JAMSHORO POWER COMPANY LIMITED
DETAILED ACCOUNT OF POWER PLANTS
Presentation
By
Muhammad Akram
Chief Executive Officer
12th November, 2010
JAMSHORO POWER CO. LTD.
850 MW THERMAL POWER STATION JAMSHORO
JAMSHORO POWER CO. LTD (GENCO-I)
BRIEF INTRODUCTION
1.
Installed Capacity
TPS Jamshoro 850 MW
GTPS Kotri
174 MW
Total
1024 MW
2.
Registered Office
WAPDA House Lahore
3.
Date of Registration
03.08.1998
4.
Date of Commencement of
Business
01.03.1999
5.
Grant of generation License
1.07.2002
6.
Authorized Capital
Rs: 50,000 M
7.
Application for Determination of
Tariff date
27.03.2003 / 19.06.2006
8.
Determination of Tariff by
NEPRA.
31.03.2004 / 02.07.2007
PROJECT DIGEST (COMPLEX-I)
Installed
Unit
Capacity
No:
(MW)
ST - 1
ST - 2
Fuel
T.P.S. Jamshoro
Project
Commissioning
Cost
Date
(Mil. Rs.)
250
Furnace
Oil (F.O)
27.01.1990
200
Dual
(Gas/FO)
03.12.1989
ST - 3
200
Dual
(Gas/FO)
17.06.1990
ST - 4
200
Dual
(Gas/FO)
21.01.1991
Total:
850
Contractor Manufacturer
6762
M/s. Fuji Elect.
M/s. Mitsui & Co, Japan
& Co. Japan
M/s. Mitsui/
Riley Japan
8869
M/s. Harbin
Turbine, Boiler
M/s. CMEC
& Electrical
China
Machinery Co.,
Harbin China
15631
PROJECT DIGEST (COMPLEX-II)
G.T.P.S KOTRI
Unit
No:
Installed
Capacity
(MW)
GT - 1
15
GT - 2
15
GT - 3
25
GT - 4
25
GT - 5
25
GT - 6
25
CCP-7
44
Total:
174
Fuel
Dual
(Gas/HSD)
Dual
(Gas/HSD)
Dual
(Gas/HSD)
Dual
(Gas/HSD)
Dual
(Gas/HSD)
Dual
(Gas/HSD)
Through
Heat
recovery
boilers on
GT 3-6
Commissioning
Date
Project
Cost
(Rs.M)
Dec. 1969
64.9
Jan. 1970
May. 1979
184.018
May. 1979
April. 1981
202.878
May. 1981
Oct. 1994
1792.479
2244.28
Contractor
Manufacturer
M/s. CIE Electro
Mech. (CEM)
CEM/BBC
France
M/s. Thomassan M/s. Thomassan
BV Holland
BV Holland
M/s. Marubeni
Japan
M/s. Hitachi
Japan
M/s. HPEEC
China
M/s. HPEEC
China
M/s. Chockerill
Mech.
