Beruflich Dokumente
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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 Qualification T. Exp., Yrs Years with NPGCL
08 Years
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) 14 years as CEO/Director Grays Leasing Ltd. 13years as Chairman/Director Friendswear(Pvt) Ltd.
F.CA
08 Years
Qualification
T. Exp., Yrs 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 20 years in Power Sector 35 Years as power plant engineer, Presently working as GM (D&D) 33 Years as power plant engineer, Presently working as CE(MMS) 34 years as power plant engineer, Presently working as CEO (GENCO-III)
B.Sc. (Honrs)
4. 5.
Mr. Hammad Ahmad Mr. Muhammad Rafiq Butt Mr. Muhammad Naeem Akhtar Mr. Ghulam Mustafa Tunio
FCMA
B.Sc (Electrical) B.Sc (Mechanical) B.E (Electrical)
1 Years 1 Years
6.
3 Months
7.
1 Years
109636.51
17938.87 2 14.09.2005 12.08.2008 14 Months 33669.46 36.77 29.18 9286.98
107735.73
17692.704 2 03.06.2007 11.11.2009 22311.12 36.77 29.58 9286.98
101876.37
15714.124 2 02.02.2009 22.06.2010 3 Months 10223.73 36.77 30.69 9286.98
88755.64
21294.643 1 21.07.2004 22.07.2010 9 Months 41087.86 36.70 31.51 9304.53
71050.66
9579.500 1 01.12.2003 13.11.2009 35195.95 31.65 26.80 10797.47
67421.09
8769.305 1 29.01.2003 15.11.2009 40398.21 31.65 27.25 10797.47
11694.96
210 110
11536.85
210 180
11120.70
210 160
10831.48
320 200
12734.91
200 95
14369.40
200 95
210-MW each
Russian Make
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
03
Sr. No. 01
Major Problems at Unit-1,2&3 TPS M/Garh 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
03 04 05 06 07 08
09 10
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 04 05 06
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. Air Pre-Heater Elements deterioration due to continuous oil firing. Requirement of Fuel Additive system to minimize the formation of scales on heating surfaces. Rehabilitation of Air/ Flue gas ducts which have been deteriorated/damaged due to continuous furnace oil firing. Requirement of Special Cooling Water Treatment system
07
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. 01 02 03 04 05 06 07 08 09 10
Major Problems at Unit-5&6 TPS M/Garh. I. D. Fan Rotor/Impeller need to be replaced. G.R.C. Fan Impeller/Rotor problem Cooling Tower Fan Gear Box problems Air Pre-heater Elements Hot end, intermediate & cold end layers deterioration/damaged Steam Coil Air Heaters deteriorated Frequent Economizer Tubes leakages in case the load is increased above 100MW. IP & LP Turbine Rotors require replacement. Rehabilitation of Air/Flue gases ducts and rehabilitation of soot blowing system of furnace and regenerative air heaters. Fuel Additive System is required to minimize the formation of scales on heating surfaces. Feed Water pumps Hydraulic coupling problems
Gas Turbine Gas Turbine Gas Turbine Gas Turbine Gas Turbine Gas Turbine Gas Turbine Gas Turbine Combine cycle
25 25 25 25 25 25 25 25 44
19 19 19 19 23 23 23 23 42
GAS/HSD -DO-DO-DO-DO-DO-DO-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.
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. Special Cooling Water Treatment. Case of procurement is under process
2 3 4 5 6 7 8 9
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 Electric Motor for C.T. Fan (02 No). Electric Motor for GRC fan. (01 No). D.C. Storage Batteries (01 Set). 220KV Circuit Breaker SF6 type (06 No). Case is under process for placement of Purchase Order. Case is under process for placement of Purchase Order. Material received and installed. Case is under process for placement of Purchase Order.
Item #
Unit #
Item Description
Present Status
10
11 12 13 14 15 16 17
4 4 4 4 4 4 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. Use of Fuel Oil Additive (100 Ton). Case of procurement is under process. Special Cooling Water Treatment as Case is under process. being used at IPPs. Up-gradation of AVR System (01 set). Case is under process. Changing of UPS 1&2. (01 set). DEH (01 set). Up-gradation of FSSS System (01 set). Case is under process for issuance of Purchase Order. Tender No.MZG-26 to be opened on 24.11.2010. Case of procurement is under process
Item #
Unit #
Item Description
Present Status
18
19
1-6
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 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. 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). Special Cooling Water Treatment. Use of Fuel Oil Additive (150 Ton). IP Turbine Rotor (01 No). Case is under process.
20 21
5-6 5-6
22 23
5-6 5-6
24 25 26 27 28
MZF-27
to
be
opened
on
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 30 31 32 33 34 35 36 37 38
5-6 5-6 5-6 5-6 5-6 5-6 5-6 5-6 5-6 5-6
Conversion of Boiler Ignition System from Natural Gas to ICB Tenders being prepared by NPGCL (GENCOHSD/Furnace Oil. III). Turbo-Generator Bearings (09 Nos). Hydraulic coupling of Boiler Feed Water Pumps (01 No). Modification of Excitation System (02 set.) Case is under process. ICB Tenders being prepared by NPGCL (GENCOIII). ICB Tenders being prepared by NPGCL (GENCOIII).
Procurement of 0.4KV Motors for Cooling Towers Fan and Tender No.T-1447 to be opened on 30.11.2010 APH (02 No) Procurement of 6.6KV Motor for C.W.Pumps, CP, ID Fan, Tender under scrutiny. FD Fan & BF Pumps (05 No). Procurement of 6.6/0.4KV Breaker (5 No. 6KV breaker, ICB Tenders being prepared by NPGCL (GENCO18Nos. 0.4Kv Breakers). III). Protection Relay for Generators. MK Breakers, Seal Oil Coolers, PMG. ICB Tenders being prepared by NPGCL (GENCOIII). Purchased Order has been placed.
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
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. 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.
(ii)
3.
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. 6. 7. 8. 9.
INSTALLATION OF TUBE WELLS, IN AREA OF POWER HOUSE. TIMELY SHUTDOWN OF THE UNITS FOR MAINTENANCE. RECRUITMENT OF STAFF ON MERIT WITHOUT ANY INFUENCE. STOPPAGE OF FREQUENT POSTING & TRANSFER OF STAFF/OFFICERS. 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. THE SALARY AND OTHER BENEFITS OF GENCOs BE MATCHED WITH IPPs TO STOP THE DRAINAGE OF SKILLED STAFF.
10.