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Technical Audit of GENCOs - Final Report April 27
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Transcript of Technical Audit of GENCOs - Final Report April 27
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Associated with PA Consulting Group Technical, Management, and Economic Counsel
Hagler Bailly Pakistan
Technical Audit Study of Jamshoro, Guddu and
Muzaffargarh Thermal Power Stations in Pakistan
Final Report
HBP REF.: R1V02TAG
April 27, 2011
Advanced Engineering Associates International
Islamabad
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Technical Audit Study of GENCO Power Plants
Hagler Bailly Pakistan Executive Summary
R1V02TAG: 04/27/11 ii
Executive Summary
An energy audit of the thermal power stations (TPSs) of the following three state owned
power plants, collectively referred to as GENCOs was carried out:
TPS Jamshoro, or the Jamshoro Power Company Ltd., commonly referred to as
GENCO I,
TPS Guddu, which is a part of Central Power Generation Company Ltd.
commonly referred to as GENCO II), and,
TPS Muzaffargarh, which is a part of Northern Power Generation Company
commonly referred to as GENCO III.D
The main objective of the study was to carry out a baseline evaluation or a benchmarking
for determining efficiency gains and operational improvements to be achieved through
the implementation of the USAID Fixed Amount Reimbursement Agreements (FARA)
Repair and Maintenance Plan currently under implementation at these GENCOs. The
key terms of reference of the study were:
Assess performance parameters such as effective output capability, heat rate and
efficiency and power plant availability of each unit
Identify reasons for drop of plant performance from the design parameters
Carry out a spot fuel oil analysis to determine the heat contents and quality of the
fuel oil being supplied to the power stations
Carry out a brief technical review to assess the potential for using high-viscosity
fuel oil to reduce the plants generation costs
The standard methodologies used by the industry to determine the baseline performance
evaluation of steam and combined cycle power plants are ANSI/ASME PTC-6 and
ANSI/ASME PTC-46 respectively. However, these methodologies could not be followed
for a number of limitations for GENCOs. These limitations include:
Lack of availability of accurate and calibrated instrumentation in the power
station for online or off-line evaluation of efficiency
Lack of trained staff and manpower to carry out detailed measurement procedures
under controlled testing conditions
Software tools to carry out the component-wise heat balance analysis of the plant
Extensive data that includes ambient conditions, design data, correction curves
and operating conditions for the main heat path components such as boilers,
turbines, condensers, and cooling towers.
A specific testing protocol was devised for each unit on the basis of its fuel supply
systems, instrumentation status, and other operating conditions. A number of units were
not available for testing due to different operational reasons. Exhibit I provides a
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Technical Audit Study of GENCO Power Plants
Hagler Bailly Pakistan Executive Summary
R1V02TAG: 04/27/11 iii
summary of units that were tested and those not tested along with the reasons for their
unavailability.
Exhibit I: Unit-wise Testing Status of GENCOs
Power Station Units Tested Units Not Tested Reasons for Not Testing the Units
TPS Jamshoro Units 1-4
TPS Guddu Steam Block
Units 1-2 Energy input could not be measured due to absence of gas flow meters
Unit 3
Energy input could not be measured accurately due to due to errors in gas and RFO flow meters
Unit 4 On prolonged shutdown from December 2010 to March 2011 due to break down of air pre-heater
TPS Guddu CCP Block
Block 2-A
(GT 7, GT8, ST 5)
Block 1
(GT 11, GT12, ST 13)
Block 2-B
(GT 9, GT10, ST6)
Energy input could not be measured accurately due to lackof functional and calibrated gas flow meters
TPS Muzaffargarh Units 2-6 Unit 1 On prolonged shutdown from November 2010 to mid- April 2011 due to delay in replacement of super heater tubes
The heat rates and efficiency parameters for the power stations have been calculated only
for the purpose of baseline evaluation or a benchmark for determining efficiency gains
and operational improvements to be achieved after the implementation of the USAID
FARA Repair and Maintenance Plan currently under implementation at these GENCOs.
It should be noted that heat rates in this study were determined under steady loading and
specific ambient and operating conditions of the units during the winter season. Average
annual heat rates for the power stations are likely to be higher due to variations in
ambient conditions and loading levels, inclusive of startups and shutdowns.
Findings and Results
All the steam units of TPS Jamshoro and TPS Muzaffargarh are dual fuel plants having
gas and residual fuel oil (RFO) firing facilities except for Unit 1 of Jamshoro that has
only fuel oil firing capability. However, these plants were only operating on RFO firing
due to shortage of natural gas. TPS Guddu uses medium calorific raw gas from Mari and
Kandhkot. Steam Unit 3 and 4 at Guddu can also operate on mixed firing with RFO as
secondary fuel. Due to poor maintenance of the power stations, GENCOs have lost
nearly one third of their capacity and nearly 17% of their thermal efficiency due to plant
degradation. The Exhibit II shows the unit-wise results of performance evaluation tests
for the power stations.
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Technical Audit Study of GENCO Power Plants
Hagler Bailly Pakistan Executive Summary
R1V02TAG: 04/27/11 iv
Exhibit II: Results of Output Capability, Heat Rate and Availability of GENCOs
Installed Capacity
MW
Present Gross
Capability MW
Present Net
Capability MW
Capacity Degradation
Design Heat Rate
Design Net
Efficiency
Gross Heat Rate
Gross Efficiency
Net Heat Rate
Net Efficiency
Average Availability in FY2010
Average Availability in FY2011
TPS Jamshoro
Unit 1 250 191 176 23% 9,315 36.6% 9,829 34.7% 10,720 31.8% 73% 80%
Unit 2 200 119 112 41% 10,068 33.9% 11,727 29.1% 12,492 27.3% 88% 69%
Unit 3 200 125 113 38% 10,068 33.9% 11,879 28.7% 13,262 25.7% 85% 58%
Unit 4 200 146 133 27% 10,068 33.9% 10,909 31.3% 11,935 28.6% 91% 79%
Total Jamshoro 850 581 535 32% 84% 72%
TPS Guddu CCP Block
Block 2-A
GT 7 100 93 92 7% 10,763 31.7% 12,840 26.6% 12,896 26.5% 78% 96%
GT 8 100 85 85 15% 10,763 31.7% 13,412 25.4% 13,467 25.3% 98% 92%
ST 5 100 71 69 29% - - - - 98% 97%
Total Block 2-A 300 248 246 17% 9,572 35.6% 9,658 35.3% 98% 95%
Block 1
GT 11 136 80 80 41% 10,629 32.1% 12,196 28.0% 12,261 27.8% 99% 100%
GT 12 136 80 80 41% 10,629 32.1% 12,236 27.9% 12,272 27.8% 99% 100%
ST 13 143 84 81 41% 97% 86%
Total Block 1 415 244 240 41% 8,081 42.2% 8,218 41.5% 98% 95%
Total Guddu CCP 715 493 487 31% 95% 95%
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Technical Audit Study of GENCO Power Plants
Hagler Bailly Pakistan Executive Summary
R1V02TAG: 04/27/11 v
Installed Capacity
MW
Present Gross
Capability MW
Present Net
Capability MW
Capacity Degradation
Design Heat Rate
Design Net
Efficiency
Gross Heat Rate
Gross Efficiency
Net Heat Rate
Net Efficiency
Average Availability in FY2010
Average Availability in FY2011
TPS Muzaffargarh
Unit 2 210 168 156 20% 9,279 36.8% 10,060 33.9% 10,784 31.6% 88% 83%
Unit 3 210 140 127 33% 9,279 36.8% 9,943 34.3% 10,773 31.7% 81% 96%
Unit 4 320 202 181 37% 9,297 36.7% 10,129 33.7% 11,312 30.2% 97% 60%
Unit 5 200 97 86 51% 10,780 31.7% 11,384 30.0% 13,026 26.2% 47% 72%
Unit 6 200 73 64 63% 10,780 31.7% 12,380 27.6% 14,392 23.7% 77% 78%
Total Muzaffargarh 1,140 680 614 40% 80% 62%
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Technical Audit Study of GENCO Power Plants
Hagler Bailly Pakistan Executive Summary
R1V02TAG: 04/27/11 vi
The key results of the performance evaluation tests are described below.
TPS Jamshoro
The average capacity degradation was found to be 32% compared to the installed
capacity with a maximum degradation of 40% for Unit 2 and a minimum degradation of
23% for Unit 1. The average drop in the net efficiency is about 20% from the design
efficiency of the power station. Unit 1 is most efficient with 32% net efficiency against
the design efficiency of 36.6%. The net efficiencies of Units 2-4 ranged between 25.7%
to 28.6% against the design efficiency of 34%. The average availability of the power
station was 84% in FY2010 and 72% in FY2011 (till November 2010). However, if this
availability is corrected for lost output of the plant due to degradation, the availability
factor would drop by about 35%, indicating poor performance of the plant.
