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.(Pa
k)
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
Gray’s 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
1½ Years
5.
Mr. Muhammad Rafiq
Butt
B.Sc
(Electrical)
35 Years as power plant
engineer, Presently working
as GM (D&D)
1½ Years
6.
Mr. Muhammad Naeem
Akhtar
B.Sc
(Mechanical)
33½ 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)
1½ 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
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
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
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.
Repair and rehabilitation of flue gases ducts upto the exists point.
04
05
06
07
08
09
10
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
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.
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
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
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-
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. #
01
02
03
04
05
Major problems at SPS, Faisalabad
Condenser Tubes fouling
Boiler Heating surfaces scaling
Re-generative air heater deterioration
Weak super heaters
Weak economizers
Remarks
UAE has gifted 320MW power plant, the
shifting of the plant, its installation and
commissioning is in the process in the
vicinity of TPS Faisalabad. After the
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
02
03
04
05
Air Pre Heater/Flue gas duct problems
Economizer frequent leakages
Reduction gear fault
Chimney Stack deteriorated.
Super heaters weak/frequent leakages in case
load increased above 30MW.
Cooling water system damaged/deteriorated.
Installation of a new CCPP 350MW has
planned, PC-I of the project has been
prepared and it is in the Ministry of
Water & Power for further process. The
new plant will be installed in the
available area of NGPS and the existing
plant will be retired very soon.
06
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,
Muzaffargarh, “INSHA ALLAH” will
Dependable Capacity of 1130 MW .
the TPS,
regain its
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 November2010. 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.
3
1,2&3
4
1,2&3
5
1,2&3
Use of Fuel Oil Additive as on Unit-4 (200 Case of procurement is under process
Tons).
Replacement of Cold layer element for
Material received and installed.
RAH (1 set).
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.
Case of procurement is under process
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).
Air
Pre-Heater
Elements Case is under process for issuance of
(Intermediate) (02 set).
Purchase Order.
11
4
12
4
Use of Fuel Oil Additive (100 Ton).
13
4
14
4
Special Cooling Water Treatment as Case is under process.
being used at IPP’s.
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
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).
Training and software/hardware cost Case is to be initiated.
for CMMS and off-line efficiency
monitoring system. All Units
19
1-6
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
Case is under process.
22
5-6
23
5-6
24
5-6
Air Preheater Elements Hot End,
Intermediate & Cold End layers
along with seals for both Units (04
Set).
Procurement
of
G.R.C.
Fan
Impeller/Rotor (01 Set).
Procurement of Cooling Tower Fan
Gear Box & its parts. (06 No. gear
box).
Economizer Tubes for both Units
(02 Set).
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).
Tender is under scrutiny.
Tender is under scrutiny.
Tender No.
25.11.2010.
MZF-27
to
be
opened
on
Item #
Unit #
Item Description
Present Status
29
5-6
Conversion of Boiler Ignition System from Natural Gas to ICB Tenders being prepared by NPGCL (GENCOHSD/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 (GENCOIII).
32
5-6
Modification of Excitation System (02 set.)
ICB Tenders being prepared by NPGCL (GENCOIII).
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 (GENCO18Nos. 0.4Kv Breakers).
III).
36
5-6
Protection Relay for Generators.
ICB Tenders being prepared by NPGCL (GENCOIII).
37
5-6
MK Breakers, Seal Oil Coolers, PMG.
Purchased Order has been placed.
38
5-6
39
5-6
Supply, Installation, Commissioning & Testing of complete
distribution control system (DCS) including field equipment ICB Tenders being prepared by NPGCL (GENCOlike sensors, transmitter & actuators etc for turbine governing III)
system DEH-III and Boiler Turbine Auto regulation system
YEWPACK-II
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.
ii.
iii.
iv.
2.
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.
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.
Supply of furnace oil through pipeline as it is being supplied by PSO to KAPCO & Lalpir.
Handing over of existing supply system of furnace oil to M/s PSO on mutual agreement which
is under the process.
PROCUREMENT PROBLEMS
(i)
(ii)
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.
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
M/S Hi Tech system, Lahore.
ii) M/S Excell Techno Solutions UAE.
M/S Excell Techno Services, Lahore.
iii) M/S Milequip, China
M/S SGW(PVT) LTD, Lahore
iv) M/S GANSU SHUNGLIN, China
M/S I.J. International Lahore
v) M/S HIPCE China
M/S Al-Tariq, Karachi
vi) M/S HPE China
M/S Albario Lahore
Principal.
Representative
Principal
Representative
Principal
Representative
Principal
Representative
Principal
Representative
Principal
Representative
Rs.20,581,715/- Ist
Rs.22,662,519/- 2nd
Rs.28,577,816/- 3rd
Rs.31,205,711/- 4th
Rs.45,318,788/- 5th
Rs.47,964,657/- 6th
•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.
ii.
Use of Fuel Additive
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 GENCOIII 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.