to use any supporting information constituting the basis for the confirmation and alteration.

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I. Parties other than the organization or department which confirmed and approved the supporting information constituting the basis for confirmation and alteration shall be able to use such information.

J. Contents of alteration shall be specified in the documents or in appropriate attached documents.

(6) Education and training

A. Contents of education and training required for all the personnel who are engaged in jobs related to the operation, maintenance and safety management shall be specified, documented, and implemented and such records shall be kept.

B. For personnel who are engaged in specified jobs, the following standards for acknowledging qualification shall be documented, maintained and implemented. ① Acknowledgement of qualification based on appropriate education and training as

necessary. ② Acknowledgement of qualification based on experience.

(7) Management of records

A. The following procedures for operation, maintenance and safety management shall be documented and maintained. ① Identification of records ② Collection of records ③ Indexing of records ④ Utilization of records ⑤ Filing of the records ⑥ Keeping and maintaining of the records ⑦ Abolition of records

B. Records shall be maintained to verify that the records are adequate for the specified requirements and the management is effectively conducted.

C. Record shall be easy to read.

D. Records shall be kept under the environment which is suitable for preventing deterioration, damage and missing.

E. Records shall be kept and maintained so that they can be easily referred to.

F. The duration of keeping records shall be specified and recorded. (Remarks) Records may be hard copies, electronic media or any other media.

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(8) Management of inspection and measurement devices (8)-1 General matters

A. Procedures for managing, rectifying and maintaining the devices used for inspection, measurement and testing (including software for tests) shall be documented and maintained.

B. Errors in measurement when the devices are used for inspection, measurement and testing shall be perceived and such devices shall meet the required measuring capability.

C. In case standard measurement devices such as testing software or testing hardware is used as a system suitable for the inspection, the following verification capabilities shall be demonstrated. ① Such measurement devices shall be inspected in advance. ② Such measurement devices shall be inspected again at specified intervals. ③ The frequency and scope of the inspection shall be specified. ④ Records of the management of such instruments shall be kept. (Remarks) The measurement devices shall include the instruments for the measurement.

(8)-2 Procedure for management

A. Appropriate inspection, measurement and testing device shall be selected and the measuring items and required accuracy shall be specified.

B. All the inspection, measurement and testing devices including measurement device which may affect the quality shall be identified, and traceability with the national standards for calibration shall be verified. The standards for correction in case there are no national standards shall be documented, or calibrated before using and adjusted.

C. The calibration process of the device for inspection, measurement and testing shall specify the following items: ① Type of the device ② Peculiar identification number ③ Setup location ④ Inspection frequency ⑤ Inspection method ⑥ Standards for judgment ⑦ Measures to be taken in case the results are unsatisfactory

D. The calibration status shall be displayed by appropriate signs or approved identification records and the inspection, measurement and testing device shall be identified.

E. The records of calibration of the inspection, measurement and testing device shall be kept.

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F. In case the results of the calibration turn out to be unsatisfactory, the validity of the past inspection and testing results shall be evaluated and documented.

G. Appropriate environmental conditions shall be ensured to conduct calibration, inspection, measurement and testing.

H. In handling, preservation and keeping of the device for inspection, measurement and testing, the maintenance of the accuracy and applicability for the use shall be ensured.

I. Protective measures shall be taken for the inspection, measurement and testing device including testing software and hardware to prevent adjustments which would invalidate the setting of calibration (2).

(9) Corrective measures (9)-1 General Items

A. Procedure for taking corrective measures shall be documented and maintained.

B. The corrective measures taken to eliminate the cause of inconformity or potential inconformity shall satisfy the following items: ① The corrective measures are appropriate for the magnitude of the problems. ② The corrective measures are in proportion to the risks. ③ Attendant on the corrective measures and preventive measures, changes of the

related procedural manual are made and recorded.

(9)-2 Procedure for corrections

A. The procedure for corrective measures shall include the following: ① Effective treatment of reports on failed parts. ② Investigation shall be conducted of the cause of the failure about the equipment,

process and management and the results are recorded. ③ Decisions on corrective measures required for the elimination of the cause of the

failure. ④ Management which ensures the effectiveness of the corrective measures.

5.5.2. Management Plans and Guideline for the Operation, Maintenance/Inspection Management of the Existing Thermal Power Equipment

(1) Operation management (the minimum required efforts)

Standards for operation management shall be specified to perform appropriate operation management.

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Table 5.5-1 Items for Operation Management Equipment Items for Operation Management Remarks

・Steam pressure & temperature at outlet of Superheater & Resuperheater 1 ・Boiler vaporization volume or feed water flow rate ・Drum water level 2 ・Drum pressure 2 ・Quality of boiler water and feed water ・Fuel used ・Spray water quantity of superheater and reheater or steam temperature before and after

spraying 2

Boilers

・Boiler efficiency 3 ・Output of the generators ・Steam pressure and temperature upstream of Main Steam Stop Valve and upstream of

Re-heater Stop Valve

・Steam turbine speed 2 ・Steam turbine exhaust pressure ・Steam turbine extraction pressure and temperature 2 ・Oil pressure at inlet of steam turbine bearings 2 ・Temperature of steam turbine bearings & oil temperature at outlet of bearings 2 ・Characteristics of lubricating oil ・Steam turbine control hydraulic pressure 2 ・Opening of steam regulating valve 2 ・Vibration of steam turbines 2 ・Steam turbine efficiency 3

Steam turbines

・Expansion and difference in expansion of shaft and casing (only for those with 2 or more casings) 2

・Output of generators 4 ・Gas turbine speed 5 ・Discharge pressure of Gas turbine air compressor 2 ・Gas temperature at gas turbine inlet 6 ・Oil pressure at gas turbine shaft inlet 2 ・Gas turbine shaft temperature or oil temperature at gas turbine shaft outlet 2 ・Characteristics of lubricant oil ・Gas turbine control fluid temperature 2 ・Vibrations of gas turbines 2 ・Gas turbine air compressor inlet air temperature 7 ・Fuel used

Gas turbines

・Gas turbine efficiency 8 Note 1: In the case of the unit system, the pressure and temperature may be covered by those upstream of Main Steam Stop Valve and

upstream of Reheating Steam Stop Valve. Note 2: Recording of the data is not always required. However, any abnormality in light of the operation management standards shall be

recorded. Note 3: In the case of the unit system, the boiler efficiency may be covered by the general efficiency of the unit. Note 4: The data may be covered by generation power output. Note 5: In the case of free turbine type gas turbine, the data shall be gas generator speed and output turbine speed. Although recording is not

always required, any abnormality in light of the operation management standards shall be recorded. Note 6: The data may be covered by gas temperature at the gas turbine outlet. Note 7: In the case of indoor equipment, the temperature may be air temperature at air intake of power generation plant, and in the case of

outdoor equipment, it may be ambient temperature. Although recording is not always required, any abnormality in light of the operation management standards shall be recorded.