Industries,
Belgium
GENCO-I TECHNICAL DATA
TPS JAMSHORO
Size (Capacity)
Dependable (MW)
(IDC NET)
Fuel Used
Commissioning
Date
Age
(Years)
250
205
F. Oil
Jan 1990
20
S/T
200
156
Gas / F. Oil
Dec 1989
21
3
S/T
200
157
Gas / F. Oil
Jun 1990
20
4
S/T
200
157
Gas / F. Oil
Jan 1991
19
TOTAL
-
850
675
-
-
-
Unit #
Type
Installed
(MW)
1
S/T
2
GTPS KOTRI
Unit #
Type
Installed
(MW)
Dependable (MW)
Fuel Used
Commissioning
Date
Age
(Years)
1
G/T
15
8.5
Gas / HSD
Dec 1969
41
2
G/T
15
8.5
Gas / HSD
Jan 1970
40
3
G/T
25
18
Gas / HSD
May 1979
31
4
G/T
25
18
Gas / HSD
May 1979
31
5
G/T
25
18
Gas / HSD
Apr 1981
29
6
G/T
25
18
Gas / HSD
May 1981
29
7
Steam
Unit (C.C.P)
44
34.5
G/T Exhaust
/Flue Gases
Oct 1994
16
TOTAL
-
174
123.5
-
-
-
JAMSHORO POWER COMPANY LIMITED
CRITICAL / SIGNIFICANT PERFORMANCE INDICATORS
July-2009 to June-2010
POWER
PLANT
INSTALLED
CAPACITY
(MW)
TESTED
I.D.C
(NET)
(MW)
MAX:
LOAD
(MW)
GROSS
GEN:
(Gwh)
GROSS
AVAIL:
FACTOR
(%Age)
PLANT
UTILIZ:
FACTOR
(% Age)
LOAD
FACTOR
(% Age)
ST-1
BLOCK-I
250
205
200
955
73
50
ST-2
BLOCK-II
200
156
180
1118
88
ST-3
BLOCK-II
200
157
180
1026
ST-4
BLOCK-II
200
157
175
GT-3
BLOCK-III
25
18
GT-4
BLOCK-III
25
GT-5
BLOCK-III
THERMAL
EFFICIENCY
(% Age)
Design
(% )
Actual
(% )
50
36.63
32.92
75
71
33.89
29.39
85
69
65
33.89
28.71
1182
91
79
77
33.89
29.70
22
135
84
62
70
27.85
21.51
18
23
111
81
51
55
27.85
21.50
25
18
23
140
99
64
70
27.75
21.47
GT-6
BLOCK-III
25
18
19
84
96
38
51
27.75
21.40
CCP-7
BLOCK-III
44
34.5
38
185
90
53
56
-
-
GT-1
BLOCK-IV
15
8.5
10
14
99
11
16
24.50
15.36
GT-2
BLOCK-IV
15
8.5
9
13
99
10
16
24.50
15.37
Overall
GENCO-I
1,024
798.5
879
4,963
90
65
68
-
-
JAMSHORO POWER COMPANY LIMITED
CRITICAL / SIGNIFICANT INDICATORS
July-2009 to June-2010
POWER
PLANT
INSTALLED
CAPACITY
(MW)
TESTED
I.D.C
MAX:
LOAD
(MW)
GEN:
(Gwh)
AVAIL:
FACTOR
(%Age)
PLANT
UTILIZ:
FACTOR
(% Age)
LOAD
FACTOR
(% Age)
THERMAL
EFFICIENCY
(% Age)
Design
(% )
Actual
(% )
BLOCK-I
JAMSHORO
250
205
200
955
73
50
55
36.63
32.92
BLOCK-II
JAMSHORO
600
470
535
3326
87
71
71
33.89
29.82
BLOCK-III
KOTRI
144
106.5
125
655
92
67
67
27.80
29.91*
BLOCK-IV
KOTRI
30
17
19
27
100
30
31
24.50
15.36
1,024
798.5
* Overall Efficiency of Block-III with CCP
FUEL SUPPLY SYSTEM
FUELS
TPS JAMSHORO
GTPS KOTRI
Fuel Oils
R.F.O
H.S.D
On fortnight basis from
PSO
-
Tank Lorries
-
Source
Mode of Supply
Oil Decanting Capacity
5000 M.T / Day
-
100,000 M.T
6, 600 M.T
30,000 M.T
NIL
M/s SSGC Ltd Hyd
M/s SSGC Ltd Hyd
Mode of Supply
Through 16” Pipeline
Through 12” Pipeline
Gas Allocation
62 MMCFD
(53 MMCFD Guaranteed))
15-20 MMCFD
(10 MMCFD Guaranteed))
925-1030
925-1030
Oil Storage Capacity
Average Stock
