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PRESENTATION

BY

CHIEF EXECUTIVE OFFICER


NORTHERN POWER GENERATION COMPANY
(GENCO-III)
Workshop on Power Sector Reforms
On 11.11.2010 to 12.11.2010
at WAPDA House, Lahore
CONTENTS OF PRESENTATION

1. Brief Introduction
2. Profile of Board of Directors
3. Technical Data of Units at TPS, Muzaffaragrh
4. Effects of Furnace Oil Firing on Boiler
5. Reasons of De-rated Capacity
6. Rehabilitation of TPS, Muzaffargarh under USAID Energy
Support Program.
7. Solutions and Suggestions
BRIEF INTRODUCTION
Northern Power Generation Company Limited
(NPGCL) is a Public Limited Company,
incorporated on October 15, 1998 under the
Companies Ordinance 1984, having Power
Generation facilities at various of locations of
the province of Punjab. It consists of eight
generating blocks having total derated
capacity 1530MW. (Muzaffargarh 1130MW,
NGPS Multan 60 MW, SPS Faisalabad
100MW & GTPS Faisalabad 240MW).
Profile of BOD
Board of Directors Qualification T. Exp., Yrs Years with
NPGCL

1. Prof. Abdul Hameed M.Sc. Dean, Faculty of Electrical 08 Years


Elect. Engg. University of
Engg. Engineering and
F.I.E.E(U Technology Lahore,
K) Director, BOD, TEVTA
F.INST. (2002-04) Chairman,
E.E.E.(Pa Bismillah Education Trust
k) Regional Director, National
Institute of Power (1992-98)
Council Member, IEE (UK)
Council Member, IEEE
(Pak)
2. Mr. Abdul Rasheed Mir F.CA 14 years as CEO/Director 08 Years
Grays Leasing Ltd. 13-
years as Chairman/Director
Friendswear(Pvt) Ltd.
Board of Directors Qualification T. Exp., Yrs Years with
NPGCL
3. Khawaja Muhammad B.Sc. 30 Years as Director, 04 Years
Younis (Honrs) Mahmood Group of
Industries, Member Executive
Committee (FPCCI), Member
Central Executive Committee
(APTMA), Director Punjab
Social Security Health
Management Company,
President, D.G.Khan &
Bahawalpur Chamber of
Commerce & Industry
4. Mr. Hammad Ahmad FCMA 20 years in Power Sector 1 Years
5. Mr. Muhammad Rafiq B.Sc 35 Years as power plant 1 Years
Butt (Electrical) engineer, Presently working
as GM (D&D)
6. Mr. Muhammad Naeem B.Sc 33 Years as power plant 3 Months
Akhtar (Mechanical) engineer, Presently working
as CE(MMS)
7. Mr. Ghulam Mustafa B.E 34 years as power plant 1 Years
Tunio (Electrical) engineer, Presently working
as CEO (GENCO-III)
TECHNICAL DATA OF UNITS AT TPS, MZG
Description Unit-1 Unit-2 Unit-3 Unit-4 Unit-5 Unit-6
Make TPE RUSSIAN CHINA
Model K-210-130-8 N320- N210 Steam Turbine
178/538/538
Date of installation 09.09.1993 23.03.1994 20.02.1995 23.12.1997 14.02.1995 14.08.1995
Running Hrs since 109636.51 107735.73 101876.37 88755.64 71050.66 67421.09
commissioning
Unit generated (MkWh) 17938.87 17692.704 15714.124 21294.643 9579.500 8769.305
since commissioning
No. of Major Overhauling 2 2 2 1 1 1
Last date of MOH 14.09.2005 03.06.2007 02.02.2009 21.07.2004 01.12.2003 29.01.2003
Last date of ABI 12.08.2008 11.11.2009 22.06.2010 22.07.2010 13.11.2009 15.11.2009
ABI Overdue 14 Months - 3 Months 9 Months - -
Running Hrs since last 33669.46 22311.12 10223.73 41087.86 35195.95 40398.21
major overhauling
Designed efficiency 36.77 36.77 36.77 36.70 31.65 31.65

Present Efficiency 29.18 29.58 30.69 31.51 26.80 27.25


Designed Heat Rate 9286.98 9286.98 9286.98 9304.53 10797.47 10797.47
(Btu/kWh)
Present Heat Rate 11694.96 11536.85 11120.70 10831.48 12734.91 14369.40
(Btu/kWh)
Designed Load (MW) 210 210 210 320 200 200
Present Load (MW) 110 180 160 200 95 95
EFFECTS OF FURNACE OIL
FIRING ON BOILER
The machines of GENCO-III steam units were designed for
mix fuel (gas + furnace oil) and gas turbines were designed
for gas operation but due to non availability of gas fuel,
plants of GENCO-III are being operated on furnace oil since
long. The continuous oil firing has caused enormous effects
on the performance of machines causing the reduction in
the de-rated capacity. The efforts are being made to recover
the lost capacity by carrying out the rehabilitation /
replacement of deteriorated / damaged components of the
plants.

