Kallpa Nov - Monthly Report

Monthly Executive Summary Report
NOVEMBER 2015
Table of Contents
Kallpa S.A. Monthly Executive Summary Report
0. Operations Summary
1. Energy Production
2. Performance
3. Maintenance and Work Planning
4. Environmental, Health and Safety
5. HR
6. Training
7. Purchasing and Inventory
8. Security and Emergency
9. Cyber Security
10. Contractors
11. Projects
12. O&M Expenses
12. Plant visits
0. OPERATIONS SUMMARY
KI
November 2015
November 25th - The auxiliary air compressor was found operating

continuously due to failure of the air pressure regulating valve. In
normal operation this compressor only operates when the pressure
drops less than regulated pressure (combustor shell pressure). The
regulating valve was changed and the instrument air system was
left in normal operation
November 28th, REP (Red Electrica del Per) informed that circuit
breaker IN-2504 of transmission line L-2097 was observed with low
pressure of SF6 gas (5.2 bar) in Chilca substation. Temporary
change of the connection was performed from busbar A to the
busbar B through the coupling circuit breaker while leakage was
corrected and SF6 was refilled in the IN-2504 circuit breaker. After
corrective works the circuit breaker was returned back to service
on November 29th
November 29th, 13:33 The unit was shutdown due to lack of
Natural Gas following a fire incident in the reception skid during
pipeline cleaning activities (PIG) performed by TGP (Gas Carrier
Company). The unit was back to service at 18:48 hrs. in simple
cycle, after Natural Gas Supply was available.
Kallpa I - Change of regulator
KII
November 2015
November 29th, 13:59 The unit tripped due to low pressure of gas
fuel during shutdown process at 47 MW. This was consequence of
Natural Gas lacking, following a fire incident in the reception skid
during pipeline cleaning activities (PIG) performed by TGP (Gas
Carrier Company).
November 29th, 17:59 Fire Abort due to sequence 3 failure during

startup process, the unit was restarted successfully at 18:06 hrs in
simple cycle after Natural Gas Supply was available.
KIII
November 14th-16th, Kallpa III - Planned outage for Compressor

Offline washing. Relevant works performed:
Change of the air pre filter and final filter in gas turbine inlet
filter house.
Manual washing of IGV blades and first stages of the
compressor.
Inspection and cleaning of Auxiliary Transformer, surge
cubicle and low voltage transformer.
Electrical protection test for main and auxiliary transformers,
starting motor ( L-2096 de energized) were performed with
successful results.
Diverter damper Hydraulic Oil was changed.
Offline compressor water wash.
November 16th, Kallpa III The unit had several startup aborts due
to Sequence 4 Trip AVG BP RISE. Fuel flow on stage "A" was
increased during the ignition, following Siemens recommendation,
in order to allow the unit reach sequence 4, and unit synchronized
finally afterwards.
November 29th, 13:38 The unit was shutdown due to lack of

Natural Gas following a fire incident in the reception skid during
pipeline cleaning activities (PIG) performed by TGP (Gas Carrier
Company). The unit was back to service at 17:48 hrs. in simple
cycle, after Natural Gas Supply was available.
November 2015
GT3 - Installation of new pre and

final filters.
Kallpa Plant - The line L-2096 de
The fuel flow on stage "A" was increased in order to allow
KIV
November 29th, 13:59 The unit (together with all gas turbines)
was shutdown due to lack of Natural Gas following a fire incident in
the reception skid during
pipeline cleaning activities (PIG)
performed by TGP (Gas Carrier Company). The unit returned back
to service on November 30th at 00:30 hrs.
BOP
Normal operation.
ACC (Air Cooled Condenser)
November 11th, Kallpa Plant, decrease of vacuum in the ACC due

to high wind speed that increased up to 12.5 m/s in South
November 2015
direction. Adjustments were made in the holding ejector in order to

improve the vacuum condition with successful result.
November 23rd, ACC A blade of fan 3 - Street 2 was found broken
when the fan was running and tripped by high vibration level. The
fan was unavailable and the root cause is being investigated. The
damaged blade as well as others in its vicinity were replaced and
the casing was repaired. The fan was returned back to normal
operation on December 4th.
Blade of Fan 3 - Street 2 was found broken - ACC
ACC - Vacuum analysis due to
November 2015
Water Treatment Plant (WTP)
The probing test was performed in the membranes of 1st RO train