TPS Guddu
CCP Block 1 has shown 40% degradation in its capacity from the installed capacity
whereas CCP Block 2-A appears to be in better condition with only 17% capacity
degradation. The gas turbines (GTs 7 and 8) in Block 2-A showed net efficiencies of
27.8% each against the design efficiency of 31.7%. The GT 11 and GT 12 in Block 1
showed the net efficiencies of 26.5% and 25.3% respectively against the design
efficiency of 32.1%. The net efficiency of the Block 2-A and Block 1 were calculated to
be 35.3% and 41.5% respectively. The average availability of the units tested under the
study at power station was in excess of 95% but if this availability is corrected for lost
output of the plant owing to degradation, the availability factor would drop by about
30%, quite low from industry standards.
TPS Muzaffargarh
The power station is operating with an overall capacity degradation of around 40%.
Capacity degradation for the units varied between 20% for Unit 2 to 63% for Unit 6. The
power station is facing an overall degradation of around 18% in its net efficiency. Units
2 and 3 are in better condition with 31% net efficiency compared with their design
efficiency of 36.8%. Unit 4 has a net efficiency of 30% against 36.7% design efficiency.
Units 5 and 6 have efficiencies of 26% and 24% respectively against the design
efficiency of 31.7% for both units. The average availability of the power station was in
80% and 62% in FY2010 and FY2011. The availability of TPS Muzaffargarh would also
drop by 40% if corrected for lost output of the plant.
The auxiliary consumption and energy sent out on many units could not be measured
with accuracy due to indiscrete or absent metering. Therefore gross output capability and
heat rates should be used for the benchmarking purpose in this study.
Conclusions
Based on the observations of the audit team, interviews with the power stations management and operational staff and review of historic records of the plants, and
capacity and heat rate tests conducted at the operational units, a number of reasons were
identified behind the overall decline in the performance of the power stations studied.
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Technical Audit Study of GENCO Power Plants
Hagler Bailly Pakistan Executive Summary
R1V02TAG: 04/27/11 vii
Quality of RFO
None of the samples complied with Pakistan Standard and Quality Control Authority
(PSQCA) specifications for RFO. High specific gravity values were obtained due to
higher water contents. Only one sample met the standard calorific value of 18,200
Btu/lb. Moreover, the low calorific value up to 8.5% below the minimum permissible
limit was observed due to high specific gravity, water and ash contents.
Measurement Accuracy of Energy Input and Output
The discrete measurement of fuel supplied and energy generated and sent out for each
unit of the plant was found to be inadequate.
No credible measurement system exists for RFO received from the supplier as
well as fed to the installed units from the storage facilities of the plant. The same
applies to natural gas supplied and consumed at Guddu power station. At Guddu,
the gas supplied to residential colony is not measured. Measurement instruments
are either not calibrated, non-functional, or absent.
No uniform standards are followed for measurement of energy output. Auxiliary
supply is not discrete or fully measured for each unit resulting in inappropriate
accounting of auxiliary consumption.
Testing quality and procedures adopted by plants internal laboratories are also highly questionable as they lack transparency and quality control. None of the
RFO samples complied with Pakistan Standard and Quality Control Authority
(PSQCA) specifications in one or more tests. Water and ash contents were found
to be higher than the maximum limits prescribed by the PSQCA
Lack of Preventive Maintenance
A number of maintenance activities are long overdue and have already resulted in loss of
output capability, increasing heat rates and lower availability.
GENCO managements are forced to delay the overhauling of the plants and are
not able to carry out regular preventive maintenance to avoid break-down of the
plants for the following reasons:
Refusal of shut-down time by the system operator (NTDC) due to shortages in
power supply in the country,
Delay in payments to GENCOs against power sales, and
Delay in procurements of parts and services for plants major overhauling.
Poor Housekeeping
GENCO managements are paying little attention to simple housekeeping activities which
do not require large expenditures. Examples include:
Frequent steam leakages in boiler and other steam usages increase heat loss at the
plant as well as raise water purification cost due to excessive use of chemicals.
A number of critical plant components are not operating at their optimal
conditions, causing frequent tripping and breakdowns of the units.
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Technical Audit Study of GENCO Power Plants
Hagler Bailly Pakistan Executive Summary
R1V02TAG: 04/27/11 viii
Plant management is generally oblivious to environmental conservation and
protection. Massive oil spills and un-optimal combustion results in higher rate of
toxic emissions and effluent discharges causing environmental threats to adjacent
population, flora and fauna.
Lack of Performance Evaluation, Monitoring, and Reporting
No attention is given to the performance evaluation of the plants and as such no standards
are observed to assess the performance of the plants.
The present monitoring and reporting system covers a few technical parameters
and is not capable to provide a detailed assessment of the plants.
Plants are running in manual mode in the absence of modern monitoring and
control systems.
The absence of performance evaluation standards and an on-line integrated
management information system (MIS) severely limits the ability of the
management to take prompt decisions and initiate actions and remedial measures
for efficient operation of the plants.
Limited Financial and Administrative Autonomy
Managements of GENCO plants have limited financial autonomy to take independent
decisions.
Payments to GENCOs are not made on time which results in deferment of
maintenance routines which is a major reason behind plant output and efficiency
degradation.
Approval process for procurement of spare parts and services through
international tendering is cumbersome and time consuming.
Management is not empowered to initiate a performance-based human resource
management system to promote efficiency and competition.
The plants are suffering from overstaffing with majority of staff working
without specialized industrial training to perform their duties
Occupational health, safety, and environmental management system and
relevant trainings are not observed at the plants increasing the potential of a
safety hazard at the plant
Recommendations
In order to improve the performance of the GENCOs, the following recommendations are
made:
A standard measurement and testing protocol needs to be devised for GENCOs
for all measurement to avoid errors in financial transactions. GENCOs should
carry out a detailed exercise to devise a robust measurement mechanism for RFO
receipts at the plants to reduce oil pilferages and acceptance of substandard oil.
A third party RFO testing mechanism should be established on regular basis to
ensure the quality of fuel received from supplier. The contracts with the fuel
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Technical Audit Study of GENCO Power Plants
Hagler Bailly Pakistan Executive Summary
R1V02TAG: 04/27/11 ix
supplier should include penalties or correction in price for supply of substandard
oil.
A detailed management study is required to prescribe key performance indicators
pertaining to financial, human and environmental performance of the plant and
the procedures to evaluate them on sustainable basis.
The Inspection, Testing and Records (ITR) and Maintenance Management System
(MMS) sections may be merged to form a Performance Monitoring Section
(PMS) at each power station to provide a wider range of performance evaluation
and monitoring services.
On-line analyzers and instruments with communication channels to a central
performance modeling system should be installed to assess the performance and
efficiency of the plant on a continuous basis. The PMS should operate this
system and advise the operations and maintenance staff on corrective and
preventive actions to be taken to meet the performance targets.
Special training and workshops should be arranged to educate and train the
management and staff about best industrial practices to operate and maintain the
power stations.
The capacity of in-house repair and maintenance workshops should be enhanced
with modern machines, tools and training of staff to provide maintenance services
of critical parts locally to reduce down-time
There is a need to establish an R&D or a Technical Services section to carryout
research on technical and management problems of the power stations and devise
solutions
Switching to heavier grade RFO will require capital investment in the
infrastructure for storage, handling, transportation, and utilization of RFO. A
detailed feasibility study including the infrastructure analysis of PSO and required
modifications at the steam turbine and diesel engine based power plants and
assessment of the resulting cost savings is recommended to ascertain the
economics of burning heavier grade fuel oils.
The government is currently implementing a Generation and Transmission Improvement
Plan (GTIP) for the GENCOs. The resolution of management and operational issues
identified in this study require a complete change in the management approach and
operational environment of the GENCOs. The government could consider bringing in
independent management under a performance based O&M contract based on a structure
of incentives and penalties against the performance of the power stations. The terms and
conditions of the O&M contract could be designed in a manner to make the contractor
responsible for injecting investment for rehabilitation of the units and bringing in highly
trained and experienced senior managers. The O&M contractor may be given extended
authority to reward and motivate employees and to take disciplinary action and adjust the
size of the work force. This approach will help in establishing and expanding the O&M
industry and in improving the efficiency of the power sector in the country.