GAS SUPPLY SYSTEM
Source
Average Gross Calorific Value
(Btu/Cft)
THERMAL POWER STATION JAMSHORO
MAXIMUM LOAD SHARED (MW)
MW
900
800
700
600
500
400
300
200
100
0
775
2005-06
760
2006-07
730
2007-08
730
2008-09
700
2009-10
GAS TURBINE POWER STATION KOTRI
MAXIMUM LOAD SHARED (MW)
MW
180
149
146
141
144
136
150
120
90
60
30
0
2005-06
2006-07
2007-08
2008-09
2009-10
THERMAL POWER STATION JAMSHORO
AVAILABILITY & UTILIZATION FACTORS
Availability (%)
100
90
80
70
60
50
40
30
20
10
0
Utilization (%)
81
75
77
65
74
64
68
61
62
47
2005-06
2006-07
2007-08
2008-09
2009-10
GAS TURBINE POWER STATION KOTRI
AVAILABILITY & UTILIZATION FACTORS
Availability (%)
Utilization (%)
120
100
92
95
88
80
94
63
59
94
64
64
54
60
40
20
0
2005-06
2006-07
2007-08
2008-09
2009-10
THERMAL POWER STATION JAMSHORO
ENERGY GENERATED (MKWH)
FUEL MIX
F.O
5000
4500
4000
3500
3000
2500
2000
1500
1000
500
0
GAS
TOTAL
4346
4281
4228
3899
3051
2718
2505
1628
2493
2453
1723
1446
2005-06
2006-07
2007-08
1709
1342
2008-09
1788
2009-10
THERMAL POWER STATION JAMSHORO
Fuel Cost (Paisa/KWH)
F.O
GAS
TOTAL
1117
1200
1050
884
900
600
450
623
1446
750
499
347
256
494
381
827
3899
288
417
422
304
300
150
0
2005-06
2006-07
2007-08
2008-09
2009-10
THERMAL POWER STATION JAMSHORO
Overall Cost (Paisa/KWH)
Overall Cost
950
850
750
650
550
450
350
250
150
50
865
685
486
385
416
2005-06
2006-07
2007-08
2008-09
2009-10
GAS TURBINE POWER STATION KOTRI
ENERGY GENERATED (MKWH)
GAS
950
850
750
650
550
450
350
250
150
50
741
791
810
785
683
2005-06
2006-07
2007-08
2008-09
2009-10
GAS TURBINE POWER STATION KOTRI
Fuel Cost (Paisa/KWH)
GAS
550
500
450
400
350
300
250
200
150
100
50
411
296
288
2006-07
2007-08
433
245
2005-06
2008-09
2009-10
GAS TURBINE POWER STATION KOTRI
Overall Cost (Paisa/Kwh)
Overall Cost
600
550
500
450
400
350
300
250
200
150
100
50
461
295
2005-06
347
336
2006-07
2007-08
2008-09
496
2009-10
Future Plan for the Repair and Rehabilitation of
Jamshoro Power Plant
For the rehabilitation of Units 1,2,3&4 of Jamshoro, a Fixed Amount Reimbursement Agreement (FARA) has been signed on 20.05.2010. Under this
agreement, the USAID will provide US$ 18.36 million for the repair &
rehabilitation.
The following table summarizes the proposed rehabilitation works and the
associated costs.
Sr.
No.
Unit Details of Works/Spares
No.
1-
1
Rehabilitation of air Pre-heater Side-B
Rotor
2-
1
Replacement of Final Super Heater
Coils
3-
1
4-
1
Estimated
Cost (US$)
500,000
Planned
Completion
date
30.11.2011
1,000,000
-do-
Complete replacement of Flue Gas
Duct & Air Pre-heater Bottom hoppers
600,000
-do-
Complete Rehabilitation of Cooling
Towers
500,000
-do-
Sr.
No.
Unit
No.