A in order to find the problem of high water conductivities.
Internal inspection of the membranes will be programed.
HRSGs
November 29th, HRSG 2 After HRSG was tie-out during the

Natural Gas lack event, a steam leak was identified. The internal
inspection of HRSG-2 was performed and leaks were found two
tubes cracked in CRH#1 lower header A and one drain tube
cracked in CRH#1 lower header B. Welding works, installation of
plugs, liquid penetrant testing and heat treatment to cracked pipes
were performed with satisfactory results. The HRSG-2 was tie-in on
December 3rd to leave the plant operating in CC 3 on 1 mode.
HRSG-2 Leaks were found in the manifold and two lines of cold reheat #1.
November 2015
LAS FLORES I
November 29th, 12:30 - Significant fire was observed in the

reception skid of Gas carrier Company outside Las Flores
boundaries, which occurred during the cleaning of the gas pipe
(PIG) that belongs to TGP and located near Las Flores Plant
facilities. LF-I at that time was in reserve shutdown, however all
the thermoelectric plants in Lima and Chilca area were forced to
shutdown by COES request.
LF-I Fire in the reception skid of PIG,
GYs
November 08th, Kallpa and Las Flores, the line-break protection

was inhibited in natural gas supply valves by TGP-COGA due to the
gas duct cleaning process in "Loop costa NG 24". After the passage
of the cleaning tool (PIG) , line-break protections were
reestablished in CT Kallpa and CT Las Flores.
GY1 - Change of 42 filter elements due to the TGP duct
cleaning activities.
November 2015

GY2 - Change of 80 filter elements due to the TGP duct
cleaning activities.
Gas turbine inlet filters continue without getting dirty (Low
differential pressure).
The cleaning of the gas pipeline by TGP was developed
every Sunday on November 15th, 22th and 29th.
The change of gas filter elements of

GY1 and GY2
GY2 - Natural gas filters C & D were

changed due to high differential pressure
Training
November 26th - Works and Rescue at height.
November 27th The following internal training were performed :

Boiler chemical control product CETAMINE.
Control Emission Monitoring System (CEMS)
Gas Turbine Combustion Dynamics DYNAMON
DYNAMON expert explaining the work of the
November 2015
1. ENERGY PRODUCTION
KALLPA CC PLANT
Gross Generation (Mwh)-Ytd 2015
November 2015
10
Net Generation (MWh) - YTD 2015
Aux Consumption (MWh) - YTD 2015
November 2015
11
CT LAS FLORES I
Gross Generation (Mwh) - Ytd 2015
November 2015
12
Net Generation (MWh) - YTD 2015
Aux Consumption (MWh) - YTD 2015
November 2015
13
2. PERFORMANCE
2.1 Heat Rate

KALLPA CC PLANT
November 2015
14

*Heat rate based on HHV
Natural Gas Net Heat Rate 2015 - (BTU/KWh)
CT LAS FLORES I
*Heat rate based on HHV
November 2015
15
Natural Gas Net Heat Rate 2015 - (BTU/KWh)
2.2 Natural Gas Consumption Cost ($US) 2015
*On November, The Value of Gas Supply was estimated.
*CC Kallpa + CT Las Flores I
November 2015
16

2.3 Natural Gas Consumption (Mm3 std)-2015
KALLPA CC PLANT
CT -LAS FLORES I
2.4 Water & Chemical Consumption (Mm3 std)-2015

Water Consumption -2015
November 2015
17
Water & Steam Cycle Chemical Consumption 2015
Water Treatment Plant chemical consumption 2015
Steam & water quality 2015
2.5 Operational KPIs

KALLPA CC PLANT
Plant Indexes
November 2015
18

Annual Summary -Equivalent forced outage rate (EFOR)
Availability 2015
Reliability 2015
November 2015
19
CT LAS FLORES I
Plant Indexes
Availability 2015
November 2015
20
Reliability 2015
November 2015
21

3. MAINTENANCE AND WORK PLANNING
3.1 MAINTENANCE WORK ORDERS BY TYPE
> In November, 717 work orders (WO) were generated, where the 94 % of WO were from
Kallpa CC and the 6%, from Las Flores.
Site: KALLPA CC
> In November 717 work orders were generated for Kallpa

CC.
> Where 575 were preventive; 95 predictive and 47 were
corrective.
> There were 671 planned activities and 46 not planned.
Site: LAS FLORES I
> Las Flores got 46 work orders in November.