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Technical Audit Study of GENCO Power Plants
Hagler Bailly Pakistan Contents
R1V02TAG: 04/27/11 x
Contents
1. Introduction ...................................................................................... 1-1
1.1 Objectives and Scope of Work ................................................................ 1-1 1.2 Study Team ............................................................................................... 1-3 1.3 Acknowledgement .................................................................................... 1-3 1.4 Organization of the Report ...................................................................... 1-3
2. Methodology .................................................................................... 2-1
2.1 Limitations of Standard Methodologies and Approach Adopted for the Study .............................................................................. 2-1
2.2 Measurements and Collection of Data on Plant Performance ............... 2-2 2.3 Testing of Fuel Quality ............................................................................. 2-2 2.4 Testing Arangements and Schedule ....................................................... 2-3
3. Description of GENCO Plants ........................................................ 3-1
3.1 Fuel Supply Arrangements ...................................................................... 3-1 3.2 TPS Jamshoro .......................................................................................... 3-5 3.3 TPS Guddu ................................................................................................ 3-6 3.4 TPS Muzaffargarh ..................................................................................... 3-7
4. Maximum Present Capability ......................................................... 4-1
4.1 General Approach and Overall Limitations ............................................ 4-1 4.2 TPS Jamshoro .......................................................................................... 4-1 4.3 TPS Guddu ................................................................................................ 4-2 4.4 TPS Muzaffargarh ..................................................................................... 4-2
5. Heat Rate Analysis .......................................................................... 5-1
5.1 Definitions ................................................................................................. 5-1 5.2 Limitations in Assessment of Heat Rates ............................................... 5-1
5.2.1 Testing Schedule .............................................................................. 5-1 5.2.2 Measurement of Fuel Flow ............................................................... 5-1 5.2.3 Metering of Electrical Output ............................................................ 5-2 5.2.4 Application of Heat Rate Assessment ............................................... 5-3
5.3 TPS Jamshoro .......................................................................................... 5-3
5.3.1 Testing Procedures and Data Analysis ............................................. 5-3 5.3.2 Results ............................................................................................. 5-3
5.4 TPS Guddu ................................................................................................ 5-5
5.4.1 Testing Procedures and Data Analysis ............................................. 5-6 5.4.2 Results ............................................................................................. 5-6
5.5 TPS Muzaffargarh ..................................................................................... 5-8
5.5.1 Results ............................................................................................. 5-8
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Technical Audit Study of GENCO Power Plants
Hagler Bailly Pakistan Contents
R1V02TAG: 04/27/11 xi
6. Power Plant Availability .................................................................. 6-1
6.1 Definitions and Limitations ...................................................................... 6-1 6.2 Data and Results ...................................................................................... 6-2
6.2.1 TPS Jamshoro ................................................................................. 6-2 6.2.2 TPS Guddu ...................................................................................... 6-2
6.3 TPS Muzaffargarh ..................................................................................... 6-3
7. Major Reasons for Degradation of Performance .......................... 7-1
7.1 Technical Issues ....................................................................................... 7-1
7.1.1 Measurement Accuracy of Fuel Received ........................................ 7-1 7.1.2 Fuel Oil Quality ................................................................................. 7-2 7.1.3 Lack of Preventive Maintenance ....................................................... 7-3 7.1.4 Poor Housekeeping .......................................................................... 7-5
7.2 Management Issues and Recommenadations ........................................ 7-7
7.2.1 Lack of Performance Evaluation ....................................................... 7-7 7.2.2 Limited Financial and Administrative Autonomy ............................... 7-7 7.2.3 Absence of Plant Automation and
Management Information System ..................................................... 7-8 7.2.4 Other Management Issues ............................................................... 7-9
7.3 Detailed Technical Assessment of GENCOs ........................................ 7-10
7.3.1 TPS Jamshoro ............................................................................... 7-10 7.3.2 TPS Guddu .................................................................................... 7-16 7.3.3 TPS Muzaffargarh .......................................................................... 7-26
8. Usage of High Viscosity Fuel Oil in GENCO Power Plants ......... 8-1
8.1 Fuel Oil Standards .................................................................................... 8-1 8.2 Potential for use in Power Generation in Paksitan ................................ 8-1 8.3 Modifications Required in Fuel Oil Handling at the Power Plants ........ 8-2 8.4 Modification and Adjustments Required in the Boilers ......................... 8-2 8.5 Fuel Oil Procurement and Supply ........................................................... 8-3
APPENDICES
Appendix A: Fuel Oil Analysis Results
Appendix B: Data and Results of the GENCOs Capacity Test
Appendix C: Testing Procedures for Measurment of GENCOs Gross and Net Heat Rates
Appendix D: Calculation of GENCOs Gross and Net Heat Rates
Appendix E: Power Plant Availability
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Technical Audit Study of GENCO Power Plants
Hagler Bailly Pakistan Exhibits
R1V02TAG: 04/27/11 xii
Exhibits
Exhibit 1.1: Locations of Power Stations Studied .................................................... 1-2
Exhibit 1.2: Formation of the Consulting Team ........................................................ 1-3
Exhibit 3.1: Natural Gas Supply Arrangements at the Power Stations ..................... 3-2
Exhibit 3.2: GENCOwise Installed and Derated Capacities, Plant and Fuel Types, and Efficiencies from PEPCO Statistics ............................. 3-3
Exhibit 3.3: 200 MW Steam Unit No. 2 at TPS Jamshoro ........................................ 3-5
Exhibit 3.4: Oil Storage Tanks at TPS Jamshoro ..................................................... 3-6
Exhibit 3.5: 200 MW Steam Unit No. 3 at TPS Guddu ............................................. 3-6
Exhibit 3.6: RFO Storage Capacity at the Power Stations-TPS Guddu .................... 3-7
Exhibit 3.7: 200 MW Steam Unit No. 6 at TPS Muzaffargarh ................................... 3-8
Exhibit 3.8: Oil Decanting from Railway Wagons and Tank Lorries atTPS Muzaffargarh ........................................................................................ 3-9
Exhibit 3.9: RFO Storage Capacity at the Power Stations-TPS Muzaffargarh ......... 3-9
Exhibit 3.10: Oil Storage Tanks at TPS Muzaffargarh ............................................. 3-10
Exhibit 4.1: Unit-wise Installed Capacity and Present CapabilityTPS Jamshoro .................................................................... 4-1
Exhibit 4.2: Unit-wise Installed Capacity and Present Capability of Units Tested Under the StudyTPS Guddu.................................................... 4-2
Exhibit 4.3: Unit-wise Installed Capacity and Present Capability of Units Tested Under the Study TPS Muzaffargarh ....................................... 4-3
Exhibit 5.1: Unit-wise Gross and Net Heat Rate and EfficiencyTPS Jamshoro ..................................................................... 5-4
Exhibit 5.2: Unit-wise Gross and Net Heat Rate and EfficiencyTPS Guddu .......................................................................... 5-7
Exhibit 5.3: Unit-wise Gross and Net Heat Rate and EfficiencyTPS Muzaffargarh ............................................................... 5-9
Exhibit 6.1: Unit-wise AvailabilityTPS Jamshoro .................................................... 6-4
Exhibit 6.2: Unit-wise Availability TPS Guddu ....................................................... 6-5
Exhibit 6.3: Unit-wise AvailabilityTPS Muzaffargarh .............................................. 6-7
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Technical Audit Study of GENCO Power Plants
Hagler Bailly Pakistan Exhibits
R1V02TAG: 04/27/11 xiii
Exhibit 7.1: Average Degradation in Performance of GENCOs ............................... 7-1
Exhibit 7.2: Summary of Results of Fuel Oil Testing ................................................ 7-2
Exhibit 7.3: Poor Maintenance of Insulation at TPS Jamshoro ................................ 7-4
Exhibit 7.4: Steam Leakages at TPS Muzaffargarh ................................................. 7-5
Exhibit 7.5: View of a Nonfunctional Soot Blower at TPS Jamshoro ........................ 7-6
Exhibit 7.6: Oil Spillage at Storage Facility at Muzaffargarh .................................... 7-6
Exhibit 7.7: View of the Joint Control Room of Units 3 and 4 at TPS Jamshoro ....... 7-8
Exhibit 7.8: Smoke Showing Poor Combustion at Unit No. 6 at TPS Muzaffargarh................................................................................. 7-9
Exhibit 7.9: River Water Quality Supplied at TPS Jamshoro in January 2011 ........ 7-11
Exhibit 7.10: Reasons for Drop in Performance of the PlantTPS Jamshoro........... 7-12
Exhibit 7.11: Damaged Air Pre-heater due to Fire of Unit No. 4 at TPS Guddu ....... 7-16
Exhibit 7.12: Poor Cooling of Turbine Section of Unit No. 3 at TPS Guddu ............. 7-18
Exhibit 7.13: Reasons for Drop in Performance of the Steam UnitsTPS Guddu ............................................................................... 7-19
Exhibit 7.14: View of Under Repair Induced Draft Fan of Unit No. 1 at TPS Muzaffargarh............................................................................... 7-26
Exhibit 7.15: Unit-wise Reasons for Drop in Performance of the Steam UnitsTPS Muzaffargarh ......................................................... 7-28
Exhibit 8.1: RFO Specifications ISO 8217:2010 ...................................................... 8-4
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Technical Audit Study of GENCO Power Plants
Hagler Bailly Pakistan Introduction
R1V02TAG: 04/27/11 1-1
1. Introduction
Advanced Engineering Associates International (AEAI) engaged Hagler Bailly Pakistan
to carry out an energy audit of the thermal power stations (TPSs) of the following three
state owned power plants:
1. TPS Jamshoro, or the Jamshoro Power Company Ltd., commonly referred to as GENCO I,
2. TPS Guddu, which is a part of Central Power Generation Company Ltd. commonly referred to as GENCO II), and,
3. TPS Muzaffargarh which is a part of Northern Power Generation Company commonly referred to as GENCO III.
These thermal power stations are collectively referred to as GENCOs in this report. The
locations of these thermal power stations in the country are shown in Exhibit 1.1.
