JAMSHORO POWER COMPANY LIMITED
DETAILED ACCOUNT OF POWER PLANTS
Presentation
By
Muhammad Akram
Chief Executive Officer
12th November, 2010
JAMSHORO POWER CO. LTD.JAMSHORO POWER CO. LTD.
850 MW THERMAL POWER STATION JAMSHORO850 MW THERMAL POWER STATION JAMSHORO
JAMSHORO POWER CO. LTD (GENCO-I)
1. Installed Capacity TPS Jamshoro 850 MW
GTPS Kotri 174 MW
Total 1024 MW
2. Registered Office WAPDA House Lahore
3. Date of Registration 03.08.1998
4. Date of Commencement of Business
01.03.1999
5. Grant of generation License 1.07.2002
6. Authorized Capital Rs: 50,000 M
7. Application for Determination of Tariff date
27.03.2003 / 19.06.2006
8. Determination of Tariff by NEPRA.
31.03.2004 / 02.07.2007
BRIEF INTRODUCTION
Unit No:
Installed Capacity
(MW)Fuel
Commissioning Date
Project Cost
(Mil. Rs.)Contractor Manufacturer
M/s. Fuji Elect. & Co, Japan
M/s. Mitsui/ Riley Japan
ST - 2 200Dual
(Gas/FO)03.12.1989
ST - 3 200Dual
(Gas/FO)17.06.1990
ST - 4 200Dual
(Gas/FO)21.01.1991
Total: 850 15631
PROJECT DIGEST (COMPLEX-I)
6762M/s. Mitsui
& Co. JapanST - 1 250
Furnace Oil (F.O)
27.01.1990
T.P.S. Jamshoro
8869M/s. CMEC
China
M/s. Harbin Turbine, Boiler
& Electrical Machinery Co., Harbin China
Unit No:
Installed Capacity
(MW)Fuel
Commissioning Date
Project Cost
(Rs.M)Contractor Manufacturer
GT - 1 15Dual
(Gas/HSD)Dec. 1969
GT - 2 15Dual
(Gas/HSD)Jan. 1970
GT - 3 25Dual
(Gas/HSD)May. 1979
GT - 4 25Dual
(Gas/HSD)May. 1979
GT - 5 25Dual
(Gas/HSD)April. 1981
GT - 6 25Dual
(Gas/HSD)May. 1981
CCP-7 44
Through Heat
recovery boilers on
GT 3-6
Oct. 1994 1792.479M/s. HPEEC
China
M/s. HPEEC China
M/s. Chockerill Mech.
Industries, Belgium
Total: 174 2244.28
G.T.P.S KOTRI
PROJECT DIGEST (COMPLEX-II)
M/s. Thomassan BV Holland
184.018M/s. Thomassan BV Holland
CEM/BBC64.9M/s. CIE Electro Mech. (CEM) France
M/s. Hitachi Japan
202.878M/s. Marubeni
Japan
Unit # Type
Size (Capacity)
Fuel UsedCommissioning
DateAge
(Years)Installed (MW)
Dependable (MW)(IDC NET)
1 S/T 250 205 F. Oil Jan 1990 20
2 S/T 200 156 Gas / F. Oil Dec 1989 21
3 S/T 200 157 Gas / F. Oil Jun 1990 20
4 S/T 200 157 Gas / F. Oil Jan 1991 19
TOTAL - 850 675 - - -
GTPS KOTRI
Unit # TypeInstalled
(MW)Dependable (MW) Fuel Used
Commissioning Date
Age (Years)
1 G/T 15 8.5 Gas / HSD Dec 1969 41
2 G/T 15 8.5 Gas / HSD Jan 1970 40
3 G/T 25 18 Gas / HSD May 1979 31
4 G/T 25 18 Gas / HSD May 1979 31
5 G/T 25 18 Gas / HSD Apr 1981 29
6 G/T 25 18 Gas / HSD May 1981 29
7Steam
Unit (C.C.P)44 34.5
G/T Exhaust
/Flue GasesOct 1994 16
TOTAL - 174 123.5 - - -
GENCO-I TECHNICAL DATATPS JAMSHORO
POWER PLANT
INSTALLEDCAPACITY
(MW)
TESTED I.D.C
(NET)
(MW)
MAX: LOAD (MW)
GROSS
GEN:
(Gwh) GROSS
AVAIL: FACTOR
(%Age)
PLANT UTILIZ:
FACTOR (% Age)
LOAD FACTOR (% Age)
THERMAL EFFICIENCY
(% Age)
Design (% )
Actual
(% )
ST-1 BLOCK-I
250 205 200 955 73 50 50 36.63 32.92
ST-2 BLOCK-II
200 156 180 1118 88 75 71 33.89 29.39
ST-3 BLOCK-II
200 157 180 1026 85 69 65 33.89 28.71
ST-4 BLOCK-II
200 157 175 1182 91 79 77 33.89 29.70
GT-3 BLOCK-III
25 18 22 135 84 62 70 27.85 21.51
GT-4 BLOCK-III
25 18 23 111 81 51 55 27.85 21.50
GT-5 BLOCK-III
25 18 23 140 99 64 70 27.75 21.47
GT-6 BLOCK-III
25 18 19 84 96 38 51 27.75 21.40
CCP-7 BLOCK-III
44 34.5 38 185 90 53 56 - -
GT-1 BLOCK-IV
15 8.5 10 14 99 11 16 24.50 15.36
GT-2 BLOCK-IV