The affected components of boiler due to continuous


oil firing are shown in following pictures.
DETERIORATED CONDITION OF BOILER
COMPONENTS OF

Block No.1 TPS, Muzaffargarh

Unit No. 1, 2 & 3

210-MW each

Russian Make
SCALE FORMATION ON HEATING SURFACES

Block No.2 TPS, Muzaffargarh

Unit No. 4

320-MW

Chinese Make
DETERIORATED CONDITION OF BOILER
COMPONENTS OF

Block No.3 TPS, Muzaffargarh

Unit No. 5 & 6

200-MW each

Chinese Make
REASONS OF DE-RATED CAPACITY

BLOCK-1
Block No.1, comprising of Units No.1, 2 & 3, was commissioned
in 1993, 1994 & 1995, respectively.
These units have operated for 109636, 107735 & 101876 running
hours since their commissioning.
Due to aging factor, wear & tear and continuous furnace oil firing
since last five (5) years,
The boilers of these units have been badly affected/deteriorated.

The following jobs are necessary to be carried out in order to operate


these units on economical loading i.e. more than 75% of rated load.

03
Sr. No. Major Problems at Unit-1,2&3 TPS M/Garh
01 Boiler super heater tubes leakages. In case load on these units increased above
100MW for unit No.1, 180MW for unit No.2 and 150 MW for unit No.3. The
super heaters leakages starts frequently causing the forced shutdown of the units.

02 RAH Cold & Hot elements deterioration and need replacement


03 Replacement of damaged/deteriorated components of ID fans side A&B of all
three units.
04 Repair and rehabilitation of flue gases ducts upto the exists point.
05 Rehablitation of soot blowing system of Furnace, Super Heaters, Re-Heaters and
Re-generative air heaters
06 Rehabilitation of cooling water system including condenser for improving the
vacuum.
07 Chemical treatment of cooling water system
08 Dozing of fuel additive system in the furnace oil in order to minimize the
formation of scales on heat transfer surfaces of boiler including super heaters &
re-heaters.
09 Replacement of of existing cooling tower fans by new one in order to improve
the performance of cooling towers.
10 Modification of Excitation system
BLOCK-2 (Unit No.4)

Block No.2 comprising of Unit No.4 was commissioned in 23.12.1997.


This unit has operated for 88755 running hours since its commissioning.
The major overhauling of this unit is overdue but could not be carried out
due to non availability of essential spare parts required for major
overhauling such as LP Turbine blades of last stages.
Due to continuous furnace oil firing at this unit we are facing following
problems:

(i)- The heating components including economizer, super heaters, re-heaters


and regenerator air elements have badly affected due to formation of
deposits / scales and a thin layer of scale has developed over the heating
surfaces causing the reduction in heat transfer.

(ii)- Due to formation of this thick layer of scale, the steam generating
capacity of boiler has considerably decreased causing reduction in the
load upto 230 MW.
Sr. No. Major Problems at Unit No.4 TPS M/Garh
01 AVR System need to be modified.
02 UPS system need to be replacement by new one
03 LP. Rotor blades of last stages removed and need to be
reinstalled by the new one.
04 Air Pre-Heater Elements deterioration due to continuous
oil firing.
05 Requirement of Fuel Additive system to minimize the
formation of scales on heating surfaces.
06 Rehabilitation of Air/ Flue gas ducts which have been
deteriorated/damaged due to continuous furnace oil
firing.

07 Requirement of Special Cooling Water Treatment system


BLOCK-3 (Unit No.5&6)

Block No.3 comprising of Units No.5 & 6 was commissioned in


14.02.1995 & 14.08.1995 respectively.