No.8: The efficiency may be covered by the general efficiency.

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(2) Routine inspection (the minimum required efforts)

The routine patrol inspection method shall be specified and the condition shall be confirmed. In the meantime, the frequency of the patrol inspection shall be 1 time or more per day to achieve early detection of any abnormality.

Table 5.5-2 Routine Inspection Items

Equipment Routine Inspection Item Boiler safety valve ・Steam leaks from valve seats

Main pipeline ・Abnormality of hangers ・Leaks of steam and gas from pipeline ・Vibration of pipeline

Boiler or furnace ・Combustion status ・Abnormality inside the furnace

HRSG ・Damage to boiler body or tubes ・Drum two-tone water level, steam leaks, damage to glass

Steam turbines

・Vibration, abnormal noise ・Steam leaks from casing ・Loosening of bolts & nuts ・Vibration, abnormal noise, spies, superheating and waste oil of bearings

Main heat exchanger, etc. ・Steam leaks ・Water level

Gas turbines

・Vibration, abnormal noise, superheating and other abnormality ・Leaks of gas, lubricant oil, etc. ・Abnormality of scaffolding, supporting metal fittings, and loosening of bolts & nuts ・Vibration, abnormal noise superheating and waste oil condition of bearings

Gas turbine air compressor

・Vibration, abnormal noise and other abnormality ・Leaks of lubricant oil ・Abnormality of scaffolding, supporting metal fittings, and loosening of bolts & nuts ・Vibration, abnormal noise superheating and waste oil condition of bearings

Generators

・Vibration, abnormal noise, offensive smell ・Leakage of hydrogen gas ・Quantity and temperature of waste oil from bearings, bubbling condition ・Vibration of CT bushing and phase separating bus bar, leak from water leakage alarm ・Wear condition, vibration of the brush, superheating and connecting condition of lead

lines Main revolver

excluding Steam turbines, Gas turbines and Gas turbine air compressors

・Vibration, abnormal noise and temperature increase of the body ・Steam and gas leaks from glands ・Oil temperature, oil surface and oil leaks from bearings

Main valves ・Vibration, abnormal noise of valves ・Leaks of steam, gas, etc. from valve glands, valve seats ・Abnormality of activating source

Main transformer ・Superheating, offensive smell, buzzing and discoloring condition ・Conservator oil surface, discoloring condition of breather silica gel

Electric equipment

・Abnormality of display lights on operation panels, monitoring panels, distribution panel switching device, Switch-on condition of alarm display

・Superheating, offensive odor and discoloring and terminal tightening condition ・ Vibration, abnormal noise, offensive smell of motor transformer, illumination

transformer

Instruments

・Damage condition of indicators and recorders, etc. ・Damage condition and any difference by comparison between indicated values and

standard values on instruments such as indicators and recorders ・Condition of ink loss from recorders and of chart processing ・Indicated value on , leaks from detector

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(3) Scheduled inspection (the minimum required efforts)

① Inspection of equipment by overhaul or dismantling ② Activation and adjustment test of equipment ③ Checking of records Scheduled inspection should be conducted by appropriately combining the above three items.

(4) Preparation of guidelines and manuals for thermal power management jobs (Minimum required efforts)

To ensure security and quality of thermal power stations and smooth implementation of the management of thermal power stations, it is recommended that the preparation of the guidelines and manuals along with efforts for the brush-up be made.

A. Preparation of Guidelines for Thermal Power Management Jobs (IP/PJB Head Office)

Items Guidelines 1. Common Standards

for Operation and maintenance

- Guideline for Names of thermal power station facilities - Guideline for handling of accidents, etc. - Guideline for specifying thermal power station facilities codes - Guideline for handling work slips - Guideline for the disposal of industrial wastes

2. Operation Standards (including Plans and Environmental Chemical, etc.)

- Guideline for preparation and management of equipment operating slips - Guideline for security system for thermal power station - Guideline for thermal efficiency management - Guideline for management of soot and smoke - Guideline for management of lubricant oil, etc. - Guideline for statistical treatment of power generation records - Guideline for handling chemicals - Guideline for preparation of daily records of security - Guideline for procedure for operational power stoppage - Guideline for water quality control

B. Preparation of Guidelines for Quality Control Job of Scheduled Inspection (IP/PJB Head Office)

Items Guidelines 1. Maintenance

Standards - Guideline for prior assessment of work safety - Guideline for security standard for thermal power facilities - Guideline for handling spare parts for thermal power station - Guideline for management of measurement control system - Guideline for preparation of specifications - Guideline for implementation of thermal power inspection - Guideline for implementation of welding inspection - Guideline for identification of inert gas, etc. - Guideline for setup of protective relay system of thermal power station - Guideline for management of radioactive isotopes - Guideline for management of skeleton drawings of pipelines of thermal

power station - Guideline for operation management of environment and chemical

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C. Preparation of Manuals for Operation Management of Power Station (Each power station)

Items Manuals 1. Prepared by

Operation Section - Manual for operator training - Manual for operation jobs - Manual for operation ad maneuvering control - Manual for patrol inspection management - Manual for scheduled tests - Manual for measurements to be taken in case an alarm is issued - Manual for management of valve locking

2. Prepared by Engineering Section

- Manual for safety and health activities - Manual for environmental security management - Manual for management of condenser tubes - Manual for high pressure gas security education plans - Manual for high pressure gas vessel management

3. Prepared by Maintenance Section

- Manual for patrol inspection standards for maintenance workers - Manual for security standards for power station facilities - Manual for handling panel operation - Manual for scheduled inspection work of measurement and control system- Manual for operation management method attendant on the change of

control circuit - Manual for budget plans and execution management

5.5.3 Human Resources Development - Review of human resources training method to establish strong thermal power -

It is recommended that the system be established to enable putting the right person in the right position by “setting the training pattern to cope with diversification” and “recording individual career.”

(1) Make all the thermal power personnel acquire the basics of “power generation jobs”

and “maintenance jobs”

• Specifically, in an effort to achieve early learning, make plans to train personnel in the common basics by setting a standard target of 5 years (3 years for operation and 2 years for maintenance).

• After completion of the common basics, in an attempt to foster professional engineers in operation, maintenance and planning (including environmental chemicals) have the personnel acquire the basics for each function and foster personnel at the application stage.

• At the application stage, conduct training management by categorizing the jobs into Application I and Application II. In the meantime, after finishing Application I, promote diversification of (O&M) abilities by planning rotation of personnel with the other power stations.

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(2) Establish training patterns in line with the role of the diversified establishments.

• In light of the above training pattern, make chronological recording of the individual careers (job experience) to establish a system which enables placing the right person in the right position.