1.1 Objectives and Scope of Work
The main objective of the study was to carry out a baseline evaluation or a benchmarking
for determining efficiency gains and operational improvements to be achieved through
the implementation of the USAID Fixed Amount Reimbursement Agreements (FARA)
Repair and Maintenance Plan currently under implementation at these GENCOs. The
main features of the scope of work of the study were:
Visual inspection of all units of three GENCO power stations, review of the
station logbooks and other available records to establish main reasons for the poor
performance of the plants and the present generation capacity. Interviews and
discussions with the plant managers/operators and determine the reasons for poor
performance.
Drawing of performance profile of each unit including operating parameters, such
as effective output capability, power plant availability, heat rate and efficiency of
each unit.
Determination of specific fuel consumption and monitor on line calorific value of
fuel being injected into each machine.
Carrying out a spot fuel oil analysis to determine the heat contents and quality of
the fuel oil being supplied to the power stations.
Determination of heat rate and efficiency of each unit.
Carrying out a brief technical review to assess the potential for using high-
viscosity fuel oil to reduce the plants generation costs.
Preparation and submission of Energy Audit Report for each of the GENCOs.
Three teams of power generation experts were formed to carry out the site visits and
conduct tests to assess the capacity and heat rates of the operational units of the plants.
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Technical Audit Study of GENCO Power Plants
Hagler Bailly Pakistan Introduction
R1V02TAG: 04/27/11 1-2
Exhibit 1.1: Locations of Power Stations Studied
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Technical Audit Study of GENCO Power Plants
Hagler Bailly Pakistan Introduction
R1V02TAG: 04/27/11 1-3
1.2 Study Team
The study team consisted of experienced engineers who have been extensively involved
in the construction and operation of the power stations studied, and have retired from
senior positions at the GENCOs. The names and specific assignment of the consultants
involved in the study are listed in Exhibit 1.2.
Exhibit 1.2: Formation of the Consulting Team
Name of Consultant Responsibility
1 Manzar Naeem Qureshi Team Leader
2 Muhammad Qasim Shaikh TPS Jamshoro
3 Abdul Waris Khan TPS Guddu Combined Cycle Power Station Block
4 Abdul Aziz Chandio TPS Guddu Steam Power Station Block
5 Abdul Karim Leghari TPS Muzaffargarh
Additional staff was engaged at each power station to assist the Consultants in taking
concurrent meter readings of input and output energy measurements at the power
stations.
1.3 Acknowledgement
The management of the GENCOs extended their generous cooperation in facilitating the
audit teams, and allowed unhindered and unlimited access to power station equipment,
instruments, data records and personnel for interviews. HBP management would like to
extend their profound gratitude to the management of the GENCOs for their support in
completing the assignment.
1.4 Organization of the Report
Section 2 of the report describes the methodology used to carry out the capability and
efficiency tests for the GENCOs. Section 3 provides an overview of the power stations
in terms of configuration and fuel supply arrangements. Section 4 presents the results of
the unit-wise maximum capability tests for each power station. Section 5 provides
detailed procedures employed for carrying out the heat rate tests and presents the results
of heat rate and efficiency for each unit of the power stations. Section 6 shows the unit-
wise annual availability in terms of load factor, utilization factor and availability.
Section 7 provides a detailed account of the main technical and management reasons
causing the drop in performance of these power stations. Section 8 sums up the
conclusions and recommendations of the study.
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2. Methodology
2.1 Limitations of Standard Methodologies and Approach Adopted for the Study
The standard methodologies used by the industry to determine the baseline performance
evaluation of steam and combined cycle power plants are ANSI/ASME PTC-6 and
ANSI/ASME PTC-46 respectively. Application of these methodologies helps in accurate
determination of performance of the power stations and generation of analysis and
information for optimization of their performance. These standard methodologies have
the following requirements:
Availability of accurate and calibrated instrumentation in the power station for
online or off-line evaluation of efficiency
Trained staff and manpower to carry out detailed measurement procedures under
controlled testing conditions
Software tools to carry out the component-wise heat balance analysis of the plant
Extensive design data and correction curves for the main heat path components
such as boilers, turbines, condensers, and cooling towers.
Ambient conditions including temperature and humidity, and
Data on operating conditions at the inlet and outlet of the main heat path
components, such as temperatures, flow rates, and stream composition.
None of the GENCOs studied fulfill the requirements listed above. Preparing the
GENCOs to fulfill these requirements would require extensive capacity building and
installation of necessary instrumentation, which was beyond the scope and schedule of
this study. It was therefore not possible to conduct a comprehensive audit of the
performance of the GENCOs using the standard industry methodologies given the
prevailing conditions and the operating environment in the GENCOs and the time
constraints for the study. In view of these limitations, the standard industry
methodologies were modified and applied in a simplified manner to measure the capacity
and input and output energy of the plants to calculate the heat rate and efficiency, and to
work out the plant availability on monthly and annual basis.
Industry experience indicates that heat rate test conducted by using formal ASTM-6
procedure has an accuracy of about 3%. Given the poor condition of instrumentation that
were not properly calibrated, unusual operating conditions for testing, and improvised
test protocols, the accuracy of the heat rate tests under this study could range between
5-10% as per expert judgment. This aspect should be kept in view while comparing the
results of benchmarking conducted under this study with the follow-up tests to be
conducted after completion of FARA program.
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2.2 Measurements and Collection of Data on Plant Performance
Special teams, comprising of instrumentation experts, were formed to carry out tests at
each unit. A specific testing protocol was devised for each unit on the basis of its fuel
supply systems, instrumentation status, and other operating conditions. The measurement
points were marked beforehand and measurement procedures were established keeping in
view the operating constraints of the unit. Special proformas were designed to prescribe
the measurement specifications and to maintain testing records. Standard conversions
and definitions were used to calculate the output and heat rates of the units. The
measurement procedures were documented and are presented in Section 5 of this report.
Residual fuel oil (RFO) consumption was calculated by using dip-tape, calibration charts
of the feeding tanks, and specific gravity of RFO at observed temperatures. Natural gas
consumption at TPS Guddu was measured through the meters installed at the units in the
power station. Electrical outputs at gross and sent-out meters, and auxiliary consumption
were recorded at the metering locations of the units studied. All the readings were taken
concurrently and coordination was managed through mobile phones and hand held radio
phones.
The Consultants did not engage any serving person from the GENCOs for the purpose of
assisting the teams in reading of instruments or recording the observations. No unit log-
sheet entries and event registers were used or consulted for extracting the information and
data for the purpose of calculation of heat rates. The Consultants ensured uninterrupted
operation of the plants throughout the testing period. The testing schedule was designed
to avoid interference with operations and management of the power station. The
Consultants relied to the extent possible on the installed measurement instruments, and
used their own equipment such as dip-tapes to carry out the assignment where required.
2.3 Testing of Fuel Quality
RFO
RFO samples were drawn from the main storage tanks of these power stations in
accordance with the ASTM methodology; Standard Practice for Manual Sampling of
Petroleum and Petroleum Products: D 4057 95 (Reapproved 2000). The parameters studied to assess the quality of RFO included specific gravity, flash point, pour point,
water contents, sulfur, ash content and calorific value.
A composite sample was drawn from each of the storage tanks consisting of a blend
created from the upper, middle, and lower samples from a single tank. The sample was
obtained with the help of a specially designed sampling tube also called special thief.
The bottom sample was taken from the height of 1.5 to 2.0 meters from bottom of the
tank as the outflow of the tank was drawn from the height of 1.0 meters. The samples
were packed in aluminum bottles and dispatched to an independent laboratory for testing.
In all, eighteen samples were drawn; 4 from TPS Jamshoro; 5 from TPS Guddu; and 9
from TPS Muzaffargarh. Samples were collected during the period of December 29,
2010 to January 5, 2011 and analysis was carried out by Quality Control Laboratory of
Attock Refinery Limited, Morgah Rawalpindi.
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2.4 Testing Arangements and Schedule
The detailed procedures developed for performance testing of each unit are described in
Section 5 of this report.
TPS Jamshoro
Prior to conducting the performance tests, inspections of all the units at the power plant
were carried out in the presence of the representatives of the power station management.
