gencos rehabilitation 27.03.2013

GENCO HOLDING COMPANY

March 29, 2013

Key Areas

A. Summary

B. GENCO-1: Jamshoro Thermal Power Plant

C. GENCO-2: Guddu Thermal Power Plant

D. GENCO-3: Muzaffargarh Thermal Power Plant

Key Agenda

2Generation Holding Company

Generation Holding Company 3

GHC Summary

INSTALLED CAPACITY

1. GENCO-1 Jamshoro1. TPS Jamshoro 850 MW2. GTPS Kotri 174 MW

2. GENCO-2 Guddu1. TPS Guddu 1,655 MW

3. GENCO-3 Muzaffargarh1. TPS Muzaffargarh 1,350 MW2. NGPS Piran Ghaib 195 MW3. GTPS Faisalabad 244 MW4. SPS Faisalabad 132 MW

4. GENCO-4 Lakhra1. Lakhra FBC Power Plant 150 MW

Total GENCOs Installed Capacity 4,750 MW


Rehabilitation Program

Major Power Plant in Operations1. Jamshoro Power Plant (GENCO-1)2. Guddu Power Plant (GENCO-2)3. Muzaffargarh Power Plant (GENCO-3)


POWER STATION

OPERATING CAPACITYMW

CAPACITY BEFOREREHABILITATION

AFTERREHABILITATION

CAPACITY GAIN

TPS Jamshoro - JPCL 225 710 485

TPS Guddu - CPGCL 980 1475 495

TPS Muzaffargarh - NPGCL 650 1175 525

TOTAL 1855 3360 1505

GHC Summary Rehabilitation – December 2013

USAID ASSISTANCE PROGRAM Under the Empower Pakistan-Energy policy program, USAID

extended its cooperation to recapture the lost capacity of powerunits and optimize their performance through rehabilitation andmaintenance of core power plants of GENCOs.

The performance of units of Thermal Power Station Jamshoro, UnitNo 5,7&8 of TPS Guddu and units of Thermal Power StationMuzaffargarh was assessed by the USAID Team of experts and again of 315 MW was estimated through an assistance of 51.621Million US$ which was later increased to 54.231 Million US$(19.329, 19.124&15.778 MUS$ for GENCO I, II & III respectively)through a Project Implementation Letter (PIL) signed between theGENCOS & USAID in April 2012.

To execute this activity, Fixed Amount Reimbursement Agreement(FARA) was signed among the generation companies and the USAIDin May 2010.


USAID ASSESSED BENEFITS

Expected BenefitsTPS Jamshoro

Unit 1-4

TPS Guddu

Unit 5,7&8

TPS

Muzaffargarh

Unit 1-6

Heat rate (%) 4 3.59 2

Additional energy

Mkwh/year530 237-272 930

Fuel savings Million

US$/year11.4 3 17

Availability (%) 4-5 3-4 3-4

Expected Gain MW 95 55 165

Finances Million US$ 19.329 19.124 15.778

SUMMARY LATEST STATUS FARA / PIL (USAID) OF GENCOSAS ON MARCH 18, 2013

COMPANY

(GENCO)

Amount allocated

under USAID (PIL)

Million US$

Reimbursed to

GENCOS Million US$

Claim submitted for

Reimbursement to

USAID Million US$

Balance Amount

allocated under

USAID (PIL) Million

US$

JPCL (GENCO-I) 19.32914.893

(77.04%)

1.070

(5.54%)

3.366

(17.41%)

CPGCL (GENCO-II) 19.12415.513

(81.12%)-

3.611

(18.88%)

NPGCL (GENCO-III) 15.7789.795

(62.08%)

2.573

(16.31%)

3.410

(21.61%)

TOTAL 54.231 40.201 3.643 10.387


JAMSHORO POWER COMPANY LIMITED (GENCO-I)PRESENT STATUS

Procurement process for the purchase of spare parts as perFARA/PIL has been started and 14.893 MUS$ (77.04%) of totalamount has been reimbursed & claims for 1.070 MUS$ (5.54%) ofthe total amount have been lodged with USAID for reimbursement.