< Human Resources Training Method for Each Function to Establish Strong Thermal Power >

(Operating personnel)

Trainee of Application Trainee of Basics (Recording and management of

learning career) Application I (Recording and

management of learning career) Application II (Recording of learning

career) Descriptions of Thermal technological

text ＋

Skills required to perform jobs (inspection, maneuvering, monitoring,

control, etc.)

Skills necessary to perform jobs (operation, monitoring, control, etc.)

• Learning of knowledge: Paper tests

• Learning of technical aspects: Simulator advanced course

Skills necessary for jobs (operation, monitoring, control, etc.)

(Maintenance personnel)

Trainee of Application Trainee of Basics (Recording and management of learning

career) Application I (Recording and

management of learning career) Application II (Recording of learning

career)

Descriptions of thermal technological text

Technical knowledge on equipment structure, principle, characteristics, etc.

＋

Skill to grasp points of attention in job

implementation A series of maintenance jobs including

work plans and implementation, measures against trouble.

• Learning and grasping of points of attention: Oral test for each item


implementation A series of maintenance jobs including

work plans and implementation, measures against trouble

(Engineering, Environment･Planning personnel)

Trainee of Application Trainee of Basics

Skill to grasp points of attention in job implementation Detailing of contents

(Recording and management of learning career)

Application I (Recording and management of learning career)

Application II (Recording of learning career)

Descriptions of thermal technological

text (Technical knowledge necessary to

perform jobs)


implementation Improvement of unit performance, environmental improvement work, water supply, oil management, etc.

━ ＋

Skill to grasp points of attention in job implementation

Final Report 5 - 46


< Image of Training Path >

Training of

common basics path (5 yrs)

・Operation: 3 yrs Patrol: 1.5 yrs Control: 1.5 yrs ・Maintenance:

2 yrs

Application training I (4 Yrs)

Basic training stage of Maintenance worker

(3 yrs)

Basic training stage of planning personnel

(1-2 yrs)

Application training I (2-4 yrs)

Application training II (Finish of application training I to

assuming managerial position)

Application training II (Finish of Application training-I to

assuming managerial posts)

Application training II (Based on basic stage skill until

assuming managerial posts)

(Operators)

(Maintenance workers)

(Engineering, Environment･Planning personnel)

Expert Class

Expert Class

Expert Class

5.5.4. Safety Management

As a measure to ensure the safety of the employees, the following activities shall be recommended.

(1) Check and review of the safety management system

A. Periodical training Periodical training/meeting for safety management should be carried out to the employees for promotion of the safety management abilities. Such training should be given to the members of sub-contractors as well.

B. Exchange of information among each power station Safety management training/meeting should be held in each power station, and the training manual and useful information in the training/meeting shall be exchanged among each power station.

(2) Promotion of the safety management

A. Promotion of OHSAS 18001 To improve the quality of work plan: ① comment given in the “accident factor specification sheet” should be reflected to

the daily work instruction sheet. ② to check weather the safety management is carried out according to the manual

instruction.

B. Execution of safety measure Training and safety management meeting for employees, manufacturers, and

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sub-contractors shall be held periodically to understand the significance of safety management.

C. On the job training for disaster prevention through the predictive maintenance and TBM (Tool Box Meeting) Training for the predictive maintenance by using self-question/answer sheets should be carried out periodically.

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5.6. Guideline and Management Plan for Hydropower Station 5.6.1. Items for Operation Job

Regarding the operation job for hydro power station, the main daily affairs are as ① start/ stop, open/close etc. of the facilities, ② supervision of the machines, ③ daily patrol check of the facilities, ④ open/close and locking of the electrical switches, valves, protection relays, etc. for maintenance work ① During operation of the facilities, preventing the miss operation is the most important.

Therefore, operation of the main machines such as unit start/stop, open/close of main circuit breakers and disconnecting switches are usually carried out by operation staff under the chief engineer’s supervision and instruction step by step.

And the operation job such as open/close the valves, start/stop the auxiliary equipment and locking the relays are permissible in case that the job is in accordance with the approved operation procedure.

② Regarding the supervision of the facilities, careful watching for meters is required at

any time. And daily trainings are important to recover from the abnormal condition quickly.

③ Regarding the daily patrol check of the facilities, not only the visual check but also the

five senses check are important. Also for easier detecting the abnormal condition of the equipment, the daily check sheet had better include the indication of normal/allowable ranges of the relevant meters and detectors, etc. and/or description of the criteria.

The patrol route is carefully considered to prevent the facilities from missing the inspection and for easier patrol.

④ Before starting the inspection work or repairing work, perfect lock of the related

switches, valves, protection relays, and so on are very important in view of safety work of maintenance staffs and the prevention of the bad influence to the power grid.

For these purposes, it is quite important that locking job is carried out based on the approved operation procedure. And it is the same manner during the restoration.

To prevent any miss operation, it is desirable to attach the indicators and/or tags nearby such as machine’s abbreviation number, each equipment name, valve number, valve open/close condition, flow direction and classification of fluid on the pipes.

The main jobs of operation team and examples of regulation and/or instruction notes to be maintained are mentioned bellow.

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(1) The role of operation staff - Start/stop operation and of output, voltage control of the units, open/close operation of

the switches, open/close operation of the valves, and lock/release of the protection relays - Setting the working area for maintenance staffs - Making out the operation procedure and the safety work sheet - Daily patrol check of the facilities - Recording the facilities operation - Making out the managing record of the facilities (operation hours, generated power,

planned outage hours, forced outage hours, energy consumption of the power station use, long term machine temperature record, etc.)

- Supervision of the facilities - Making out the temporary report of the troubles and/or incidents

(2) The role of chief operator

- Direction to the operation staffs concerning the operation jobs of the facilities and confirmation of the operation jobs

- Communication and adjustment with dispatching center, maintenance team and others - Review and approval of operation procedures and safety jobs sheet provided by

operation staffs - Review and confirmation of daily patrol check result - Review and confirmation of facilities operation record - Recording daily log note - Supervision of the facilities

(3) Example of the regulation and/or instruction for better work

- Rule of operation of the facilities; items to be complied during the operation work, principle of planning the operation procedure and safety work sheet, format of the related record sheets, principle of items to be recorded in the daily log notes

- Rule of daily patrol check; important points to be checked closely during daily patrol, daily patrol check items and route, format of the daily patrol check sheets

- Rule of record for operation management; items to be managing, principle of data management, format of recording sheets

5.6.2. Items for Maintenance Job

Regarding the maintenance job for hydro power station, the main affairs are as ① planning, action and evaluation of periodical inspections such as weekly, monthly, yearly and reflection of the inspection result on the next inspection plan, ② in case of trouble or incident, recovering, investigation of the causes and study on prevention of recurrence, ③ examination and management of setting values of protection relays, ④ management of design drawings and calculation sheets, instruction documents, commissioning test records

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and periodical inspection reports, etc.