> There were three types of work orders in Las Flores, where 43 were preventive; 7
predictive and 3 corrective.
November 2015
22

3.2 PERCENTAGE OF WORK ORDERS BY TYPE
> In November , from the total of work orders (considering Kallpa CC and Las
Flores), 80% were
preventive, 13 % predictive and 7% were corrective.
> Kallpa CC got a total of 717 work orders, where the 80% were preventive; 13%, predictive
and 7%, corrective.
> While in Las Flores, from the total of 46 work orders, 78% were preventive; 15% predictive
and 17%, corrective.
3.3 PERCENTAGE OF EXECUTED WORK ORDERS BY DEPARTMENT

Site: Kallpa CC
> In Kallpa CC, 43% of WO were mechanical activities, 26% were from I&C and 31% from
electrics
and 0.6 % chemical
> In November, 23% of mechanical's work orders were open, as well as the 6% of the electrics
and 55%
of the I&C orders.
November 2015
23

Site: LAS FLORES I
>31% of the work orders were from electric, 47% from mechanical and
22% from I&C.
> Electric got 100%, I&C got 100% and ,Mechanical 100% finished.
3.4 MAINTENANCE MAN POWER
November 2015
24

KPI Planning -2015
November 2015
25
KPI Corporate Report Maintenance- 2015
November 2015
26
3.5 MAINTENANCE ACTIVITY REPORT

1. Maintenance 2015 Goals
Maintenance goals in progress:
Revision and execution of 150 procedures on maintenance
o Procedures worked up to date are 107 I&C, 46
Mechanical, 12 Electrical. Goal was accomplished.
Formatting procedures to new documentary control
process are ongoing.
November 2015
27

Execute more than 15 improvements projects
o 10 improvement projects have been executed up to
date.
o 2 improvement projects are ongoing.
o 5 improvement projects are in logistic process.
Consumables expenses lower 10% compared against 2014
o Consumables points were identified and plan to
measure and implement are ongoing.
2. Routine Maintenance
Routine maintenance during the reporting period included the
following:
Predictive & Preventive Maintenance was performed
according the program in both plant, Kallpa and Las Flores.
National gas line duct is under maintenance, cleaning tool
(pig) has been using during execution. It will take all
November and part of December. Planning for gas filter
replacement was performed due to dusting generated by
pigging process.
Kallpa 3 outage to perform offline compressor wash was
carried out on 14 and 15 November.
o Final filter and Pre filter replacement
o Primary regulation logic was implemented
o Blade path thermocouple replacement
o Protection relays annual test
o Electrical test over medium voltages devices
o Transmission line L-2096 preventive maintenance
(cleaning and protection duties)
o Preventive maintenance over instrumentation and
motor was performed.
o Exhaust Flow shield repair
o IGV manual washing
3. Corrective Maintenance
Important correctives activities were performed.
Kallpa 2 HRSG fault during a trip sequence, reparation over
CRH#1 module was performed. Cracks on root of pipes to
November 2015
28

header were found. Plugging procedure was performed and
planned to finish on December 4th.
Follow up for ACC fans #18 for leaks
Kallpa # AVR alarm came up, troubleshooting are on the
way.
Hydrogen Generator failed intermittent. Software was
reloaded and unit back in operation. Device is waiting for
manufacturer assistance.
4. Improvements Projects
Project protection fence installed for natural gas and
instruments air pipes is under excecution.
Bid process for hazardous warehouse and controlled disposal
warehouse was complete, paper work related to this projects
are on going in order to start construction in November.
Improvement on primary frequency regulation logic are still
on going.
DP transmitters for Inlet air filters installed for units Kallpa 1,
Kallpa 2 and Kallpa 3.
Document control improvement process is been executing
with all planta areas participating. Maintenance documents
were approved.
5. Engineering on going
Lub Oil Upgrade in Gas Turbine is ongoing. Results are
focused to increase reliability.
Root causes-analysis has already done in order to investigate
ACC Gearbox leakage. Oil was changed in one Gearbox in
order to decrease leakage.
ACC Fan Blade Cracked.
CRH#1 HRSG2
Monthly analysis reports was submitted, vibration trend is
still under observation.
CPH operation mode is ongoing. Results are focused to
recover efficiency on HRSG.
November 2015
29

6. Personnel
Instrumentation engineer start training on Siemens T3000 in
Siemens alpharetta
Electrical engineer was trained on Transformer monitoring on
oil analisis in LABORELEC
Mechanical crew receive training on machinery Alignment &
Visual inspection level 1&2 in ADEMINSA
Qualification personnel process according goals career have
been performed along the month.
4. ENVIRONMENTAL, HEALTH AND SAFETY
4.1 Environmental
Domestic waste disposal in Plants Kallpa and Las Flores.