These units have operated for 71050 & 67421 running hours,
since their commissioning. These units are facing following
problems:

These units are Chinese made and since their commissioning, the
availability, reliability and loading of the units remained less as
compared with the installed capacity. Due to continuous furnace oil
firing following major faults have been developed.
Sr. No. Major Problems at
Unit-5&6 TPS M/Garh.
01 I. D. Fan Rotor/Impeller need to be replaced.
02 G.R.C. Fan Impeller/Rotor problem
03 Cooling Tower Fan Gear Box problems
04 Air Pre-heater Elements Hot end, intermediate & cold end layers
deterioration/damaged
05 Steam Coil Air Heaters deteriorated
06 Frequent Economizer Tubes leakages in case the load is increased
above 100MW.
07 IP & LP Turbine Rotors require replacement.
08 Rehabilitation of Air/Flue gases ducts and rehabilitation of soot
blowing system of furnace and regenerative air heaters.
09 Fuel Additive System is required to minimize the formation of scales
on heating surfaces.
10 Feed Water pumps Hydraulic coupling problems
Block-4 & 6, GTPS, Faisalabad
The GTPS power plant was commissioned in 1975 and its CCP was commissioned in 1994.
The gas turbines of the plant are being operated in simple & combined cycle. But due to non
availability of Gas these machines are being operated on Diesel Fuel.
Unit Type COD/Age Installed Dependable Designed Present Fuel FSA
Name Capacity Capacity Efficiency Efficiency
(%) (%)

GT-1 Gas 09.03.1975 25 19 27.60 17.30 GAS/HSD Under


Turbine Negotiation
GT-2 Gas 10.03.1975 25 19 27.60 19.67 -DO- -DO-
Turbine
GT-3 Gas 04.05.1975 25 19 27.60 20.95 -DO- -DO-
Turbine
GT-4 Gas 06.03.1975 25 19 27.60 22.39 -DO- -DO-
Turbine
GT-5 Gas 31.07.1975 25 23 27.60 21.64 -DO- -DO-
Turbine
GT-6 Gas 05.07.1975 25 23 27.60 20.78 -DO- -DO-
Turbine
GT-7 Gas 10.07.1975 25 23 27.60 21.76 -DO- -DO-
Turbine
GT-8 Gas 14.11.1975 25 23 2760 21.61 -DO- -DO-
Turbine
CCP-9 Combine 28.12.1994 44 42 - - -DO- -DO-
cycle
THERMAL POWER STATION FAISALABAD.

Block-5, SPS, Faisalabad.

It comprises of two steam units of 2x66 MW installed capacity. These units were commissioned in
1966 and 1967 respectively. The units have completed their useful life but due to better technology
and continuous maintenance efforts made by the engineers and staff of the plant these units are
in operation since 43 years which is a record. Due to continuous oil firing the condition of boiler has
deteriorated and its major components such as flue gases ducts, air pre heater structures, economizer
and super heaters have become weak. The following are the major problems.

Sr. # Major problems at SPS, Faisalabad Remarks


01 Condenser Tubes fouling UAE has gifted 320MW power plant, the
02 Boiler Heating surfaces scaling shifting of the plant, its installation and
03 Re-generative air heater deterioration commissioning is in the process in the
04 Weak super heaters vicinity of TPS Faisalabad. After the
05 Weak economizers commissioning of the gifted power plant
the existing steam units will be standby.
Block-7, NGPS-Piranghaib, Multan
NGPS Multan comprises 04 units. These units were commissioned in 1960 and 1963. The unit has
completed their useful life and at present these units are being operated due to load crises at derated
loading of 30MW each, the efficiency and availability of these units is poor but due to load requirement
of the system these units are being operated as per demand of NPCC. Due to non availability of gas
boilers are operated on furnace oil since long, the continuous furnace oil firing has also badly affected
the regenerative air heater elements, flue gases ducts, economizer and super heaters. The unit No.2 has
already been cannibalized. Whereas unit No.3 is under shutdown due to fault in its reduction gear.

Sr. No. Major problems of NGPS, Multan Remarks

01 Air Pre Heater/Flue gas duct problems Installation of a new CCPP 350MW has
02 Economizer frequent leakages planned, PC-I of the project has been
03 Reduction gear fault prepared and it is in the Ministry of
04 Chimney Stack deteriorated. Water & Power for further process. The
05 Super heaters weak/frequent leakages in case new plant will be installed in the
load increased above 30MW. available area of NGPS and the existing
06 Cooling water system damaged/deteriorated. plant will be retired very soon.
Rehabilitation of TPS
Muzaffargarh
The rehabilitation program of GENCO-III especially
for TPS, Muzaffargarh has been signed with the
USAID. The rehabilitation is under process in the
light of agreement FARA and recently a MOU has
been signed between WAPDA CCC and GENCO-III
regarding the procurement of the spares required
for rehabilitation of the TPS, Muzaffargarh.