15 8.5 9 13 99 10 16 24.50 15.37
Overall GENCO-I
1,024 798.5 879 4,963 90 65 68 - -
JAMSHORO POWER COMPANY LIMITEDCRITICAL / SIGNIFICANT PERFORMANCE INDICATORS
July-2009 to June-2010
POWER PLANT
INSTALLED CAPACITY
(MW)
TESTED I.D.C
MAX: LOAD (MW)
GEN:
(Gwh)
AVAIL: FACTOR
(%Age)
PLANT UTILIZ:
FACTOR (% Age)
LOAD FACTOR (% Age)
THERMAL EFFICIENCY
(% Age)
Design (% )
Actual
(% )
BLOCK-I JAMSHORO
250 205 200 955 73 50 55 36.63 32.92
BLOCK-II JAMSHORO
600 470 535 3326 87 71 71 33.89 29.82
BLOCK-III KOTRI
144 106.5 125 655 92 67 67 27.80 29.91*
BLOCK-IV KOTRI
30 17 19 27 100 30 31 24.50 15.36
1,024 798.5
JAMSHORO POWER COMPANY LIMITEDCRITICAL / SIGNIFICANT INDICATORS
July-2009 to June-2010
* Overall Efficiency of Block-III with CCP
FUEL SUPPLY SYSTEM
FUELS TPS JAMSHORO GTPS KOTRIFuel Oils R.F.O H.S.D
SourceOn fortnight basis from
PSO-
Mode of Supply Tank Lorries -
Oil Decanting Capacity 5000 M.T / Day
-
Oil Storage Capacity 100,000 M.T 6, 600 M.T
Average Stock 30,000 M.T NIL
GAS SUPPLY SYSTEM
Source M/s SSGC Ltd Hyd M/s SSGC Ltd Hyd
Mode of Supply Through 16” Pipeline Through 12” Pipeline
Gas Allocation62 MMCFD
(53 MMCFD Guaranteed))
15-20 MMCFD
(10 MMCFD Guaranteed))
Average Gross Calorific Value (Btu/Cft)
925-1030 925-1030
THERMAL POWER STATION JAMSHOROMAXIMUM LOAD SHARED (MW)
775 760 730 730700
0100200300400500600700800900
2005-06 2006-07 2007-08 2008-09 2009-10
MW
GAS TURBINE POWER STATION KOTRIMAXIMUM LOAD SHARED (MW)
149146
141 144 136
0
30
60
90
120
150
180
2005-06 2006-07 2007-08 2008-09 2009-10
MW
THERMAL POWER STATION JAMSHOROAVAILABILITY & UTILIZATION FACTORS
77
65
75
64
7461
68
47
81
62
0102030405060708090
100
2005-06 2006-07 2007-08 2008-09 2009-10
Availability (%) Utilization (%)
GAS TURBINE POWER STATION KOTRIAVAILABILITY & UTILIZATION FACTORS
92
59
88
63
95
64
94
64
94
54
0
20
40
60
80
100
120
2005-06 2006-07 2007-08 2008-09 2009-10
Availability (%) Utilization (%)
THERMAL POWER STATION JAMSHOROENERGY GENERATED (MKWH)
FUEL MIX
1628
2718
4346
1723
2505
4228
1446
2453
3899
1342
1709
3051
2493
1788
4281
0500
100015002000250030003500400045005000
2005-06 2006-07 2007-08 2008-09 2009-10
F.O GAS TOTAL
THERMAL POWER STATION JAMSHOROFuel Cost (Paisa/KWH)
499
256
347494
304
381
1446
2883899
884
417
623
1117
422
827
0
150
300
450
600
750
900
1050
1200
2005-06 2006-07 2007-08 2008-09 2009-10
F.O GAS TOTAL
THERMAL POWER STATION JAMSHOROOverall Cost (Paisa/KWH)
385 416486
685
865
50
150
250
350
450
550
650
750
850
950
2005-06 2006-07 2007-08 2008-09 2009-10
Overall Cost
GAS TURBINE POWER STATION KOTRIENERGY GENERATED (MKWH)
741 791 810 785
683
50
150
250
350
450
550
650
750
850
950
2005-06 2006-07 2007-08 2008-09 2009-10
GAS
GAS TURBINE POWER STATION KOTRI Fuel Cost (Paisa/KWH)
245296 288
411 433
50100150200
250300350400450500550
2005-06 2006-07 2007-08 2008-09 2009-10
GAS
GAS TURBINE POWER STATION KOTRIOverall Cost (Paisa/Kwh)
295347 336
461 496
50100150200250300350400450500550600
2005-06 2006-07 2007-08 2008-09 2009-10
Overall Cost
Future Plan for the Repair and Rehabilitation of Jamshoro Power Plant
For the rehabilitation of Units 1,2,3&4 of Jamshoro, a Fixed Amount Re-imbursement Agreement (FARA) has been signed on 20.05.2010. Under this agreement, the USAID will provide US$ 18.36 million for the repair & rehabilitation.