The operational conditions of the units were observed and necessary information and
details were gathered.
Although all the units were in operating condition, the plant management could run only
one unit at a time due to shortage of demineralized water. Further, the units could not
operate at optimum load on continuous basis for longer periods on RFO firing due to
choking of rotary air pre-heaters. Therefore, the Consultants team faced considerable difficulty in finding an appropriate window of time to carry out heat rate and capacity
tests for continuous three days without interruption at optimum operating conditions.
Heat rate and capacity tests at the plants were performed in the following sequence:
Unit 1: January 19-21, 2011 for heat rate tests and January 21-23, 2011 for
capacity tests
Unit 2: January 21-23, 2011 for both heat rate and capacity tests
Unit 3 & 4: February 17-19, 2011 for both heat rate and capacity tests
TPS Guddu
Meetings were held with the concerned management of each unit before the beginning of
testing. Block 2 B comprising of Units 6, 9 and 10 did not have functional gas flow
meters and therefore could not be tested. Similarly, Unit 4 was on long shut down due to
break down of air pre-heater. Units 1 & 2 also do not have gas flow meters and therefore
were not tested. The testing of these units was deferred until gas flow meters are made
operational on all of these units and repair/replacement of air pre-heater of Unit 4.
Capacity and Heat Rate Tests at the plants were performed in the following sequence:
Unit 3: December 30, 2010 to January 1, 2011
Block 2 A (Unit 5, 7& 8): December 30, 2010 to January 2, 2011
Block 1 (Unit 13, 11& 12): January 3-6, 2011
TPS Muzaffargarh
Before undertaking the performance tests, inspection of all the units installed in different
phases (1 & 2) was carried out in the presence of representatives of the power station
management. The operational conditions of the units were observed and necessary
information and details were gathered.
Unit 1 was placed under a long shutdown since November 11, 2010 for
repair/replacement of super heater tubes. However, the repair/replacement of ends of
super-heater tubes was delayed due to arrival of Russian experts of the Original
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Equipment Manufacturer (OEM). The unit could not be restarted until the middle of
April 2011 and therefore the performance testing of this unit could not be conducted.
Heat Rate Tests & Capacity Tests at the plants were performed in the following
sequence:
Unit 2 & 3: January 9-11, 2011
Unit 4: January 5-7, 2011
Unit 5 & 6: January 2-4, 2011
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3. Description of GENCO Plants
Total installed capacity of the three power plants studied is 3,8551 MW out of which
2,840 MW consists of dual fuel steam turbines, and 1,015 MW of gas fired gas turbine
combined cycle (CCGT) power plants installed at Guddu. The dual fuel plants operate
on pipeline quality natural gas and residual fuel oil (RFO), whereas CCGT units installed
at Guddu use medium calorific value (MCV) gas (780-800 Btu/scft).
Nearly 90% of the installed capacity of GENCOs is over 15 years old, and is generally in
poor condition. Due to the weak financial conditions prevailing amongst power sector
entities, the Water and Power Development Authority (WAPDA) which owned the units
until 1998 and the Pakistan Electric Power Company Ltd. (PEPCO) which owns them
now, have not been able to allocate adequate funds to meet the operational and
maintenance expenditures of these plants. These factors have contributed to a gradual
loss of effective capacity, efficiency, and dispatch availability of these plants.
Consequently, the GENCOs are currently operating their plants at a derated capacity that
is 25% below their respective nameplate capacities. The combined cycle units at Guddu,
however, are an exception and can operate on full capacity if natural gas injection
pressures are restored to the design levels.
The average forced outage rate for the GENCOs has been about 12%, compared with 6%
for thermal IPPs in the country. Nearly all of the GENCO power plants studied are
operating at a much lower efficiency levels than the industry-wide standards for plants of
similar age and configuration. Exhibit 3.2 provides a snapshot of the current status, age,
and origin of these plants.
3.1 Fuel Supply Arrangements
Most of the steam units at the power stations have the provision of dual fuel combustion
on natural gas and RFO. Unit 1 at TPS Jamshoro can only operate on RFO. The Steam
Units 1-2, and combined cycle units at TPS Guddu operate on MCV gas supplied from
Mari, Kandhkot, and Zamzama gas fields. The power station-wise details of the fuel
supplies are given below.
Natural Gas
All the power stations have connections with the utilities for supply of natural gas.
However, gas utilities used these plants as swing customers and curtailed the gas supplies
during winter to meet the heating demand of the residential and commercial consumers.
TPS Jamshoro and TPS Muzaffargarh do not have firm supply contracts with their
respective gas supply utilities and therefore receive natural gas only when there is surplus
in the national gas network. The county is presently facing a shortfall in the natural gas
supplies due to rising gas demand and the gas utilities have been unable to maintain
supply of pipeline quality gas to these power stations even during the summer period.
1 Power System Statistics, 34th Edition, 2009
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Exhibit 3.1 contains the sources and fuel supply arrangements for natural gas for the
GENCO plants.
Exhibit 3.1: Natural Gas Supply Arrangements at the Power Stations
Power Station Gas Supply Source Contract Status
TPS Jamshoro Sui Southern Gas Company No firm contract as and when available
TPS Guddu Mari Gas Mari Gas Company* 60 MMscfd
Kandhkot gas Pakistan Petroleum Limited (110 + 90) MMscfd
Zamzama Gas through SNGPL and SSGC networks
No firm contract Not supplied since 2005
TPS Muzaffargarh Sui Northern Gas Pipelines No firm contract as and when available
* Gas supplies to Guddu from Mari have been reduced to 60 MMscfd from 110 MMscfd after diversion of 50 MMscfd to Fatima Fertilizer from November 27, 2009.
Residual Fuel Oil (RFO)
RFO is supplied to all GENCOs by Pakistan State Oil (PSO). However, only TPS
Muzaffargarh has a fuel supply agreement with PSO, whereas the government has
advised TPS Jamshoro and TPS Guddu to purchase RFO from PSO exclusively. PSO
mainly supplies the RFO from Karachi through railway tank wagons and tank lorries.
GENCO plants are designed to operate on fuel oil having kinematic viscosity of 180
centistokes (cst) during summer and 120 cst during winter.
RFO Measurement
The GENCOs follow a uniform procedure for measurement of the quantity of RFO
received from PSO. The initial volumetric measurement is taken by using dip-sticks for
both railway tank wagons and tank lorries and fuel oil volumes are converted to weight
for the calculation of payments by using specific calibration charts for the lorries/wagons
after applying corrections for temperature and specific gravity of RFO. For tank lorries,
the weighbridges are also present at all the power stations. The weight of RFO calculated
using dip-sticks is verified at the weighbridges by taking measurements of the tank lorries
before and after the oil decanting. Several checks are applied to ensure complete
decanting of RFO from tank lorries and railway wagons. The weighbridge measurement
is not used for making payments to fuel supplier.
All tank lorries and railway wagons are tested for temperature and specific gravity of the
fuel oil and about 20-25% are randomly selected for detailed analysis of RFO
specifications in the local laboratory of the concerned power station. A small proportion
of the samples are also tested through independent laboratories to verify the result of the
internal laboratory. RFO that does not meet specifications is rejected for procurement.
The results of the third party analysis of the RFO samples collected from GENCO power
stations are presented in Appendix-A.
Oil Storage
All the power stations have their own RFO storage facilities at their premises for storage
of 20-30 day requirement of RFO.
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Exhibit 3.2: GENCOwise Installed and Derated Capacities, Plant and Fuel Types, and Efficiencies from PEPCO Statistics
Plant Installed Capacity
(MW)
Year of Commissioning Fuel Country of Origin Thermal Efficiency (Design)
TPS Jamshoro
Unit 1 250 January 1990 RFO Japan 36.6%
Unit 2 200 December 1990 Natural Gas/RFO China 33.9%
Unit 3 200 June 1990 Natural Gas/RFO China 33.9%
Unit 4 200 January 1991 Natural Gas/RFO China 33.9%
TPS Guddu
Steam
Unit 1 110 1974 Natural Gas Czech Slovakia 28.0%
Unit 2 110 1974 Natural Gas Czech Slovakia 28.0%
Unit 3 210 1980 Natural Gas/RFO USSR 30.0%
Unit 4 210 1980 Natural Gas/RFO China 30.0%
CCGT Block 2-A
GT-7 100 December 1985 Natural Gas USA 31.7%
GT-8 100 March 1986 Natural Gas 31.7%
ST-5 100 December 1987 N/A
CCGT Block 2-B
GT-9 100 April 1986 Natural Gas USA 31.7%
GT-10 100 April 1986 Natural Gas 31.7%
ST-6 100 March 1988 N/A
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Plant Installed Capacity
(MW)
Year of Commissioning Fuel Country of Origin Thermal Efficiency (Design)
CCGT Block 1
GT-11 136 September 1992 Natural Gas Germany 32.1%
GT-12 136 December 1992 Natural Gas 32.1%
ST-13 143 May 1994 N/A
TPS Muzaffargarh
Unit 1 210 September 1993 Natural Gas/ RFO Russia 36.8%
Unit 2 210 March 1994 Natural Gas/ RFO Russia 36.8%
Unit 3 210 February 1995 Natural Gas/ RFO Russia 36.8%
Unit 4 320 December 1997 Natural Gas/ RFO China 36.7%
Unit 5 200 February 1995 Natural Gas/ RFO China 31.7%
Unit 6 200 August 1995 Natural Gas/ RFO China 31.7%
Source: Power System, Statistics, 34th Edition, 2009.