Hazard waste disposal in Plant Kallpa.
Pest control activities were conducted in Plants Kallpa and Las
Flores.
Environmental monitoring: Noise and emissions in CT Las Flores.
Environmental Monitoring of irrigation water for the ANA
performed by Nakamura Consulting in Kallpa.
4.2 Health
02 occupational medical examinations

conducted.
02 tetanus vaccinations were performed.
Induction first aid target 02 people.
Kallpa
staff
were
4.3 Safety
Training defensive driving target to 12 people.

Certificated in handling Forklift target to 01 people
Power Plant Las Flores
Inspection of fire extinguishers was performed.

Inspection of showers and eyewash was performed.
November 2015
30

5. HR
5.1 HR Statistics 2015
5.2 Hours Lost by Illness 2015
November 2015
31
5.3 Turnover 2015
6. TRAINING
6.1 Training Hours 2015
November 2015
32

During November 2015 were performed 329.5 Training hours for EHS,
Administration and Operations.
6.2 Employees training list:

No of
participants
Duration(
hrs)
Total
training
hours
5 Minutes Speak Operations
13
0.5
6.5
5 Minutes Speak Maintenance
16
0.8
12.8
5 Minutes Speak
Administration
0.5
4.5
Training cardiopulmonary
resuscitation.
14
27
54
23
2.5
57.5
Safety reinduction
Safety Induction
0.5
0.5
IPERc
0.5
0.5
Safety Induction
15
30
10
10
Departm
ent
Training
IPERc
First Aid
EHS
Effective supervision
Safety reinduction
Operation Gas turbine combustion
November 2015
33

systems
Gas turbine operation - CT Las

Flores
HRSG
12
Gas turbines
Closed cooling water (CCW)
16
Diverter Damper System
GPiLearn curso virtual
23.85
95.4
7. PURCHASING AND INVENTORY

> In November, 118 purchase orders (PO) were issued. That made US$
296,990.7 as a total.
November 2015
34
INVENTORY
November 2015
35

> The dispatches that were executed in November made a total of US$ 310, 470,
50 where the
92% of the total was from the main warehouse, while the %8 from the Chemical
warehouse.
8. SECURITY AND EMERGENCY
November 2015
36
8.1 General emergency

No General emergency during November.
8.2 Emergency Events
No Emergency Events during November.
8.3 General security
No Events during November.
8.4 Security events
Simulation earthquake night
8.5 CCTV and access control
No events during November.
8.6
Security staf
The staff includes 15 security guards:

- 7 security guards for the Plant Kallpa
- 4 security guards for the Plant Las Flores
- 4 security guards for the Kallpa Terrain
8.7 General
Man-hours Kallpa 2604
Man-hours Las Flores 1488
Man-hours Kallpa Terrain 1488
9. CYBER SECURITY
November 2015
37

9.1 General Security Events
No events during November.
9.2 Exceptional Events
No exceptional events during November.
10. CONTRACTORS ON SITE
> In November, contractors gave their services, adding up 6157 man-hours.
11. PROJECTS STATUS
November 2015
38

Project
manag
er
Project
Status
Schedule
d
completi
on date
Cost
code
Budget
November 2015
Budget
consum
ed
39