The following table summarizes the proposed rehabilitation works and the associated costs.
Sr. No.
Unit No.
Details of Works/Spares Estimated Cost (US$)
Planned Completion
date
1- 1 Rehabilitation of air Pre-heater Side-B Rotor
500,000 30.11.2011
2- 1 Replacement of Final Super Heater Coils
1,000,000 -do-
3- 1 Complete replacement of Flue Gas Duct & Air Pre-heater Bottom hoppers
600,000 -do-
4- 1 Complete Rehabilitation of Cooling Towers
500,000 -do-
Sr. No.
Unit No.
Details of Works/Spares Estimated Cost (US$)
Planned Completion
date
5- 1 P-Gradation/Replacement of Auto Burner Control System & Data Acquisition System
300,000 30.11.2011
6- 1 F.D. Fan duct up to Steam Coil Air Heater
200,000 -do-
7- 1 Major Overhauling 1,650,000 -do-
8- 1 Soot Blower Spare Parts 100,000 -do-
9- 1 Tube Bundles of Steam Converter 250,000 -do-
10- 1 Spares for Oil & HSD Burners & Igniters
200,000 -do-
11- 1 Air Pre-heater Elements & Seal 670,000 -do-
12- 1,2,3&4
Use of fuel oil additives to prevent soot buildup and cooling water treatment chemicals to prevent scale buildup
1,000,000 -do-
Sr. No.
Unit No.
Details of Works/Spares Estimated Cost (US$)
Planned Completion
date
13- 2,3&4 Replacement of HP Heaters along with the valve and controllers including Rehabilitation of Instrument Control & Protection System
3,450,000 30.11.2011
14- 2,3&4 Complete Rehabilitation of Cooling Towers
750,000 -do-
15- 2,3&4 Modification/Rehabilitation of Electro Hydraulic and Mechanical Hydraulic Governing System
900,000 -do-
16- 2,3&4 Complete Rehabilitation of Drain Valves
300,000 -do-
17- 2,3&4 Rehabilitation of soot blowing system
600,000 -do-
18- 2,3&4 Replacement of Coagulator Agitators
1,200.000 -do-
Sr. No.
Unit No.
Details of Works/Spares Estimated Cost (US$)
Planned Completion
date
19- 2,3&4 Replacement of Data Acquisition System (DAS-100), Auto Regulation System (MZ-III) & Temperature Scanners for Generator Winding Temperature, Super Heater/Re-Heater Temp:, Boiler Drum Metal Temp: FD, ID Fan Motor Temp: Boiler Feed Pump Temp: with latest Distributed Control System (DCS)
900,000 30.11.2011
20- 2,3&4 Replacement of Existing FSSS along with Furnace Flame Monitoring
390,000 -do-
21- 2 Procurement of Boiler Feed Pump Motor Complete
100,000 -do-
22- 3 Replacement of Final Super Heater Coils
1,000,000 -do-
23- 3 Three Way valve of Oil Burner 200,000 -do-
24- 3 Spares for Overhauling of Turbine 500,000 -do-
Sr. No.
Unit No.
Details of Works/Spares Estimated Cost (US$)
Planned Completion
date
25- 2 & 4 Replacement of Turbine Vibration System with ViBro-Control-4000 Schenk
200,000 30.11.2011
26- 4 ID Fan Impellers 500,000 -do-
27- 1,2,3 & 4
Off-line Efficiency Monitoring System & Training
400,000 -do-
Total Cost (US$) 18,360,000
Targeted load after Rehabilitation
The targeted rehabilitation of the four Units will re-capture 95MW of the de-rated capacity. The MW recovered after targeted rehabilitation as under:-
Unit # Installed Capacity
(MW)
Declared De-rated
Capacity (MW) Gross
Present Operational
Capacity (MW) Gross
Gain After Rehabilitation
(MW)
Capacity after Rehabilitation
(MW)
1 250 225 190 35 225
2 200 170 170 20 190
3 200 170 170 20 190
4 200 170 170 20 190
Total 850 735 700 95 795
Critical Issue
Serious Problem due to saline River Water of high conductivity (1,200µs/cm against designed 500µs/cm).