After completion of Rehabilitation, the TPS,


Muzaffargarh, INSHA ALLAH will regain its
Dependable Capacity of 1130 MW .
STATUS OF MATERIAL PROCUREMENT FOR
REHABILITATION OF TPS, MZG UNDER FARA-USAID
Item # Unit # Item Description Present Status
1 1,2&3 Rehabilitation of Boiler super heater tubes Material has arrived at Karachi Port and is
to overcome failure of tubes expected to be received at site in November-
2010. Shutdown of each machine has been
planned for 60 days to replace damaged tubes
of super heaters.
2 1,2&3 Special Cooling Water Treatment. Case of procurement is under process
3 1,2&3 Use of Fuel Oil Additive as on Unit-4 (200 Case of procurement is under process
Tons).
4 1,2&3 Replacement of Cold layer element for Material received and installed.
RAH (1 set).
5 1,2&3 Modification of Excitation system (1 set). Case of procurement is under process
6 1,2&3 Electric Motor for C.T. Fan (02 No). Case is under process for placement of
Purchase Order.
7 1,2&3 Electric Motor for GRC fan. (01 No). Case is under process for placement of
Purchase Order.
8 1,2&3 D.C. Storage Batteries (01 Set). Material received and installed.

9 1,2&3 220KV Circuit Breaker SF6 type (06 No). Case is under process for placement of
Purchase Order.
Item # Unit # Item Description Present Status

10 4 Re-blading of LP. Rotor (LP Turbine Tender is under scrutiny.


Rotor blades of row (6&7), pins &
locking device).
11 4 Air Pre-Heater Elements Case is under process for issuance of
(Intermediate) (02 set). Purchase Order.
12 4 Use of Fuel Oil Additive (100 Ton). Case of procurement is under process.
13 4 Special Cooling Water Treatment as Case is under process.
being used at IPPs.
14 4 Up-gradation of AVR System (01 set). Case is under process.
15 4 Changing of UPS 1&2. (01 set). Case is under process for issuance of
Purchase Order.
16 4 DEH (01 set). Tender No.MZG-26 to be opened on
24.11.2010.
17 4 Up-gradation of FSSS System (01 set). Case of procurement is under process
Item # Unit # Item Description Present Status

18 4 Up-gradation of TSI system BNC Case is to be initiated.


3300 (Turbine Supervisory
Instrument) (01 set).
19 1-6 Training and software/hardware cost Case is to be initiated.
for CMMS and off-line efficiency
monitoring system. All Units
20 5-6 I.D.Fan Rotor/Impeller along with The Purchase Order has been placed and
Housing and Dampers (04 Set). material is awaited to be received at site.
21 5-6 Air Preheater Elements Hot End, Case is under process.
Intermediate & Cold End layers
along with seals for both Units (04
Set).
22 5-6 Procurement of G.R.C. Fan Tender is under scrutiny.
Impeller/Rotor (01 Set).
23 5-6 Procurement of Cooling Tower Fan Tender is under scrutiny.
Gear Box & its parts. (06 No. gear
box).
24 5-6 Economizer Tubes for both Units Tender No. MZF-27 to be opened on
(02 Set). 25.11.2010.
25 5-6 Special Cooling Water Treatment. Case is under process.

26 5-6 Use of Fuel Oil Additive (150 Ton). Case is under process.
27 5-6 IP Turbine Rotor (01 No). Case is under process.
28 5-6 Replacement of Damaged Exhaust Case is under process.
flue gas ducts of material Russian
Grade Steel sheets (50 M.T).
Item # Unit # Item Description Present Status

29 5-6 Conversion of Boiler Ignition System from Natural Gas to ICB Tenders being prepared by NPGCL (GENCO-
HSD/Furnace Oil. III).
30 5-6 Turbo-Generator Bearings (09 Nos). Case is under process.
31 5-6 Hydraulic coupling of Boiler Feed Water Pumps (01 No). ICB Tenders being prepared by NPGCL (GENCO-
III).
32 5-6 Modification of Excitation System (02 set.) ICB Tenders being prepared by NPGCL (GENCO-
III).
33 5-6 Procurement of 0.4KV Motors for Cooling Towers Fan and Tender No.T-1447 to be opened on 30.11.2010
APH (02 No)
34 5-6 Procurement of 6.6KV Motor for C.W.Pumps, CP, ID Fan, Tender under scrutiny.
FD Fan & BF Pumps (05 No).
35 5-6 Procurement of 6.6/0.4KV Breaker (5 No. 6KV breaker, ICB Tenders being prepared by NPGCL (GENCO-
18Nos. 0.4Kv Breakers). III).
36 5-6 Protection Relay for Generators. ICB Tenders being prepared by NPGCL (GENCO-
III).
37 5-6 MK Breakers, Seal Oil Coolers, PMG. Purchased Order has been placed.
38 5-6 Supply, Installation, Commissioning & Testing of complete
distribution control system (DCS) including field equipment ICB Tenders being prepared by NPGCL (GENCO-
like sensors, transmitter & actuators etc for turbine governing III)
system DEH-III and Boiler Turbine Auto regulation system
YEWPACK-II
39 5-6 Rehabilitation of Furnace safety Supervisory System (FSSS) ICB Tender in process.
including Furnace camera, flame monitoring & ignition
system
SOLUTIONS & SUGGESTIONS
1. MIX FIRING (FURNACE OIL & GAS)