Details of Works/Spares
Estimated
Cost (US$)
Planned
Completion
date
5-
1
P-Gradation/Replacement of Auto
Burner Control System & Data
Acquisition System
300,000
30.11.2011
6-
1
F.D. Fan duct up to Steam Coil Air
Heater
200,000
-do-
7-
1
Major Overhauling
1,650,000
-do-
8-
1
Soot Blower Spare Parts
100,000
-do-
9-
1
Tube Bundles of Steam Converter
250,000
-do-
10-
1
Spares for Oil & HSD Burners &
Igniters
200,000
-do-
11-
1
Air Pre-heater Elements & Seal
670,000
-do-
12-
1,2,3
&4
1,000,000
-do-
Use of fuel oil additives to prevent
soot buildup and cooling water
treatment chemicals to prevent
scale buildup
Sr.
No.
Unit
No.
Details of Works/Spares
Estimated
Cost (US$)
3,450,000
Planned
Completion
date
13-
2,3&4 Replacement of HP Heaters along
with the valve and controllers
including Rehabilitation of
Instrument Control & Protection
System
30.11.2011
14-
2,3&4 Complete Rehabilitation of Cooling
Towers
750,000
-do-
15-
2,3&4 Modification/Rehabilitation of
Electro Hydraulic and Mechanical
Hydraulic Governing System
900,000
-do-
16-
2,3&4 Complete Rehabilitation of Drain
Valves
300,000
-do-
17-
2,3&4 Rehabilitation of soot blowing
system
600,000
-do-
18-
2,3&4 Replacement of Coagulator
Agitators
1,200.000
-do-
Sr.
No.
Unit
No.
Details of Works/Spares
Estimated
Cost (US$)
Planned
Completion
date
19-
2,3&4 Replacement of Data Acquisition
System (DAS-100), Auto Regulation
System (MZ-III) & Temperature
Scanners for Generator Winding
Temperature,
Super
Heater/ReHeater Temp:, Boiler Drum Metal
Temp: FD, ID Fan Motor Temp:
Boiler Feed Pump Temp: with latest
Distributed Control System (DCS)
900,000
30.11.2011
20-
2,3&4 Replacement of Existing FSSS
along with Furnace Flame
Monitoring
390,000
-do-
100,000
-do-
1,000,000
-do-
21-
2
Procurement of Boiler Feed Pump
Motor Complete
22-
3
Replacement of Final Super Heater
Coils
23-
3
Three Way valve of Oil Burner
200,000
-do-
24-
3
Spares for Overhauling of Turbine
500,000
-do-
Sr.
No.
Unit
No.
Details of Works/Spares
25-
2&4
Replacement of Turbine Vibration
System with ViBro-Control-4000
Schenk
200,000
30.11.2011
26-
4
ID Fan Impellers
500,000
-do-
27-
1,2,3
&4
Off-line Efficiency Monitoring
System & Training
400,000
-do-
Total Cost (US$)
Estimated
Cost (US$)
18,360,000
Planned
Completion
date
Targeted load after Rehabilitation
The targeted rehabilitation of the four Units will re-capture 95MW of the derated capacity. The MW recovered after targeted rehabilitation as under:Unit # Installed Declared DePresent
Capacity
rated
Operational
(MW)
Capacity
Capacity
(MW) Gross (MW) Gross
Gain After
Rehabilitation
(MW)
Capacity after
Rehabilitation
(MW)
1
250
225
190
35
225
2
200
170
170
20
190
3
200
170
170
20
190
4
200
170
170
20
190
Total
850
735
700
95
795
Critical Issue
Serious Problem due to saline River Water of
high
conductivity
(1,200µs/cm
against
designed 500µs/cm).
This has badly affected the operation of the
Power Plant and caused high consumption of
Chemicals, resulting increase in per unit cost
Solution
Installation of Reverse Osmosis Plant
Thank you
29
ORGANIZATION STRUCTURE
Board of Directors
Company Secretary
Chief Executive Officer
Internal Audit
Finance
Director
Technical
Director
Jamshoro
Plant
HR &Admn.
Director
M.I.S.