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3.2 TPS Jamshoro
TPS Jamshoro is one of the major generation installation connected to the National Grid
System in the south of Pakistan. The present installed capacity of TPS Jamshoro is
850 MW consisting of four steam power units. Exhibit 3.3 shows 200 MW Steam
Turbine Unit No. 2 at TPS Jamshoro.
Exhibit 3.3: 200 MW Steam Unit No. 2 at TPS Jamshoro
The staff strength at the power station is 1,550. About 50% of the staff is residing in the
residential colony with their families built adjacent to the power house. The residential
colonies provide all the basic and civil amenities like school, hospital, recreational
centers, playgrounds, mosques, and shopping centers to cater for the needs of the
employees.
Water supply for cooling and drinking is taken from the Indus River through a pipeline
and pumping station network. For drinking purpose, the river water is only clarified
whereas for supply to the power plant it is treated further to produce demineralized water
for boilers.
RFO decanting: TPS Jamshoro has decantation arrangements for both railway tank
wagons and road tankers. However, the power station receives RFO only through tank
lorries from Karachi as delivery through railway was discontinued in 2003. The station
has two arrangements for decanting of RFO from tank lorries and railway wagons; an
open channel and an oil receiving header. The channel is normally used during dry
weather whereas the oil header was initially constructed to decant oil during rainy periods
but it is used round the year due to increasing number of incoming tank lorries. Oil is
lifted by transfer pumps from the channel and header into storage tanks. In recent times,
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RFO Storage: TPS Jamshoro has common RFO storage facilities for all units. It has
4 main storage tanks of 26,500 tonnes each having a total storage of 106,000 tonnes at the
plant. These tanks are interconnected and used as common storage for all units. Exhibit
3.4 shows the oil storage facilities at TPS Jamshoro.
Exhibit 3.4: Oil Storage Tanks at TPS Jamshoro
3.3 TPS Guddu
TPS Guddu has both steam and combined cycle units that operate on medium calorific
value (MCV) gas from Mari, Kandhkot and Chachar. Exhibit 3.5 shows a view of the
turbine hall of 200 MW Steam Unit No. 3 at TPS Guddu.
Exhibit 3.5: 200 MW Steam Unit No. 3 at TPS Guddu
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The plant has a staff of about 1,950 persons living with their families at the residential
colony built adjacent to the powerhouse. Civil amenities like schools, hospitals,
recreational centers, playgrounds, mosques, and shopping centers have been provided at
the cost of the company to cater for the needs of the employees.
Water supply for cooling and for boiler feed water is taken from the Indus River through
a pipeline and pumping station network at the nearby Begari Feeder, Sindh. For drinking
purposes, the water taken from the canal is clarified and supplied through overhead tanks.
Water is treated to produce demineralized water for boiler feed and other usage at the
plant.
TPS Guddu is the major generation installation connected to the national grid system in
Pakistan in the middle of the country. The other important feature of this plant is that it
generates electricity on MCV gas to provide electricity at a comparatively lower cost to
national grid.
Oil Decanting: The power station has decantation arrangement for road tankers. Oil is
decanted into a channel and lifted by transfer pumps into storage tanks.
Oil Storage: TPS Guddu has common storage facilities for the steam units 3 & 4. The
plant has 9 storage tanks with total capacity of 56,400 tonnes of RFO. Exhibit 3.6 shows
the RFO storage facilities at the power stations.
Exhibit 3.6: RFO Storage Capacity at the Power Stations-TPS Guddu
Power Station Unit No. No. of FO Tanks
Capacity of each Tank (Tonnes)
Total Storage Capacity (Tonnes)
TPS Guddu 2 12,000 24,000
4 5,000-5,500 21,000
3 3,800 11,400
Total 9 56,400
3.4 TPS Muzaffargarh
TPS Muzaffargarh is connected to the National Grid System in the mid-country near
major load centers. The present installed capacity of TPS Muzaffargarh is 1,350 MW
consisting of six steam power units. The Exhibit 3.7 shows the 200 MW Steam Turbine
of Unit No. 6 at TPS Muzaffargarh.
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Exhibit 3.7: 200 MW Steam Unit No. 6 at TPS Muzaffargarh
The plant has staff strength of around 1,500 personnel most of which live with their
families in the residential colony built adjacent to the powerhouse. Like other GENCO
plants, the staff residential colony provides the civil amenities like school, hospital,
recreational centers, playgrounds, mosques, and shopping centers.
Water for cooling and drinking purpose is supplied through 35 Tube-wells, which are
installed along the banks of Taliri canal flowing 8Km away in the east.
Muzaffargarh Thermal Power Plant is the major generation installation connected to the
National Grid System in Pakistan in the middle of the country.
Oil Decanting: The power station has decantation arrangements for both railway tank
wagons as well as tank lorries. Similar to TPS Jamshoro, the oil is decanted into a deep
channel and lifted by transfer pumps into storage tanks. The decantation of RFO at
Unit 4 as well as Unit 5 & 6 is carried out through oil receiving headers. Presently, only
the header for Unit 4 is operational. Exhibit 3.8 shows the RFO decanting station with
both railway wagons and tank lorries off-loading oil.
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Exhibit 3.8: Oil Decanting from Railway Wagons and Tank Lorries
at TPS Muzaffargarh
Oil Storage: Each phase of TPS Muzaffargarh has its own dedicated storage facilities
that have now been interconnected and can supply fuel to all the operating units. The
power station has 11 storage tanks with a maximum capacity of around 241,000 tonnes.
Exhibit 3.9 shows the phase-wise installed RFO storage capacity at the power stations.
Exhibit 3.10 shows the Oil Storage Facilities at TPS Muzaffargarh.
Exhibit 3.9: RFO Storage Capacity at the Power Stations-TPS Muzaffargarh
Power Station Unit No. No. of FO Tanks Capacity of each Tank
(Tonnes)
Total Storage Capacity
(Tonnes)
TPS Muzaffargarh
1, 2 & 3 6 20,000 18,500 120,000 to 111,000
4 2 20,000 ~ 18,500 40,000 37,000
5 & 6 3 27,000 ~ 25,000 81,000 75,000
Total 11 241,000-223,000
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Exhibit 3.10: Oil Storage Tanks at TPS Muzaffargarh
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4. Maximum Present Capability
4.1 General Approach and Overall Limitations
The capacity tests were carried out under certain limitations and restrictions specific to
each unit of the power plants. Most of the units could not be operated, even for a shorter
duration of time, under full opening of the turbine steam control valve, as recommended
under ASME PTC-6, to assess their maximum output capability. Based on their
experience, the management had apprehended risk of damage to heater tubes in the
boilers and other risks if the boilers were operated above certain loads. Owing to these
reasons and the prevailing shortage of power generation capacity in the country, it was
agreed with the power station managements that the units will be operated in safe mode
for testing purposes to avoid any disruption in operations. The capacity tests were carried
out for continuous operation of each unit for 3-4 hours at a time with gross and net output
capacity observed and recorded at an interval of one hour. The test was carried out for
three days at a unit. The gross and net capability of the unit was calculated on the basis
of average readings over the testing period. Detailed data on capacity measurements for
each unit of the Jamshoro, Guddu and Muzaffargarh power stations is provided in
Appendix B as Exhibit B.1, B.2 and B.3 respectively.
4.2 TPS Jamshoro
Limitations of Test: The speed governors of Units 2-4 were not functioning on auto
control. The load was therefore adjusted manually to maintain output at a certain level.
In case of Unit 1, the output of the unit was temporarily reduced to 187 MW from 200
MW because of overheating of turbine bearing.
Results: The results of the capacity tests for TPS Jamshoro are presented in Exhibit 4.1.
The capacity tests indicated a maximum degradation of around 40% for Unit 2 from its
design capacity and a minimum degradation of around 23% for Unit 1. The overall
power station capability has dropped by 32% in the present operating conditions.
