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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.
3.
4.
5.
6.

Profile of Board of Directors


Technical Data of Units at TPS, Muzaffaragrh
Effects of Furnace Oil Firing on Boiler
Reasons of De-rated Capacity
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

1. Prof. Abdul Hameed

2. Mr. Abdul Rasheed Mir

Qualification

T. Exp., Yrs

Years with
NPGCL

M.Sc.
Elect.
Engg.
F.I.E.E(U
K)
F.INST.
E.E.E.
(Pak)

Dean, Faculty of Electrical


Engg. University of
Engineering and Technology
Lahore, Director, BOD,
TEVTA (2002-04) Chairman,
Bismillah Education Trust
Regional Director, National
Institute of Power (1992-98)
Council Member, IEE (UK)
Council Member, IEEE
(Pak)

08 Years

F.CA

14 years as CEO/Director
Grays Leasing Ltd. 13years as Chairman/Director
Friendswear(Pvt) Ltd.

08 Years

Board of Directors

Qualification

T. Exp., Yrs

Years with
NPGCL

3.

Khawaja Muhammad
Younis

B.Sc.
(Honrs)

30 Years as Director,
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

04 Years

4.

Mr. Hammad Ahmad

FCMA

20 years in Power Sector

1 Years

5.

Mr. Muhammad Rafiq


Butt

B.Sc
(Electrical)

35 Years as power plant


engineer, Presently working
as GM (D&D)

1 Years

6.

Mr. Muhammad Naeem


Akhtar

B.Sc
(Mechanical)

33 Years as power plant


engineer, Presently working
as CE(MMS)

3 Months

7.

Mr. Ghulam Mustafa


Tunio

B.E
(Electrical)

34 years as power plant


engineer, Presently working
as CEO (GENCO-III)

1 Years

TECHNICAL DATA OF UNITS AT TPS, MZG


Description

Unit-1

Unit-2

Unit-3

Make

TPE RUSSIAN

Model

K-210-130-8

Unit-4

Unit-5

Unit-6

CHINA
N320178/538/538

N210 Steam Turbine

Date of installation

09.09.1993

23.03.1994

20.02.1995

23.12.1997

14.02.1995

14.08.1995

Running Hrs since


commissioning

109636.51

107735.73

101876.37

88755.64

71050.66

67421.09

Unit generated (MkWh)


since commissioning

17938.87

17692.704

15714.124

21294.643

9579.500

8769.305

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


major overhauling

33669.46

22311.12

10223.73

41087.86

35195.95

40398.21

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


(Btu/kWh)

9286.98

9286.98

9286.98

9304.53

10797.47

10797.47

Present Heat Rate


(Btu/kWh)

11694.96

11536.85

11120.70

10831.48

12734.91

14369.40

Designed Load (MW)

210

210

210

320

200

200

Present Load (MW)

110

180

160

200

95

95

No. of Major Overhauling

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

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.
RAH Cold & Hot elements deterioration and need replacement

02
03
04
05
06
07
08
09
10

Replacement of damaged/deteriorated components of ID fans side A&B of all


three units.
Repair and rehabilitation of flue gases ducts upto the exists point.
Rehablitation of soot blowing system of Furnace, Super Heaters, Re-Heaters and
Re-generative air heaters
Rehabilitation of cooling water system including condenser for improving the
vacuum.
Chemical treatment of cooling water system
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.
Replacement of of existing cooling tower fans by new one in order to improve
the performance of cooling towers.
Modification of Excitation system

Sr. No.
01
02
03

Major Problems at Unit No.4 TPS M/Garh


AVR System need to be modified.
UPS system need to be replacement by new one
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

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
Name

Type

COD/Age

Installed
Capacity

Dependable
Capacity

Designed
Efficiency
(%)

Present
Efficiency
(%)

Fuel

FSA

GT-1

Gas
Turbine

09.03.1975

25

19

27.60

17.30

GAS/HSD

Under
Negotiation

GT-2

Gas
Turbine

10.03.1975

25

19

27.60

19.67

-DO-

-DO-

GT-3

Gas
Turbine

04.05.1975

25

19

27.60

20.95

-DO-

-DO-

GT-4

Gas
Turbine

06.03.1975

25

19

27.60

22.39

-DO-

-DO-

GT-5

Gas
Turbine

31.07.1975

25

23

27.60

21.64

-DO-

-DO-

GT-6

Gas
Turbine

05.07.1975

25

23

27.60

20.78

-DO-

-DO-

GT-7

Gas
Turbine

10.07.1975

25

23

27.60

21.76

-DO-

-DO-

GT-8

Gas
Turbine

14.11.1975

25

23

2760

21.61

-DO-

-DO-

CCP-9

Combine
cycle

28.12.1994

44

42

-DO-

-DO-

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 FARAUSAID

SOLUTIONS & SUGGESTIONS

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.