① For the planning of the inspection schedule and items, it is very important that inspection frequency is decided under consideration of reliability and level of importance of each facility. And the inspection sheet is proposed to include the criterion measure/average level in order to judge whether the machine condition is normal or abnormal at a glance.

Regarding the yearly inspections such as Annual Inspection and General Inspection, these are relatively large scale inspections, therefore it is important that inspection items is decided in advance under the close consideration of previous inspection results. In case that the items which were judged as “good”, it is better to reconsider the extension of the inspection period.

Especially concerning Major Overhaul, it is large scale inspection and gives influence to the power grid reliability and also economical viewpoint, therefore it is quite important that the timing of the M.O is considered closely actual machine condition.

It is not necessary to carry out M.O only by the reason that unit operating hours reach the planned M.O timing.

In the inspection report, detail description of repaired work and operation test results are especially desired for serving subsequent inspections.

② In case of trouble or incident, of course quick recover is very important and it is also

important to investigate it’s cause closely and to prevent recurrence of same trouble. ③ Regarding the protection relays, review of setting values are needed sometime

according to changing the power grid condition and/or changing machine’s operation condition. Therefore, it is important to prepare rule of the calculation method of protection relays.

④ Drawings, calculation sheets, instruction documents, erection records and test records

during the construction period, periodical inspection reports, and so on are quite important for good maintenance. Therefore preparation the managing method is important to prevent any missing the materials.

The main jobs of maintenance team and examples of regulation or instruction notes to be maintained are mentioned bellow.

(1) The role of maintenance staff - Action for weekly, monthly and yearly inspection - Planning of schedule for weekly, monthly and yearly inspection - Planning of items for weekly, monthly and yearly inspection - Evaluation of result for weekly, monthly and yearly inspection

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- Planning, action and evaluation of performance test after inspection - Examination of normal range of equipment - Examination of setting value of protection relays - Recover of trouble and/or incident and examination of causes, and making out the detail

report - Making out of periodical inspection report - Maintaining the drawings, design and calculation documents, instruction documents,

erection and test reports before commissioning, periodical inspection reports, etc.

(2) The role of chief of maintenance - Review and approval of inspection schedule - Review and approval of inspection items - Review and approval of inspection results - Review and approval of test results - Review and approval of examination result of normal ranges of equipment - Review and approval of examination results of protection relays setting value - Instruction of jobs - Review and approval of examination results of cause of trouble or incident and review

and approval of the detail report - Review and approval of periodical inspection reports

(3) Example of the regulation and/or instruction for better work

- Rule of setting method of protection relays - Rule of periodical inspection; inspection period of every facility, inspection items and

points, format of the inspection sheets 5.6.3. Items for Training

(1) General

Basically, on the job training is usually the most effective to improve the skill of the power station staffs. Also, it is quite important that staff’s direct supervisor trains his staffs through the jobs. The mutual study of the staff members themselves is one of good measures to improve the skills. It is also important to impose themes to be studied for each staff and to study the given theme by themselves, and holding the presentation meeting to introduce their study result to all staff is good way to improve the skills. And periodical job rotation between operation staff and maintenance staff is also probably effective to improve the skills. It is important that personnel management is always considered from the long term

Final Report 5 - 52


viewpoint, such as appropriate age grouping and experience grouping to prevent the age and experience gap. Regarding the training of safety work, periodical training is necessary to root out any personnel trouble and facility trouble. In preparedness of possible accidents, the related daily training is important.

(2) Example of Principle and System of Staff Training

Example of the recent principle and system for the staff training is introduced as follows.

1) Technical skill to be achieved

Operation - Technical skill to realize stable and economical operation of the power system - Technical skill to establish speedy recovering plan and to carry out perfect

countermeasure against to wide range incident in the power grid system and facilities

Maintenance; - Technical skill to realize appropriate judgment for deterioration of the facilities and

appropriate planning of maintenance policy. - Technical skill to establish speedy recovering plan and to carry out perfect

countermeasure against to wide range incident in the power grid system and facilities

- Technical skill of dismantling/disassembling and inspection, repairing, diagnosis and testing of turbine, generator, governor and technical skill of inspection, adjustment and testing of excitation system and control system

Repairing and modification work; - Technical skill of appropriate planning and action of repairing/modification work. - Technical skill of planning and applying new technology and method from the view

point of reliability, safety, economy and future.

2) Management of skill level of staff

Technical level of the staff is basically classified 5 stages. And detail technical items to be achieved, is established for each technical level. (relating operation job; 6 items and relating maintenance job; 17 items)

5 - 53 Final Report


Relation between Technical Level Stage and Technical Level to be achieved Level stage Technical level to be achieved

Possible to carry out easy routine work by own and possible to carry out rather complex routine work under conducting of chief engineer Stage 1

Possible to carry out every routine work by own and possible to carry out for out of routine work under occasional conducting of chief engineer Stage 2

Possible to carry out every out of routine work by own and possible to conduct routine work to junior engineer Stage 3

Be high specialty and possible to carry high level work by own and possible to conduct the work to junior engineer Stage 4

Stage 5 Possible to carry out whole out of routine work by own and possible to conduct every work to whole staff engineer and also possible to offer improvement the jobs

3) Policy of staff training

System of yearly staff training policy is shown in the following table. Based on this policy, detail training program is planned every year for skill up the staff.

System of Yearly Staff Training Policy

Division Manager of power station Each staff

Policy

Target

P

Planning

D Practice

Evaluation

C

Analysis

A Utilization

4) Actual contents of training

The contents of the training is basically consist of 2 level items. One is the item to be trained all company level and other is the item to be trained section or power station level and training program is prepared each skill level. Training items are planned basically section or power station level according to each power station’s specialty and own characteristics.

Yearly training policy

Setting the target

Analysis of result of training

Setting the target

Training program Training plan Skill up by own (planning)

Practice On the job training Skill up by own (practice)

Evaluation of the staff skill

Job rotation

Evaluation, analysis & conduct of all staff

skill improvement

Self evaluation for skill up

The contents of training for each skill level is shown in the following table.

Final Report 5 - 54


Contents of Training for Each Skill Level Stage 1 Stage 2 Stage 3 Stage 4 Stage 5

Mai

nten

ance

Maintenance of turbine &generator

Over haul work of turbine & generator

Maintenance of GOV & AVR

Maintenance of GIS

Maintenance of transformer

Ope

ratio

n

Individual training section or P/S level

(Setting training curriculum

according to own specialty)

Individual training section or P/S level（Same as left）

Individual training section or P/S level

(Same as left)

Self study Individual training section or P/S level (Same as left)

Operation of hydro power

Role of senior operator and senior maintenance staff

Example of detail contents of training is mentioned as bellow.

