2. PRESENTATION BY NORTHERN POWER GENERATION COMPANY (GENCO-III) CHIEF EXECUTIVE OFFICER Workshop on Power Sector Reforms On 11.11.2010 to 12.11.2010 at WAPDA House, Lahore

3. CONTENTS OF PRESENTATION 1. Brief Introduction 2. Profile of Board of Directors 3. Technical Data of Units at TPS, Muzaffaragrh 4. Effects of Furnace Oil Firing on Boiler 5. Reasons of De-rated Capacity 6. Rehabilitation of TPS, Muzaffargarh under USAID Energy Support Program. 7. Solutions and Suggestions

4. 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).

5. Profile of BOD Board of DirectorsQualificationT. Exp., YrsYears with NPGCL 1.Prof. Abdul HameedM.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 2.Mr. Abdul Rasheed MirF.CA14 years as CEO/Director Gray’s Leasing Ltd. 13- years as Chairman/Director Friendswear(Pvt) Ltd. 08 Years

6. Board of Directors Qualification T. Exp., YrsYears 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 AhmadFCMA20 years in Power Sector1½ 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

7. DescriptionUnit-1Unit-2Unit-3Unit-4Unit-5Unit-6 MakeTPE RUSSIANCHINA ModelK-210-130-8N320- 178/538/538 N210 Steam Turbine Date of installation09.09.199323.03.199420.02.199523.12.199714.02.199514.08.1995 Running Hrs since commissioning 109636.51107735.73101876.3788755.6471050.6667421.09 Unit generated (MkWh) since commissioning 17938.8717692.70415714.12421294.6439579.5008769.305 No. of Major Overhauling222111 Last date of MOH14.09.200503.06.200702.02.200921.07.200401.12.200329.01.2003 Last date of ABI12.08.200811.11.200922.06.201022.07.201013.11.200915.11.2009 ABI Overdue14 Months-3 Months9 Months-- Running Hrs since last major overhauling 33669.4622311.1210223.7341087.8635195.9540398.21 Designed efficiency 36.77 36.7031.65 Present Efficiency 29.1829.5830.6931.5126.8027.25 Designed Heat Rate (Btu/kWh) 9286.98 9304.5310797.47 Present Heat Rate (Btu/kWh) 11694.9611536.8511120.7010831.4812734.9114369.40 Designed Load (MW) 210 320200 Present Load (MW) 11018016020095 TECHNICAL DATA OF UNITS AT TPS, MZG

8. 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.

9. DETERIORATED CONDITION OF BOILER COMPONENTS OF Block No.1 – TPS, Muzaffargarh Unit No. 1, 2 & 3 210-MW each Russian Make

14. SCALE FORMATION ON HEATING SURFACES Block No.2 – TPS, Muzaffargarh Unit No. 4 320-MW Chinese Make

19. DETERIORATED CONDITION OF BOILER COMPONENTS OF Block No.3 – TPS, Muzaffargarh Unit No. 5 & 6 200-MW each Chinese Make

27. 03 REASONS OF DE-RATED CAPACITY

28. Sr. No.Major Problems at Unit-1,2&3 TPS M/Garh 01Boiler 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. 02RAH Cold & Hot elements deterioration and need replacement 03Replacement of damaged/deteriorated components of ID fans side A&B of all three units. 04Repair and rehabilitation of flue gases ducts upto the exists point. 05Rehablitation of soot blowing system of Furnace, Super Heaters, Re-Heaters and Re-generative air heaters 06Rehabilitation of cooling water system including condenser for improving the vacuum. 07Chemical treatment of cooling water system 08Dozing 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. 09Replacement of of existing cooling tower fans by new one in order to improve the performance of cooling towers. 10Modification of Excitation system

30. Sr. No.Major Problems at Unit No.4 TPS M/Garh 01AVR System need to be modified. 02UPS system need to be replacement by new one 03LP. Rotor blades of last stages removed and need to be reinstalled by the new one. 04Air Pre-Heater Elements deterioration due to continuous oil firing. 05Requirement of Fuel Additive system to minimize the formation of scales on heating surfaces. 06Rehabilitation of Air/ Flue gas ducts which have been deteriorated/damaged due to continuous furnace oil firing. 07Requirement of Special Cooling Water Treatment system

32. Sr. No.Major Problems at Unit-5&6 TPS M/Garh. 01I. D. Fan Rotor/Impeller need to be replaced. 02G.R.C. Fan Impeller/Rotor problem 03Cooling Tower Fan Gear Box problems 04Air Pre-heater Elements Hot end, intermediate & cold end layers deterioration/damaged 05Steam Coil Air Heaters deteriorated 06Frequent Economizer Tubes leakages in case the load is increased above 100MW. 07IP & LP Turbine Rotors require replacement. 08Rehabilitation of Air/Flue gases ducts and rehabilitation of soot blowing system of furnace and regenerative air heaters. 09Fuel Additive System is required to minimize the formation of scales on heating surfaces. 10Feed Water pumps Hydraulic coupling problems

33. Block-4 & 6, GTPS, Faisalabad Unit Name TypeCOD/AgeInstalled Capacity Dependable Capacity Designed Efficiency (%) Present Efficiency (%) FuelFSA GT-1Gas Turbine 09.03.1975251927.6017.30GAS/HSDUnder Negotiation GT-2Gas Turbine 10.03.1975251927.6019.67-DO- GT-3Gas Turbine 04.05.1975251927.6020.95-DO- GT-4Gas Turbine 06.03.1975251927.6022.39-DO- GT-5Gas Turbine 31.07.1975252327.6021.64-DO- GT-6Gas Turbine 05.07.1975252327.6020.78-DO- GT-7Gas Turbine 10.07.1975252327.6021.76-DO- GT-8Gas Turbine 14.11.19752523276021.61-DO- CCP-9Combine cycle 28.12.19944442---DO- 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.

36. 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. Rehabilitation of TPS Muzaffargarh

37. STATUS OF MATERIAL PROCUREMENT FOR REHABILITATION OF TPS, MZG UNDER FARA-USAID

41. SOLUTIONS & SUGGESTIONS

43. 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 1 st 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.