Director
Kotri
Plant
BOARD OF DIRECTORS
Private Sector
PEPCO
Prof. Dr. Khawaja Amjad Saeed,
Chairman
Mr. Salman Iqbal
Executive Director (L&CA)
Syed Wajid Ali Shah
Chief Engineer, GSO, Lahore
Mr. Ashfaq Ahmed Waraich,
GM,Wazir Ali Industry Hyd
Mr. Muhammad Mumtaz
Chief Engineer (WPPO)
Mr. Mohammad Akram,
Chief Executive Officer, GENCO-I
Mr. Yousuf Suleman
Ex-President Hyderabad
Chamber of Commerce &
Industries, Hyderabad
WAPDA/JPCL
Total Land of JPCL = 800 Acres
JAMSHORO POWER COMPANY LIMITED
Energy Generation
Since Commissioning up to June 2010
T.P.S Jamshoro
Unit No
Date of Commissioning
Operation Hours
Energy Generated (MKWH)
ST-1
27.01.1990
123074
20092
ST-2
03.12.1989
116366
17081
ST-3
27.06.1990
110537
16311
ST-4
21.01.2991
108584
15918
458561
69402
G.T.P.S Kotri
Unit No
Date of Commissioning
Operation Hours
Energy Generated (MKWH)
GT-1
Dec-69
104730
896
GT-2
Jan-70
125540
1021
GT-3
May-79
164438
2923
GT-4
May-79
186340
3305
GT-5
Apr-81
160377
2878
GT-6
May-81
163089
2864
CCP-7
Oct-94
117441
2910
1021955
16797
A- Present De-rated Load
This Power Plant comprises four conventional Steam Power
Units with a total capacity of 850MW. The Units have been derated to a capacity of 675 MW. The Unit wise configuration of
this Power Station along with the de-rated capacity is
enumerated as under:Unit #
Installed
Capacity
(MW)
Declared
De-rated
Capacity
(MW)
Make
Year of
Commissioning
01-
250
205
Fuji Japan
1990
02-
200
156
CMEC China
1989
03-
200
157
CMEC China
1990
04-
200
157
CMEC China
1991
Total
850
675
C- Reasons of De-rating
i)
a)
b)
c)
d)
e)
f)
g)
h)
i)
Unit-1
Aging Factor
Damaged APH Elements
Damaged Steam Coil Air Heaters
Condenser Choking
Frequent leakages in Final Super Heaters
Frequent leakages in Re-heaters
Low Efficiency of Cooling Towers
Leakages from Air Pre-Heaters
Damaged flue Gases duct
a)
b)
c)
d)
e)
Unit-2,3&4
Aging Factor
Outage of HP Heater
Frequent choking of APH Elements
Condenser Choking
Low Efficiency of Cooling Towers
ii)
KEY PERFORMANCE INDICATORS
1.
2.
3.
4.
5.
Plant Availability Factor (%)
Plant Utilization Factor (%)
Plant Load Factor (%)
Plant Heat Rate (Btu/kWh)
Thermal Efficiency (%)
Rehabilitation of Jamshoro Power Plants
Recovering the lost output of existing power plant is the dire need of
PEPCO’s system to bridge the gap to some extent between demand and
supply and reduce the generation cost per Kwh. It has therefore been
planned to regain the lost capacity of Jamshoro Power Plant by rehabilitation.
Keeping in view the present power crises in the country, US Government
plans to assist the GoP and resolving the power crises through Repair &
Maintenance measures to improve the operating capacity of the Jamshoro
Power Plant.
Rehabilitation of old Units means to refurbish or upgrade the components in
order to recapture the lost capacity and bring the performance near to the
designed capacity. Despite proper operation & maintenance, aging is a major
factor causing higher generation cost due to excessive forced outages period
resulting less availability, loss of output and increase in heat rate.
Rehabilitation of old steam power units is not only a financially viable option
but also shorter in implementation period as compared to installing a new
power unit.