- Training of maintenance work of turbine and generator Basic technical knowledge and skill are trained through the machine dismantling work by trainee themselves and also machine component is studied. Maintenance work technique and quality management technique is studied to improve the skill. Training items is as follows. Schematic diagram of pressure oil system, Checking the machine drawings, Treatment of maintenance tools, Treatment of measuring instruments, Type and component of turbine, Type･component and cooling type of generator, Type and component of bearing and temperature management, Measurement method of runner gap and guide vane gap, Measurement method of insulation level of stator and rotor winding, Measurement method of voltage balancing of rotor pole, Procedure of assembling and disassembling for turbine and generator (vertical shaft and horizontal shaft type), Non destructive inspection, Inspection and test items of inlet valve, Inspection and test items of governor and management of characteristic of governor function,

- Training of operation Based on assumed abnormal conditions, trouble shooting technology to find out abnormal point and countermeasure technology are trained by simulator. And speedy recovering skill against turbine and generator trouble is improved. Training items are as follows Role and intention of operation staff, Principle and function of protection relays, Sequence diagram of power plant, Check point of technical drawings and diagrams, Report cause of trouble, Basic recovering method of troubles and check point of

5 - 55 Final Report


alarm indications, Principle function of bearings and management of bearing temperature, protection relays for turbine and generator, Startup and manual parallel technology of turbine and generator

- Others Regarding the operation and maintenance technology, training program is established individually according to each power station specialty and skill up of the staff is planned through on the job training, mutual study of staff, etc.

5.6.4. Items for Safety Work Securing the safety work environment is always the first priority and it is necessary not only to prepare sufficient tool and equipment but also to prepare detail regulations for safety work. And trying hard to keep every one informed about above mentioned regulations is required. In order to prevent un-safety work, close communication between the operation staff and maintenance staff is quite important. Regarding the safety work, regulations mentioned in detail are necessary concerning the prevention from electric shock, prevention of fall down, vicinity of energized equipment, serious influence to the power grid by miss-operation of equipment, countermeasure of emergency situation and etc. Examples of the safety countermeasure are mentioned as follows.

① For protection from electrical shock, grounding to the electrical circuit, close lock of the switches, setting the working area, etc. during the work for electrical equipment

② For protection from miss-watering to the penstock and spiral case, open lock of the valves, open lock of the intake gate, open lock of the tail race gate, control of the staff who are working inside, etc.

③ Measures to prevent fall out the some material and/or leaving the tools during the work in the generator

④ Safety measures during the job of altitude point

⑤ During the work for mechanical equipment, to prevent mal-operation, locking the valves, locking the control pressure oil, etc.

⑥ During the work for the control and/or protection equipment, to prevent mal-operation, locking the relays, locking switches for the power source

(1) Main items to be maintain for safety work

- Helmet, work clothes, hard shoes, insulated glove, insulated boot - Safety net, safety belt, voltage detector, grounding rod, oxygen detector

Final Report 5 - 56


- Indication panel for refuge at emergency - Frame work during emergency - Stretcher, fire extinguisher, fire hydrant - Periodical medical examination for all party

(2) Example of the regulation and/or instruction for safety work

- Rule of safety work - Rule of periodical inspection of the tool and equipment for safety

5.6.5. Sample of Regulation, Rule, Standard, Manual for Operation, Maintenance and Safety

(1) General

Rules concerning the operation, maintenance and safety are stipulated as the regulation of operation and maintenance under the all company level regulations which are stated basic rule. And detail operation and maintenance standards and manuals are prepared individually each power station under the above mentioned regulations

System of Regulations, Standards, Manuals for Operation, Maintenance and Safety

(regulation of all company level)

Organization Authorization Power dispatching Security, safety ・・・

(Regulation) Maintenance job for hydro, sub station Dispatching & operation job Maintenance job for civil facilities of hydroMaintenance job for information and communication system ・・・

(Standard, manual) Standard and manual of branch office Operation and maintenance manual for each power station ・・・

(2) Stipulation of the regulations

Above table’s regulation is stipulated as common apply for division and the contents of regulation concerning the hydro power is mentioned bellow.

1) The regulation of maintenance job for hydro power, substation

General Observation, inspection, modification work Action of work Countermeasure of troubles Treatment of safety work and health Management of maintenance data Activity of cooperation with community

5 - 57 Final Report


Management of spare parts Prevention of any incident caused by human factor

2) The regulation of dispatching and operation job

The rule related to hydro power operation stipulated in the regulation is as follows. General General control and operation job Control and operation during normal condition Control and operation in case of trouble Control and operation during abnormal whether condition

3) Operation and maintenance manual

Outline described in OM manual is shown in the following table.

Outline described in OM Manual Operation Manual Maintenance Manual Safety Manual

(Law, statute or regulation) /Regulation of noise /Regulation of vibration (Operation) /Power system operation /Water system operation (Monitoring and supervising) /Plant condition monitoring system /Supervising of each equipment (Operation of equipment) /Operation of system /Operation of equipment /Automatic operation /Description of operation procedure sheet /Pointing out and recitation for confirmation /Operation of power supply /Grounding (Countermeasure against trouble) /recovering trouble /recording trouble /Trouble shooting /Simulator training (Prevention of emergency situation) /Abnormal natural phenomena /Lighting struck /Fire fighting

(Law, statute or regulation) (Periodical observation) /Routine observation item and frequency /Routine observation sheet /Management of routine observation dada (Periodical inspection) /Periodical inspection item and frequency /Periodical inspection sheet /Management of periodical inspection data /Long range plan of periodical inspection /Periodical inspection report (Repair) /Cost reduction of inspection or repair work (Management of instrument) /Check item and frequency of instrument /Method of check /Point of calibration test /Record of check or management sheet (Disassemble or assemble sheet) /Description of sheet /Repair report and check sheet / (Maintenance schedule) /Outline of maintenance management system /Report of maintenance /Repair planning /Procedure for trouble shooting /Protection from small animals /Risk management from disaster /Use of transportable equipment /management of spare parts

(Law, statute or regulation) /Works required license (Management system for safety and health) /Role of manager of safety /Role of chief of safety on site (Essential point for safety) /Grounding of electrical circuit /Permission signature for work /Protection and safety tool (Essential point to prevent human damage) /Protection of falling down from height /Operation of crane /Operation of winch /Welding work /Risky work of oxygen deficit /Measures of human factor (management for hazardous materials) /Treatment of hazardous materials /Treatment for storage of hazardous materials

Final Report 5 - 58


6. TECHNOLOGY TRANSFER 6.1. Thermal Power Station 6.1.1. Background

In the 1st Field Work, the JICA Study Team visited twelve (12) thermal power stations and LITBANG, PLN’s research institute, and confirmed the current achievement of Remaining Life Assessment (RLA) for thermal power stations in Indonesia in order to reflect technology transfer.