Franco
Liza
Croy
Montoro
Alvaro
Meza
Diego
Valenzu
ela
Alejandr
o
Galarza
Walter
Jara
Omar
Juarez
Vanessa
Nonato/
Angel
Castillo
Miguel
Barba
Julio
Villegas
Partial discharging
measurement
system
Construction of
dressing room
Installation of
Hydrogen Monitor in
H2/CO2 Supply
Station
Corrosion
Measurement in
Combined Cycle
Potable water
treatment system for
administration
building
DP Transmitters in
Air Filter Houses
Implementation of
Arc Flash Protection
procedures
Improvement in
Sodium Hypochlorite
storage
Complet
ed
20-01-15
22, 23,
24, 25
$ 410 388
Complet
ed
Complet
ed
31-05-15
03
$ 122 000
30-04-15
05
Complet
ed
31-05-15
04
Complet
ed
31-08-15
04
$ 10 000
In
Process
In
Logistic
Process
In
Logistic
Process
31-12-15
04
$5 000
31-12-15
05
31-12-15
05
Modifications in seals
of Drainpot pumps
Complet
ed
31-07-15
05
Implementation of
Flushing valves to
hypochlorite pipes
Construction of
Collector house for
Steam Turbine
Change of ACC
Auxiliary
Transformers wiring
Construction of
diesel storage
system
Modification of
chemicals
warehouse
Construction of
dangerous waste
warehouse
In
Logistic
Process
Complet
ed
31-12-15
05
28-02-15
25
$15 000
9 960
Complet
ed
31-01-15
25
$ 100 000
$ 85 807
Complet
ed
31-08-15
05
$ 50 000
$ 31 950
In
Logistic
Process
In
Logistic
Process
31-10-15
04
$ 30 000
31-10-15
04
$ 30 000
November 2015
40
12. O&M EXPENSES
November 2015
41
13. PLANT VISITS
November 2015
42

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Monthly Executive Summary Report

Kallpa S.A. Monthly Executive Summary Report

Kallpa S.A. Monthly Executive Summary Report

November 25th - The auxiliary air compressor was found operating

Kallpa I - Change of regulator

Kallpa S.A. Monthly Executive Summary Report

November 29th, 17:59 Fire Abort due to sequence 3 failure during

November 14th-16th, Kallpa III - Planned outage for Compressor

November 29th, 13:38 The unit was shutdown due to lack of

Kallpa S.A. Monthly Executive Summary Report

GT3 - Installation of new pre and

Kallpa Plant - The line L-2096 de

The fuel flow on stage "A" was increased in order to allow

ACC (Air Cooled Condenser)

November 11th, Kallpa Plant, decrease of vacuum in the ACC due

Kallpa S.A. Monthly Executive Summary Report

direction. Adjustments were made in the holding ejector in order to

Blade of Fan 3 - Street 2 was found broken - ACC

ACC - Vacuum analysis due to

Kallpa S.A. Monthly Executive Summary Report

Water Treatment Plant (WTP)

The probing test was performed in the membranes of 1st RO train

November 29th, HRSG 2 After HRSG was tie-out during the

Kallpa S.A. Monthly Executive Summary Report

November 29th, 12:30 - Significant fire was observed in the

LF-I Fire in the reception skid of PIG,

November 08th, Kallpa and Las Flores, the line-break protection

Kallpa S.A. Monthly Executive Summary Report

The change of gas filter elements of

GY2 - Natural gas filters C & D were

November 26th - Works and Rescue at height.

November 27th The following internal training were performed :

DYNAMON expert explaining the work of the

Kallpa S.A. Monthly Executive Summary Report

Gross Generation (Mwh)-Ytd 2015

Kallpa S.A. Monthly Executive Summary Report

Net Generation (MWh) - YTD 2015

Aux Consumption (MWh) - YTD 2015

Kallpa S.A. Monthly Executive Summary Report

Gross Generation (Mwh) - Ytd 2015

Kallpa S.A. Monthly Executive Summary Report

Net Generation (MWh) - YTD 2015

Aux Consumption (MWh) - YTD 2015

Kallpa S.A. Monthly Executive Summary Report

2.1 Heat Rate

Kallpa S.A. Monthly Executive Summary Report

Natural Gas Net Heat Rate 2015 - (BTU/KWh)

*Heat rate based on HHV

Kallpa S.A. Monthly Executive Summary Report

Natural Gas Net Heat Rate 2015 - (BTU/KWh)

2.2 Natural Gas Consumption Cost ($US) 2015

*On November, The Value of Gas Supply was estimated.

*CC Kallpa + CT Las Flores I

Kallpa S.A. Monthly Executive Summary Report

2.4 Water & Chemical Consumption (Mm3 std)-2015

Kallpa S.A. Monthly Executive Summary Report

Water & Steam Cycle Chemical Consumption 2015

Water Treatment Plant chemical consumption 2015

Steam & water quality 2015

2.5 Operational KPIs

Kallpa S.A. Monthly Executive Summary Report

Kallpa S.A. Monthly Executive Summary Report

Kallpa S.A. Monthly Executive Summary Report