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NORTHERN POWER GENERATION COMPANY

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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 ... – PowerPoint PPT presentation

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Title: NORTHERN POWER GENERATION COMPANY


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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
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CONTENTS OF PRESENTATION
  • Brief Introduction
  • 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

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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).
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Profile of BOD
Board of Directors Board of Directors Qualification Qualification Qualification T. Exp., Yrs Years with NPGCL

1. Prof. Abdul Hameed Prof. Abdul Hameed M.Sc. Elect. Engg. F.I.E.E(UK) 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) 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
2. Mr. Abdul Rasheed Mir Mr. Abdul Rasheed Mir F.CA 14 years as CEO/Director Grays Leasing Ltd. 13-years as Chairman/Director Friendswear(Pvt) Ltd. 14 years as CEO/Director Grays Leasing Ltd. 13-years as Chairman/Director Friendswear(Pvt) Ltd. 08 Years

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Board of Directors Board of Directors Qualification Qualification Qualification T. Exp., Yrs T. Exp., Yrs T. Exp., Yrs Years with NPGCL
3. Khawaja Muhammad Younis B.Sc. (Honrs) 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 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 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 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 FCMA 20 years in Power Sector 20 years in Power Sector 20 years in Power Sector 20 years in Power Sector 1½ Years
5. Mr. Muhammad Rafiq Butt B.Sc (Electrical) B.Sc (Electrical) 35 Years as power plant engineer, Presently working as GM (DD) 35 Years as power plant engineer, Presently working as GM (DD) 35 Years as power plant engineer, Presently working as GM (DD) 35 Years as power plant engineer, Presently working as GM (DD) 1½ Years
6. Mr. Muhammad Naeem Akhtar B.Sc (Mechanical) B.Sc (Mechanical) 33½ Years as power plant engineer, Presently working as CE(MMS) 33½ Years as power plant engineer, Presently working as CE(MMS) 33½ Years as power plant engineer, Presently working as CE(MMS) 33½ Years as power plant engineer, Presently working as CE(MMS) 3 Months
7. Mr. Ghulam Mustafa Tunio B.E (Electrical) B.E (Electrical) 34 years as power plant engineer, Presently working as CEO (GENCO-III) 34 years as power plant engineer, Presently working as CEO (GENCO-III) 34 years as power plant engineer, Presently working as CEO (GENCO-III) 34 years as power plant engineer, Presently working as CEO (GENCO-III) 1½ Years

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TECHNICAL DATA OF UNITS AT TPS, MZG
Description Unit-1 Unit-2 Unit-3 Unit-4 Unit-5 Unit-6
Make TPE RUSSIAN TPE RUSSIAN TPE RUSSIAN CHINA CHINA CHINA
Model K-210-130-8 K-210-130-8 K-210-130-8 N320-178/538/538 N210 Steam Turbine 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
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 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
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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.
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DETERIORATED CONDITION OF BOILER COMPONENTS
OF Block No.1 TPS, Muzaffargarh Unit No. 1,
2 3 210-MW each Russian Make
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SCALE FORMATION ON HEATING SURFACES Block No.2
TPS, Muzaffargarh Unit No. 4 320-MW Chines
e Make
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DETERIORATED CONDITION OF BOILER COMPONENTS
OF Block No.3 TPS, Muzaffargarh Unit No. 5
6 200-MW each Chinese Make
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REASONS OF DE-RATED CAPACITY
03
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Sr. No. Major Problems at Unit-1,23 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 AB 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
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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
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Sr. No. Major Problems at Unit-56 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
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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-
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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 .
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STATUS OF MATERIAL PROCUREMENT FOR REHABILITATION
OF TPS, MZG UNDER FARA-USAID
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SOLUTIONS SUGGESTIONS
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  • 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.

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