(1) Current Achievement of Remaining Life Assessment

The Study Team collected data/information for PLTU, the objective of Remaining Life Assessment, regarding; - operation hours - rehabilitation and modification works in the past - whether Remaining Life Assessment has been conducted for a boiler, a turbine and a

generator

The results revealed the following facts; 1) The maximum operation hours are 28 years and some power stations exceed the design

life time. 2) Facility Assessment regarding a boiler has been conducted by them and some facilities

have been replaced step by step. 3) Remaining Life Assessment relating to a turbine and a generator has been conducted by

manufactures.

PLTG is excluded from technology transfer of Remaining Life Assessment because the facilities seem to be rather new and maintenance method by equivalent operation hours has been established.

The results of investigation are shown in Table 6.1-1 and Figure 6.1-1.

(2) Current Achievement of Remaining Life Assessment by LITBANG

In the meeting with LITBANG, the following matters are confirmed relating to RLA. 1) LITBANG has already Remaining Life Assessment technology for a boiler. 2) LITBANG hopes for Remaining Life Assessment technology for a turbine and a

generator.

6 - 1 Final Report


Table 6.1-1 Achievement of RLA and Rehabilitation/Modification Unit Capacity Commissioning Operating

Time Remaining Life Assessment &

Performance Assessment Situation of Replacement Power Station

(MW) yy.mm 2006.2 base Boiler Turbine Generator Boiler Turbine Generator

1 TU 400 1985.04 20Y10M ○ ○

2 TU 400 1985.06 20Y 8M ○ ○ ○ ○ ○ ○

3 TU 400 1989.02 17Y00M ○

4 TU 400 1989.11 16Y 9M ○

5 TU 600 1997.06 8Y 8M

6 TU 600 1997.09 8Y 5M

Suralaya

7 TU 600 1997.12 8Y 2M

3 TU 50 (1998) Retired ○ ○ Tanjung Priok

4 TU 50 2005.12 2M ○ ○

1 TU 50 1978.09 27Y 5M ○ ○

2 TU 50 1978.1 27Y 4M ○

Tambak Lorok

3 TU 200 1983.07 22Y 7M ○ ○

1 TU -25 1964 -

2 TU -25 1964 -

3 TU 50 1978.04 27Y10M ○

IP

Perak

4 TU 50 1978.07 27Y 7M ○

1 TU 100 1979.02 27Y00M ○

2 TU 100 1979.02 27Y00M ○

3 TU 100 1979.06 26Y 8M

4 TU 200 1981.11 28Y 3M ○

Muara Karang

5 TU 200 1982.06 27Y 8M ○

1 TU 100 1981.08 24Y 6M ○

2 TU 100 1981.11 24Y 3M ○

3 TU 200 1988.03 17Y11M

Gresik

4 TU 200 1988.07 17Y 7M ○

1 TU 400 1994.04 11Y10M ○ ○ ○

PJB

Paiton

2 TU 400 1993.11 12Y3M ○ ○ ○

Final Report 6 - 2


Suralaya

0

5

10

15

20

25

30

1u 2u 3u 4u 5u 6u 7u

Unit No.

Year

Operating Time

Perak

0

5

10

15

20

25

30

1u 2u 3u 4u

Unit No.

Yea

r

Operating Time

Muara Karang

0

5

10

15

20

25

30

1u 2u 3u 4u 5u

Unit No.

Yea

r

Operating Time

Gresik

0

5

10

15

20

25

30

1u 2u 3u 4u

Unit No.

Yea

r

Operating Time

Paiton

0

5

10

15

20

25

30

1u 2u

Unit No.

Year

Operating Time

Figure 6.1-1 Operating Time (Years) for PLTU

(3) Conclusion

Based on the above investigation, the following issues are confirmed for RLA. 1) LITBANG, PLN’s research institute, has already RLA technology for a boiler. 2) RLA for a turbine and a generator has been carried out by manufacturers and

LITBANG hopes for technology transfer of RLA regarding a turbine and a boiler. 3) Since some power stations have already exceeded the design life time, the execution of

RLA is required. Considering the deterioration of facilities, rehabilitation/modification works in the past and effectiveness of RLA technology for Indonesia side addition to the above confirmation, the contents of technology transfer for a boiler, a turbine and a generator had been set by the

6 - 3 Final Report


Study Team and consensus was obtained in the 2nd Workshop. The adoption process of technology transfer for each power generation facility is described from the next page.

6.1.2. Technology Transfer 6.1.2.1 Content of Technology Transfer

(1) Turbine 1. Thermal Power Station RLA has been conducted by turbine manufacturers. 2. LITBANG LITBANG hopes for technology transfer of RLA

Deterioration of turbine might be caused by various factors, such as creep, fatigue and embrittlement etc.

→ Among the above factors, deterioration by embrittlement is important because turbine failure by embrittlement causes the serious damage.

Example of burst of turbine rotor due to embrittlement

(USA Gallatin #2 1974) Turbine rotors manufactured in 1970s have more embrittlement components, such as P, Sn, Sb,

As, and S, than those manufactured in 1980s. Therefore, attention shall be paid to those turbine rotors. Power stations which have the turbine rotors manufactured in 1970s are as follows;

Perak : Units 3, 4 (1978) Tambak Lorok : Units 1, 2 (1978) Gresik : Units 1, 2 (1981)

Based on the above reasons, Non-destructive Evaluation of Temper Embrittlement in Cr-Mo-V Rotor (Measuring method of embrittlement rate by corroding gain boundary on the surface) was introduced. Method, content and characteristics of RLA in Japan was explained.

Final Report 6 - 4


(2) Boiler 1. Achievement of RLA RLA has been conducted by LITBANG. 2. Current Status of Boiler Many unit trips occur due to boiler tube leak and some of leaked tubes are still with the design life time.

The above phenomenon could be interpreted as the phenomenon has happened due to not only the single factor such as creep damage or fatigue or corrosion damage but also compound damage consisting of these damages. Therefore, the following compound damage mechanism and evaluation method are introduced.

１

1) Compound creep damage 2) Corrosion fatigue damage

When the evaluation of compound damage for boiler tubes is conducted, it is necessary to know the current tube condition such as degree of corrosion and steam oxidation scale thickness at inner tube. Therefore, more easy-to-use and more accuracy inspection devices are introduced.