Exhibit 4.1: Unit-wise Installed Capacity and Present CapabilityTPS Jamshoro
Unit No. Installed Capacity
Present Gross Capability
Auxiliary Load Present Net Capability
Capacity Degradation
MW MW MW MW
Unit 1 250 191 15 176 23%
Unit 2 200 119 6 112 41%
Unit 3 200 125 12 113 38%
Unit 4 200 146 13 133 27%
Total 850 581 46 535 32%
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4.3 TPS Guddu
Limitations of Test: The gas flow meters of steam Unit 1 and Unit 2 and CCP Block 2B
were not functional and therefore tests could not be carried out for these units. Steam
Unit 4 was on extended shut down from December 11, 2010 to March 15, 2011 due to
damaged air preheater and therefore could not be tested in the timeframe of this study.
Gas flow meters for CCP Block 1 and Block 2-A were functional and capacity tests were
therefore carried out at these two units only.
Results: CCP Block 1 has shown 40% degradation in its capacity from the installed
capacity whereas CCP Block 2-A appears to be in better condition with only 17%
capacity degradation, most of which was contributed by the steam turbine Unit 5 which
has lost about 29% of its capacity. Exhibit 4.2 provides the unit-wise installed capacity
and present capability of the units assessed under the testing procedures.
Exhibit 4.2: Unit-wise Installed Capacity and Present Capability of Units Tested
Under the StudyTPS Guddu
Installed Capacity
Present Gross Capability
Auxiliary Load Present Net Capability
Capacity Degradation
MW MW MW MW
CCP Block 1
GT 11 100 93 92 7%
GT 12 100 85 85 15%
ST 13 100 71 1 69 29%
Total Block 1 300 248 2 246 17%
CCP Block 2-A
GT 7 136 80 80 41%
GT 8 136 80 80 41%
ST 5 143 84 3 81 41%
Total Block 2-A 415 244 4 240 41%
Total 715 493 6 487 31%
4.4 TPS Muzaffargarh
Limitations of Test: Unit 1 was on extended shut down from November 2010 to end of
March 2011 due to delay in arrival of experts from the Russian manufacturer of
equipment to supervise the replacement work. Units 2-6 were tested.
Results: Results of capacity tests for Units 2-6 are presented in Exhibit 4.3. Significant
degradation was observed on all units when compared with their respective design
capacities. Unit 2 was in the best operating condition with 20% degradation in capacity
whereas Unit 6 was the worst with 63% degradation in capacity.
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Exhibit 4.3: Unit-wise Installed Capacity and Present Capability of Units Tested
Under the Study TPS Muzaffargarh
Unit No. Installed Capacity
Present Gross Capabilit
Auxiliary Load Present Net Capability
Capacity Degradation
MW MW MW MW
Unit 2 210 168 11 156 20%
Unit 3 210 140 13 127 33%
Unit 4 320 202 21 181 37%
Unit 5 200 97 11 86 51%
Unit 6 200 73 10 64 63%
Total 1,140 680 66 614 40%
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5. Heat Rate Analysis
5.1 Definitions
The following definitions were followed in the analysis of heat rates:
Heat Rate: Heat rate of a plant is the amount of thermal energy required to generate one
unit of electrical energy and is generally expressed as K calories/kWh or Btu/kWh. In
this report, Btu/kWh has been adopted as the standard units for heat rate.
Thermal Efficiency: Thermal efficiency of the power plant also simply referred to as the
efficiency of the plant is the ratio of the output energy to the input energy of the plant. It
is usually calculated as 3,412/ (heat rate of the plant) expressed in Btu units.
Gross and Net Efficiency: Both the heat rate and efficiency could be gross or net
depending on the point of measurement of the output of the plant. The gross efficiency is
the ratio of the total energy generated from the plant to the total energy input whereas the
net efficiency is calculated as the ratio of total energy sent-out from the plant to the total
energy input of the plant. The energy sent-out is calculated by subtracting auxiliary
consumption of the plant and losses of plants cable and step-up transformer from the gross generation of the plant. In certain cases, a discrete sent-out meter is installed at the
plant that can provide a direct measure of the energy sent out from the plant.
5.2 Limitations in Assessment of Heat Rates
A number of limitations were encountered in carrying out the heat rate tests and
efficiency in nearly all the cases. These are summarized in the following sections.
5.2.1 Testing Schedule
The GENCO power stations do not have functional flow meters to measure the fuel oil
supplied to each unit in continuous manner over a specified period. Oil measurements
were taken by using dip-tapes from the service tank or main storage tank depending on
the specific arrangement for each unit. Service tanks are smaller in size and provide
storage of 3-4 hours of units consumption and need to be refilled every 4 hours. The refilling process takes about 1-2 hours. The testing team was working in single shift and
therefore could only record observations during daytime working hours. Owing to these
reasons, heat rate tests were carried out for continuous operation of each unit for 2-3
hours at a time with input and output energy observed and recorded. The test was carried
out once in the morning and once in the afternoon and continued for three days to capture
variations in the heat rates under different operating conditions of the unit. The present
gross and net heat rates and resulting efficiency of the plant were calculated on the basis
of average of the observed readings over the testing period.
5.2.2 Measurement of Fuel Flow
The steam units at the power stations studied have the provision of dual fuel combustion
on natural gas and RFO with the exception of Unit 1 at TPS Jamshoro that can only
operate on RFO and the Units 1-2 and combined cycle units at TPS Guddu that operate
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on medium calorific value (MCV) gas. However, as gas was not being supplied to the
plants during the study period, the heat rates of all the dual fuel steam units were tested
on RFO.
It was observed that the GENCOs have not followed a standard fuel supply arrangement.
No credible measurement system was in place for the RFO received from supplier at the
power plants. Similarly, no credible measurements were being taken for the RFO fed to
each unit from plants main storage. Most of the measurement instruments were either not calibrated, non-functional, or simply missing. At TPS Muzaffargarh and TPS Guddu,
many units have common fuel supply pipelines without adequate measurement
instruments at each unit. Similarly, a number of units do not have RFO service tanks to
monitor their fuel flow. The same is the case at Guddu where gas flow meters are mostly
missing and gas is supplied through common pipelines to the steam and CCGT units. It
was therefore quite a challenge to discretely measure the fuel input at most of the units.
RFO consumption was calculated by using dip-tape, calibration charts of the feeding
tanks (the specific day storage or service tank or the main storage tank, where a day tank
is not present), and specific gravity of RFO at observed temperatures. The input valves
of the respective feeding tanks of the concerned units were closed before the beginning of
the tests and sealed with locks to stop inflow of RFO and recirculation of RFO and
condensate. Electrical outputs at gross and sent-out meters, and auxiliary consumption
were recorded at the respective meter locations. All the readings at a specific time were
taken concurrently and coordination was managed through use of devices such as mobile
phones and RF radio equipment. Special teams, comprising of instrumentation experts,
were formed to concurrently read the measurement instruments to carry out tests at each
unit.
At TPS Guddu, the residential colony is also supplied gas from the header meant for
steam Units 1 and 2 with no gas measurement for the residential colony. The residential
gas consumers have individual gas meters at their premises but due to severe leakages in
the gas distribution network, the consumers are charged a flat rate with respect to size of
their houses.
5.2.3 Metering of Electrical Output
The same applied to the output side of the plants as no uniform standards are followed for
measurement of energy output. Auxiliary supply is not discrete for certain units resulting
in inappropriate accounting of auxiliary consumption. In many instances, auxiliary
consumption is not even fully measured. The units at TPS Muzaffargarh do not have
discrete sent-out meters at each unit to record net output. In case of TPS Jamshoro, the
measurement scale of the sent-out meter was in GWh at the NTDC grid station, giving
little resolution to measure the difference in kWh. The cable and step-up losses could not
be calculated at any instance due to absence of appropriate metering protocol and
therefore were not included in the calculation of net heat rate and efficiency. It was
therefore recommended to use the gross heat rates and efficiency as the baseline or
benchmark for the purpose of this study instead of net heat rate and efficiency.
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5.2.4 Application of Heat Rate Assessment
The heat rates and efficiency parameters for the power stations have been calculated only
for the purpose of baseline evaluation or a benchmark for determining efficiency gains
and operational improvements to be achieved after the implementation of the USAID
FARA Repair and Maintenance Plan currently under implementation at these GENCOs.
It should be noted that heat rates in this study were determined under steady loading and
specific ambient and operating conditions of the units during the winter season. Average
heat rates for the power stations are likely to be higher due to variations in ambient
conditions and loading levels, inclusive of startups and shutdowns.
5.3 TPS Jamshoro
5.3.1 Testing Procedures and Data Analysis
TPS Jamshoro has four dual fuel steam units that were operating on RFO only during the
testing period. Heat rate tests were carried out for all the units of the power station. The
specific procedure for calculation of heat rates for TPS Jamshoro is illustrated in
Appendix C. The unit-wise detailed data compiled on heat rate measurements for TPS
Jamshoro is presented in Appendix D as Exhibit D.1.