This has badly affected the operation of the Power Plant and caused high consumption of Chemicals, resulting increase in per unit cost
SolutionInstallation of Reverse Osmosis Plant
Thank you
29
ORGANIZATION STRUCTURE
Internal Audit
Company Secretary
Board of Directors
Chief Executive Officer
Finance Director
M.I.S. Director
HR &Admn. Director
Technical Director
Jamshoro Plant
Kotri Plant
BOARD OF DIRECTORS
Private SectorPrivate Sector PEPCOPEPCO WAPDA/JPCLWAPDA/JPCL
Prof. Dr. Khawaja Amjad Saeed, Chairman
Mr. Salman Iqbal
Executive Director (L&CA)
Syed Wajid Ali Shah
Chief Engineer, GSO, Lahore
Mr. Ashfaq Ahmed Waraich,
GM,Wazir Ali Industry Hyd
Mr. Muhammad Mumtaz
Chief Engineer (WPPO)
Mr. Mohammad Akram, Chief Executive Officer, GENCO-I
Mr. Yousuf Suleman
Ex-President Hyderabad Chamber of Commerce & Industries, Hyderabad
Total Land of JPCL = 800 Acres
JAMSHORO POWER COMPANY LIMITEDEnergy Generation
Since Commissioning up to June 2010T.P.S Jamshoro
Unit No Date of Commissioning Operation Hours Energy Generated (MKWH)
ST-1 27.01.1990 123074 20092
ST-2 03.12.1989 116366 17081
ST-3 27.06.1990 110537 16311
ST-4 21.01.2991 108584 15918
458561 69402
G.T.P.S Kotri
Unit No Date of Commissioning Operation Hours Energy Generated (MKWH)
GT-1 Dec-69 104730 896
GT-2 Jan-70 125540 1021
GT-3 May-79 164438 2923
GT-4 May-79 186340 3305
GT-5 Apr-81 160377 2878
GT-6 May-81 163089 2864
CCP-7 Oct-94 117441 2910
1021955 16797
A- Present De-rated Load
This Power Plant comprises four conventional Steam Power Units with a total capacity of 850MW. The Units have been de-rated to a capacity of 675 MW. The Unit wise configuration of this Power Station along with the de-rated capacity is enumerated as under:-
Unit # Installed Capacity
(MW)
Declared De-rated Capacity
(MW)
Make Year of Commissioning
01- 250 205 Fuji Japan 1990
02- 200 156 CMEC China 1989
03- 200 157 CMEC China 1990
04- 200 157 CMEC China 1991
Total 850 675
C- Reasons of De-ratingi) Unit-1
a) Aging Factor
b) Damaged APH Elements
c) Damaged Steam Coil Air Heaters
d) Condenser Choking
e) Frequent leakages in Final Super Heaters
f) Frequent leakages in Re-heaters
g) Low Efficiency of Cooling Towers
h) Leakages from Air Pre-Heaters
i) Damaged flue Gases duct
ii) Unit-2,3&4
a) Aging Factor
b) Outage of HP Heater
c) Frequent choking of APH Elements
d) Condenser Choking
e) Low Efficiency of Cooling Towers
KEY PERFORMANCE INDICATORS
1. Plant Availability Factor (%)
2. Plant Utilization Factor (%)
3. Plant Load Factor (%)
4. Plant Heat Rate (Btu/kWh)
5. Thermal Efficiency (%)
Rehabilitation of Jamshoro Power Plants
Recovering the lost output of existing power plant is the dire need of PEPCO’s system to bridge the gap to some extent between demand and supply and reduce the generation cost per Kwh. It has therefore been planned to regain the lost capacity of Jamshoro Power Plant by rehabilitation. Keeping in view the present power crises in the country, US Government plans to assist the GoP and resolving the power crises through Repair & Maintenance measures to improve the operating capacity of the Jamshoro Power Plant.
Rehabilitation of old Units means to refurbish or upgrade the components in order to recapture the lost capacity and bring the performance near to the designed capacity. Despite proper operation & maintenance, aging is a major factor causing higher generation cost due to excessive forced outages period resulting less availability, loss of output and increase in heat rate. Rehabilitation of old steam power units is not only a financially viable option but also shorter in implementation period as compared to installing a new power unit.