2

Boiler Inspection Device

1) Corrosion fatigue detecting MT device

2) Steam oxidation scale thickness measuring device

3) Coil deep space inspection device

sampling inspection ntubes from N tubes.Supposing themaximum value ofreducing thethickness of eachtubes are Xi

(1)Presumed value of reducing the thickness of object tubes(2)Proportion of tubes below tsr

Presumed Information

(1)Advance prevention of explosion(2)Making clear the stage of renewal everyblock

aplication

tube

LΔL

Header

ExampleN

Xireducing the thickness

cumulativeprobability

Ti

T(reflexive period)

⎟⎠⎞

⎜⎝⎛

Δ⋅⋅

=ln

LNTN

NX

estimate

presumed maximum reducing the thickness(N tubes)

Measurement of pitting corrosion is sometimes forced to be conducted within the limited duration in the course of periodic inspection of a boiler and or some measurement points require a scaffold to access the points. One of the alternatives to avoid such restrictions is Extreme Value Statistical Analysis Method, which can estimate the maximum pitting depth and the minimum tube thickness statistically for the objective portion by the limited tube thickness data sampled at periodic inspection. Extreme Value Statistical Analysis Method, of which concept is shown in the following figure, was introduced.

3

6 - 5 Final Report


(3) Generator Defects of a power generation body are mainly cased by the deterioration of insulator,

although defects are caused by many factors. Concerning the insulator deterioration, the deterioration of a stator coil has been going on

in proportion to operation hours due to electric charge, thermal stresses and low cycle fatigues. Once dielectric breakdown at a stator coil occurs, a power station has to stop the generation promptly and it takes a lot of time and money to restore generally. For the above reasons, the deterioration diagnosis technology for a stator coil is introduced.

Insulator deterioration at a stator coil causes occurrence and enlargement of a void. The more and larger voids occur, the lower dielectric breakdown voltages (BDV) become. Therefore, the degree of insulator deterioration can be estimated by the measurement of dielectric breakdown voltages at an each generator unit. However, since BDV cannot be measured directly for an actual generator, the degree of insulator deterioration can be also estimated by measuring a partial discharge, which has the strong correlativity with BDV.

The monitoring device called as “On-line Partial Discharge Monitor for Turbine Generator”, which can measure a partial discharge without stopping the operation, was introduced.

PD sensorground brush

Generator

Turbine

Exciter

Transformer

Isolated- phase bus

Partial discharge monitor

PD - monitor - setting ,display, record

PD - monitor - setting ,display, record

Antenna (option)- for noise reduction

Antenna (option)- for noise reduction

RFCT (option) r noise reduction

- foRFCT -

(option) for noise

reduction RFCT - for receiving PD

signal

RFCT - for receiving PD signal

Rotor axis

Final Report 6 - 6


6.1.2.2. Schedule of Technology Transfer

(1) RLA general, turbine-related and boiler-related

The technology transfer relating to a boiler and a turbine was conducted at the IP head office on the following schedule. ・General of Remaining Life Assessment and turbine-related…………….…July 13, 2006 ・Boiler-related and exercise of “Extreme Value Statistical Analysis”………July 14, 2006 The program on July 13 and 14 is shown below. Date: July 13-14, 2006 Place: INDONESIA POWER HEAD OFFICE 5th floor Meeting Room Subject: Technology Transfer Relating to Remaining Life Assessment

Time Content Presenter

09:30 ~ 09:40 Opening Speech by PJB, IP

09:40 ~ 12:00 General of Remaining Life Assessment Technology Mr. Haruki

12:00 ~ 13:00 Lunch Time

13:00 ~ 14:30 Technology Transfer on Turbine RLA Part 1 (Introduction of Technical Paper for Turbine) Mr. Haruki

14:30 ~ 14:45 Coffee Break

14:45 ~ 15:40 Technology Transfer on Turbine RLA Part 2 (Introduction of Technical Paper for Turbine) Mr. Haruki

15:40 ~ 16:00 Question and Answer

16:00 ~ 16:05 Closing Speech by PJB

2. July 14, 2006



09:40 ~ 10:30 Technology Transfer on Boiler RLA (Introduction of Corrosion fatigue and Compound creep damage)

10:30 ~ 11:30 Introduction of Extreme Value Statistical Analysis Method Mr. Matsuno

11:30 ~ 13:00 Lunch Time

13:00 ~ 15:00 Actual training for Management Method of Extreme Value Statistical Analysis Mr. Matsuno

15:00 ~ 15:05 Closing Speech by PJB, IP

6 - 7 Final Report


(2) Generator-related including hydropower station

The technology transfer relating to a generator including hydropower station was conducted at the IP head office on the following schedule. ・Generator relating to a hydropower station and a thermal power station……July 24, 2006 The program on July 24 is shown below.

Date: July 24, 2006 Place: INDONESIA POWER HEAD OFFICE Subject: Technology Transfer Relation to Remaining Life Assessment



09:40 ~ 10:10 Remaining Life Assessment by using nondestructive examination results for casing and stay vane Mr. Aoyama

10:10 ~ 10:50 Remaining Life Assessment by using management of welding volume for turbine runner Mr. Aoyama

10:50 ~ 11:30 Remaining Life Assessment based on results of electrical insulation examination for generator stator winding Mr. Aoyama


12:00 ~ 13:00 Lunch Time

13:00 ~ 14:40 Introduction of PDM(Partial Discharge Monitor) Mr. Akemoto/Mr. Suetake

14:40 ~ 15:00 Coffee Break

15:00 ~ 15:40 Introduction of PDM(Partial Discharge Monitor) Mr. Akemoto/Mr. Suetake


16:00 ~ 16:10 Closing Speech by PJB, IP

(3) Demonstration

Inspection devices for a boiler-related The demonstration and explanation of inspection devices shown as below were conducted at unit 4 in Muara Karang Power Station on the following program. (a) Date : July 11 and 12, 2006 (b) The number of participants : 14 people (c) Place : The meeting room and unit 4 in Muara Karang Power Station (d) Demonstration devices: ① Corrosion fatigue detecting MT device ② Steam oxidation scale thickness measuring device ③ Coil deep space inspection device (portable)

Final Report 6 - 8


The outline of each device for a boiler-related is as follows.

Inspection device and technique Outline Application

part Inspection

factor

1 Corrosion fatigue defect detecting MT device

The corrosion fatigue crack of the inside tube is inspected by the defect leakage flux.

Water wall Corrosion fatigue

2 Steam oxidation scale thickness measuring device

The steam oxidation scale thickness on the tube inside is measured by the ultrasonic wave from the outside of tube.

Tube, Main piping

Creep, corrosion

3 Coil deep space inspection device (portable)

Visual inspection and the thickness measurement is performed in the deep and narrow space of the coil.

Horizontal coil Erosion

(e) Demonstration result The results of demonstration at unit 4 indicated the following findings: - Tube thickness of superheater at a boiler is normal condition as far as inspected area. - Some amount of steam oxidation scale thickness is observed. The periodic monitoring for the deterioration of boiler tubes was recommended.