5.3.2 Results
The gross and net heat rate and efficiency for the generation units at TPS Jamshoro are
presented in Exhibit 5.1. Unit 1 is most efficient with 32% net efficiency against the
design efficiency of 36.6%. The net efficiencies of Units 2-4 ranged between 25.7% to
28.6% against the design efficiency of 34%, corresponding to an overall drop in the
efficiency of the power station of about 20% compared to the design.
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Exhibit 5.1: Unit-wise Gross and Net Heat Rate and EfficiencyTPS Jamshoro
Unit No.
Gross Energy
Generation
(kWh)
Fuel
Consumption
(Mmbtu)
Gross Heat
Rate
(Btu/kWh)
Gross
Efficiency*
Auxiliary
Consumption
(kWh)
Net Sent-out
Energy
(kWh)
Net Heat Rate
(Btu/kWh) Net Efficiency
(%)
Unit 1 2,786,946 27,392 9,829 34.7% 231,862 2,555,084 10,720 31.8%
Unit 2 1,361,912 15,971 11,727 29.1% 83,370 1,278,542 12,492 27.3%
Unit 3 1,242,596 14,761 11,879 28.7% 129,597 1,112,999 13,262 25.7%
Unit 4 1,422,838 15,521 10,909 31.3% 122,336 1,300,502 11,935 28.6%
* Gross heat rates and efficiency is recommended to be used for benchmarking purpose.
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5.4 TPS Guddu
TPS Guddu has two main set of power generation units, a steam block and a Combined
Cycle Power Station (CCP) block. In the steam block complex, the plant has four (4)
steam units out of which Units 1 and 2 can operate only on natural gas. Units 3 and 4 are
dual fuel on natural gas and RFO. In the CCP block, the plant has three combined cycle
sub-blocks of (2 GT+1 ST) gas fired CCGT. The plant receives MCV gas from Mari,
Kandhkot and Chachar.
Measurement of Fuel Supply
TPS Guddu has major shortcomings with respect to fuel measurement both on supply
side as well as for the consumption in the power plant. No gas sales meters are installed
by the gas suppliers at the premises of the plant and gas is billed from the meters installed
at the supplier end of the pipelines. Gas from various supply sources is mixed at a gas
mixing station on the plants premises. The mixing station has separate headers for steam and CCP blocks from where it is branched through separate pipelines to each unit. The
gas is supplied at a pressure for of 11 bar to steam units and at 23 bar to CCP. No
measurements are taken for the outflow of gas from mixing headers. Units 3 and 4 have
functional gas flow meters whereas Units 1 and 2 are operating without the gas flow
meters. Units 1 and 2, therefore, have no gas inflow measurements to establish the input
energy for the purpose of calculation of heat rate and efficiency. The heat rate and
capacity testing of Units 1 and 2 was postponed until installation of appropriate gas
metering system on supply of gas to each unit.
Fuel oil is also supplied to Units 3 and 4 through a common line with no service tanks but
the two units have separate RFO flow meters to measure their respective RFO
consumption. The testing of Unit 4 could not be carried out due long shut down caused
by damage of air pre-heater. Testing was limited to Unit 3 for these reasons.
The pipelines supplying gas to CCP block also do not have a gas meter at the gas mixing
header. Out of three CCP sub-blocks, the Block 2-B does not have functional gas flow
meters to measure gas consumed in the gas turbines (Unit 9 and 10). Gas consumption of
Block 2 B could therefore not be ascertained for calculation of the heat rate and
efficiency of this block.
Attempts were made to establish fuel input of the steam Units 1 and 2 and that of CCGT
Block 2-B by using secondary data from the plant operations. Due to absence of credible
data, gas consumption of these units could not be segregated. It was therefore decided to
postpone the heat rate and capacity testing of these units until installation of appropriate
gas metering system.
Measurement of Energy Output
On the output side, all units at TPS Guddu have their individual gross energy generation
meters. However, the steam units do not have adequate metering on their auxiliary
supply as well as that of sent-out energy. Unit wise auxiliary load for steam units was
calculated on the basis of connected auxiliary load at a fixed rate of 8% of gross
generation. The sent-out energy was calculated by subtracting the estimated auxiliary
consumption from gross generation. All the CCP blocks have appropriate meters for
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gross generation, auxiliary consumption and energy sent-out. Therefore, it is again
recommended to use gross heat rates and efficiency for the benchmarking of steam units.
5.4.1 Testing Procedures and Data Analysis
Specific procedures were developed to carry out energy measurements for steam and
CCP blocks of the power station which have been illustrated in Appendix C. The unit-
wise detailed data compiled on heat rate measurements for TPS Guddu is presented in
Appendix D as Exhibit D.2.
5.4.2 Results
The summary of results of heat rate tests for TPS Guddu is presented in Exhibit 5.2. The
heat rate test of the Guddu Steam Unit 3 showed inaccurate results in terms of its
efficiency higher than the design efficiency of the unit. It appears the measurement of the
existing gas flow meter is not reliable and it was showing lower consumption of gas than
the actual. The heat rate test of Unit 3 therefore was rejected.
The gas turbines (GTs 7 and 8) in Block 2-A showed the net efficiencies of 27.8% each
against the design efficiency of 31.7%. The GT 11 and GT 12 in Block 1 showed the net
efficiencies of 26.5% and 25.3% respectively against the design efficiency of 32.1%.
The net efficiency of the Block a-A and Block 1 were calculated to be 35.3% and 41.5%.
The design efficiencies of these clocks under combined cycle operations were not
provided by the management.
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Exhibit 5.2: Unit-wise Gross and Net Heat Rate and EfficiencyTPS Guddu
Gross Energy Generation
(kWh)
Fuel Consumption
(MMBtu)
Gross Heat Rate*
(Btu/kWh)
Gross Efficiency*
(%)
Auxiliary Consumption
(kWh)
Net Sent-out Energy (kWh)
Net Heat Rate (Btu/kWh)
Net Efficiency (%)
CCP Block 1
GT 11 7,192,000 92,347 12,840 26.6% 31,360 7,160,640 12,896 26.5%
GT 12 6,633,000 88,962 13,412 25.4% 26,880 6,606,120 13,467 25.3%
ST 13 5,116,000 110,000 5,006,000 0.0%
Total Block 1 18,941,000 181,309 9,572 35.6% 168,240 18,772,760 9,658 35.3%
CCP Block 2-A
GT 7 6,346,000 77,396 12,196 28.0% 33,685 6,312,315 12,261 27.8%
GT 8 6,320,000 77,331 12,236 27.9% 18,701 6,301,299 12,272 27.8%
ST 5 6,482,000 267,000 6,215,000 0.0%
Total Block 2-A 19,148,000 154,727 8,081 42.2% 319,386 18,828,614 8,218 41.5%
* Gross heat rates and efficiency is recommended to be used for benchmarking purpose.
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5.5 TPS Muzaffargarh
TPS Muzaffargarh has six steam units installed in two phases. Phase 1 consists of
Units 1-3, and Phase 2 units 5-6. Unit 4 at TPS Muzaffargarh is managed separately by a
Resident Engineer. Unit 1 of phase 1 was on extended shut down during the testing
period so heat rate tests could not be carried out. TPS Muzaffargarh does not have
individual net output meters at each unit as each unit directly feeds to common busbars at
the switchyards. Unit wise net output, therefore, was calculated by subtracting auxiliary
consumption from gross generation. The detailed procedure for calculation of heat rate
for each unit is given here under.
The specific procedures for calculation of heat rates for TPS Muzaffargarh at each phase
of the power station are illustrated in Appendix C. The unit-wise detailed data compiled
on heat rate measurements for TPS Muzaffargarh is presented in Appendix D as
Exhibit D.3.
5.5.1 Results
The unit wise gross and net heat rate and efficiency of TPS Muzaffargarh are presented in
Exhibit 5.3. Units 2 and 3 are in better condition with 31% net efficiency compared with
their design efficiency of 36.8%. Unit 4 has a net efficiency of 30% against 36.7%
design efficiency. Units 5 and 6 have efficiencies of 26% and 24% respectively against
the design efficiency of 31.7% for both units. The power station is facing an overall
degradation of around 18% in its net efficiency.
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Exhibit 5.3: Unit-wise Gross and Net Heat Rate and Efficiency TPS Muzaffargarh
Unit No.
Gross Energy Generation
(kWh)
Fuel Consumption
(MMBtu)
Gross Heat Rate*
(Btu/kWh) Gross Efficiency*
(%)
Auxiliary Consumption
(kWh)
Net Sent-out Energy (kWh)
Net Heat Rate (Btu/kWh)
Net Efficiency (%)
Unit 1
Unit 2 3,665,000 36,870 10,060 33.9% 246,074 3,418,926 10,784 31.6%
Unit 3 3,083,000 30,655 9,943 34.3% 237,521 2,845,479 1