i. In order to minimize the damages to boiler due to continuous furnace oil firing of high sulpher
oil, it is suggested that at least 200mmcfd gas may please be arranged/got approved by
competent authority for Muzaffargarh to have mix/dual firing. It will not only improve the
efficiency of the plant but reliability, availability & loading will also be improved. Forced shut
downs will also be considerably reduced.
ii. Arrangement of sufficient quantity of LSFO instead of HSFO. The approx: quantity of furnace
oil per month is 150,000 M.Ton in case of all units are in operation.
iii. Supply of furnace oil through pipeline as it is being supplied by PSO to KAPCO & Lalpir.
iv. Handing over of existing supply system of furnace oil to M/s PSO on mutual agreement which
is under the process.

2. PROCUREMENT PROBLEMS

(i) The procurement process of spare parts be expedited and it is suggested that ICB tender be
invited by GM(Thermal) as in the past and send to end user of scrutiny & evaluation. As such
the most of spares are common for all the three GENCOs, in case each genco is processing the
case individually, there will be difference in the rates quoted by the bidders causing audit
problems at later stage.
(ii) There is no set up for the procurement of material through ICB at GENCOs level. In the new
set up the target of procurement as per time schedule of USAID could not be achieved because
the lot of time has already been wasted in shifting of files and corrigendum issued regarding the
extension an opening date etc by the Head Office.
3. Difficulties in Evaluation of ICB Tenders

International tenders were opened by Tender Opening Committee on due date i.e.
31.08.2010, in the office of General Manager (Thermal) PEPCO, Wapda House, Lahore for
procurement of 6.6 kV auxiliary motors Unit # 5 & 6.

Following six firms participated in the tender.

i) M/S Imperail Tender Czech Republic Principal. Rs.20,581,715/- Ist


M/S Hi Tech system, Lahore. Representative
ii) M/S Excell Techno Solutions UAE. Principal Rs.22,662,519/- 2nd
M/S Excell Techno Services, Lahore. Representative
iii) M/S Milequip, China Principal Rs.28,577,816/- 3rd
M/S SGW(PVT) LTD, Lahore Representative
iv) M/S GANSU SHUNGLIN, China Principal Rs.31,205,711/- 4th
M/S I.J. International Lahore Representative
v) M/S HIPCE China Principal Rs.45,318,788/- 5th
M/S Al-Tariq, Karachi Representative
vi) M/S HPE China Principal Rs.47,964,657/- 6th
M/S Albario Lahore Representative
First lowest M/s Hi Tech System Lahore offered Check republic made motors
(other than OEM) amounting Rs.2,05,81,715/-

OEM made motors was offered by M/s Al-Tariq Karachi which was fifth lowest
amounting Rs.4,53,18,788/-

Cost difference in first lowest (other than OEM) and OEM offer was
Rs.2,47,37,073/- which is almost 120% high as compared to 1st lowest.

PPRA Rules require to recommend the lowest bidder but the risk of material
quality and dimensions is involved in equipment other than OEM.

Due to these problems the procurement of spare parts is delayed


which ultimately results delay in completion of rehabilitation jobs.
4. USE OF CHEMICALS

i. Use of Fuel Additive


ii. Water Treatment in C.W. system.

5. INSTALLATION OF TUBE WELLS, IN AREA OF POWER HOUSE.

6. TIMELY SHUTDOWN OF THE UNITS FOR MAINTENANCE.

7. RECRUITMENT OF STAFF ON MERIT WITHOUT ANY INFUENCE.

8. STOPPAGE OF FREQUENT POSTING & TRANSFER OF STAFF/OFFICERS.

9. ESTABLISHMENT OF SEPARATE GENCO TO LOOK AFTER THE


MANAGEMENT OF NANDIPUR, CHICHOKIMALIAN AND RENTAL POWER
PLANTS IN ORDER TO REDUCE THE EXCESSIVE WORK LOAD ON GENCO-
III WHICH IS OVER LOADED AS COMPARED WITH OTHER GENCOS.

10. THE SALARY AND OTHER BENEFITS OF GENCOs BE MATCHED WITH IPPs
TO STOP THE DRAINAGE OF SKILLED STAFF.