Monitoring device for a generator-related The demonstration and explanation of “On-line Partial Discharge Monitoring for Turbine Generator” were conducted at Muara Karang Power Station on the following program. (a) Date : July 28, 2006 (b) The number of participants : 20 people (c) Place : The meeting room and unit 1 and unit 5 in Muara Karang Power Station (d) Demonstration result The demonstration result indicated that no specific issue relating to deterioration of

insulator was observed. The periodic monitoring for the deterioration of insulator was recommended.

6.1.2.3. General Overview

(1) RLA general, turbine-related and boiler-related

1) The number of participants 34 people (as shown in Section 6.1.3.1)

2) Validity of technology transfer During the technology transfer, a questionnaire as shown in Table 6.1-2 was handed over to each participant to collect the comments on the topics of technology transfer and to know the degree of understanding. All respondents to a questionnaire answered that the topics were useful for their daily maintenance activities of power generation facilities and almost of all respondents to a questionnaire could understand the content of topics more than 50 %. Especially concerning a turbine-related topics, more than 90 % of respondents could understand the content 50 % and more, even though the

6 - 9 Final Report


topics included heavy subject matters. Concerning a boiler-related, more than 90 % respondents could understand the content 50 % or more, and 20 % of the total respondents could understand the content 80 % or more. Considering these understanding of participants, technology transfer might be assessed as successfully conducted.

Table 6.1-2 Result of Questionnaire for Technology Transfer

Results of Questionnaire Survey on Technology Transfer Seminar relating to Remaining Life Assessment for Boiler and Turbine

On July 13 and 14, 2006 at IP Head Office 1. Technology Transfer relating to Turbine (July 13, 2006) N=11 1.1 Topics in the Seminar Were you interested in the topics presented in the Seminar? Yes (11) No (0) If your answer is “No”, what a kind of topic are you expecting? Please write your expecting

topics in the following columns. a) b) 1.2 Understanding of topics Could you understand the content of topics in the Seminar? Please mark. 80 ~ 100 % understood (0) 50 ~80 % understood (10) 0~50 % understood (1) 1.3 Contribution toward your work Are the topics useful for your work? Yes (11) No (0) 2. Technology Transfer relating to Boiler (July 14, 2006) 2.1 Topics in the Seminar N=14 Were you interested in the topics presented in the Seminar? Yes (14) No (0) If your answer is “No”, what a kind of topic are you expecting? Please write your expecting

topics in the following columns. a) b) 2.2 Understanding of topics Could you understand the content of topics in the Seminar? Please mark. 80 ~ 100 % understood (2) 50 ~80 % understood (10) 0~50 % understood (1) 2.3 Contribution toward your work Are the topics useful for your work? Yes (14) No (0) If you have any comments on our Seminar, please write in the following column. - Please English speaking fluency

- Please show the data you collected related to the calculation of the graph - Give us information technology (topics) more clearly in presentation. All topics are very

interesting. - If you have any documents about demonstration of monitoring or evaluation of material. - Please provide all references that have been used in the mentioned seminar.

Final Report 6 - 10


Table 6.1-3 Level of Understanding for Technology Transfer (7/13, 7/14) Topics in the Seminar Turbine Boiler

1st day 2nd day Date 2006/7/13 2006/7/14

80 ~ 100 % understood 0 2 50 ~80 % understood 10 10 0~50 % understood 1 1 No answer 0 1 Number of collected questionnaires 11 14

(2) Generator-related including hydropower station

1) The number of participants 28 people (as shown in Section 6.1.3.2)

2) Validity of technology transfer Many relevant staff participated in the technology transfer seminar. Many comments and questions arisen in the seminar indicated that they were much interested in RLA relating to a generator and all respondents to a questionnaire showed their high level of interest in fact. More than half respondents out of the total respondents could understand the content 50 % or more. Considering these understanding of participants, technology transfer for a generator-related might be assessed as successfully conducted as well as a turbine and a boiler.

Boiler

10

211

Turbine

101

80 ~ 100 % understood 50 ~80 % understood 0~50 % understood No answer

6 - 11 Final Report


Table 6.1-4 Result of Questionnaire for Technology Transfer Results of Questionnaire Survey on

Technology Transfer Seminar relating to Remaining Life Assessment for Hydro and Generator

1. Technology Transfer relating to Hydro and Generator N=14 1.1 Topics in the Seminar Were you interested in the topics presented in the Seminar? Yes (14) No (0) If your answer is “No”, what a kind of topic are you expecting? Please write your

expecting topics in the following columns. a) b) 1.2 Understanding of topics Could you understand the content of topics in the Seminar? Please mark. 80 ~ 100 % understood (1) 50 ~80 % understood (10) 0~50 % understood (2) 1.3 Contribution toward your work Are the topics useful for your work? Yes (13) No (0)

Table 6.1-5 Level of Understanding for Technology Transfer (7/24)

Topics in the Seminar Hydro, Generator Date 3rd day 2006/7/24 80 ~ 100 % understood 1 50 ~80 % understood 10 0~50 % understood 2 No answer 1 Number of collected questionnaires 14

12

10

1

80 ~ 100 % understood 50 ~80 % understood 0~50 % understood No answer

Final Report 6 - 12


(3) Demonstration

1) The number of participants

(a) Boiler-related 14 people as shown in Section 6.1.3.3

(b) Generator-related 20 people as shown in Section 6.1.3.4

2) Validity of demonstration Many relevant people, from IP, PJB and LITBANG participated in the demonstration conducted at Muara Karang power station and “On-line Partial Discharge Monitoring for Turbine Generator” was requested to be demonstrated at Kamonjang Geothermal power station.

Unit 4 Boiler Superheater

Inspection Area

Location for Demonstration of Boiler Inspection Devices (7/12, 13)

6 - 13 Final Report


Photos of Technology Transfer (Thermal Power Station)

7/12 Explanation of Boiler Inspection Devices(Corrosion fatigue detecting MT device)

7/12, 13 Demonstration at Boiler Unit 4

7/12 Demonstration of Coil Deep Space Inspection Devices

7/12 Coil Deep Inspection Device

7/12 Demonstration of Steam Oxidation Scale Thickness Measuring Devices

7/12 Steam Oxidation Scale Thickness Measuring Devices

Final Report 6 - 14


7/13,14 Technology Transfer

7/24 Technology Transfer

7/27 Muara Karang Unit 1 Generator 7/27 Confirmation of Terminal Box at Muara Karaang Unit 1 Generator

7/28 PDM Demonstration at Muara KarangUnit 5 Generator

7/27 Result of PDM at Muara Karang Unit 1

6 - 15 Final Report

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5. I MPROVEMENT MEASURES RELATING TO OPERATION...

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