Under rehabilitation of boiler equipment, replacement of Air Pre-Heater Elements, final super heater tube elements, all burner gunsand some of the sootblowers of Unit No. 1 has been done so farand the remaining work will be done after the receipt of material atsite. The capacity has been increased from 125 MW to 200 MW atthis Unit.

HP Heaters & Economizer tubes at Unit No.2,3&4 have beenreplaced and the work has been completed successfully. Thecapacity has been increased from 100 to 510 MW at these units(Unit 2, 3&4).

Completion date of the project is March 31,2014.


CENTRALPOWER GENERATION COMPANY LIMITED (GENCO-II)PRESENT STATUS

• Purchase & Service Orders on April 10 & April 20, 2012have been placed on to General Electric (GEII - OEM) forthe rehabilitation/up-rating work respectively.

• After opening of L/C (October 30, 2012), USAID waspersuaded and the funds have been delivered to SBP nostroaccount amounting Million USD 15.513 (81.12%).

• M/s GE is ready to ship the parts (spares) ofuprate/upgrade of ST-5, Gt-07 and GT-08.

• The schedule of the shutdown of units will be afterreaching the last consignment at site (Guddu), tentativew.e.f. April, 2013.

• Expected completion date of the project is August, 2013.


NORTHERN POWER GENERATION COMPANY LIMITED (GENCO-III)PRESENT STATUS

So far 9.795 Million US$ (62.08%) of the allocatedfunds have been reimbursed & claims for 2.573 MUS$(16.31%) of the total amount have been lodged withUSAID for reimbursement.

Rehabilitation of Unit No.1, 2&3 of TPS Muzaffargarhhas been completed and attained a gain of 220 MWagainst the assessed capacity of 70 MW which is dueto further deration of units.

Replacement of Economizer tubes & Air PreheaterElements of Unit No. 6 is in progress after that thesame will be replaced at Unit No.5.

Completion date of the project is June 30, 2013.




Jamshoro Power Plant (GENCO-1)


GENERATIONGENCO – 1 Jamshoro Power Plant (1/3)

Unit Make DOC FuelInstalled capacity

Current capacity

DesignEfficiency

Current Efficiency

Unit 1 Japan 1990 RFO 250 MW 200 MW 36.63 % 30.60 %

Unit 2 China 1989 RFO/Gas 200 MW 170 MW 33.89 % 25.20 %



Total 850 MW 710 MW

Current Status


GENERATIONGENCO – 1 Jamshoro Power Plant (2/3)

UnitInstalled capacity

2007 IDCNEPRA

Current capacity

DesignEfficiency

2007 IDC NEPRA

Current Efficiency

Unit 1 250 MW 205 MW 125 MW 36.63 % 32.00 % 30.60 %

Unit 2 200 MW 165 MW 170 MW 33.89 % 27.80 % 25.20 %

Unit 3 200 MW 165 MW 170 MW 33.89 % 27.80 % 25.20 %

Unit 4 200 MW 165 MW 170 MW 33.89 % 27.80 % 25.20 %

Total 850 MW 700 MW 710 MW

This is the problem: The differential between tariff and actual generation.

CAPACITY GAIN AFTER REHABILITATION

Unit No.Capacity Before Rehabilitation

MW

Capacity After Rehabilitation

MW

Capacity Gain By March 2013

MW

Thermal Efficiency %

Before After Gain

1 125 200 75 33.95 35.88 5.70

2

100

170 70 28.47 32.37 13.70

3 170 170 28.47 32.37 13.70

4 170 170 28.47 32.37 13.70

Total 225 710 485 29.84 33.25 11.70

THERMAL POWER STATION JAMSHORO

PARAWISE REPLY OF NEPRA’s QUERRIES JPCL (GENCO-I)

a. Fuel flow meters have already been installed at units of Power Complex Jamshoro.

b. No Gas Chromatograph is installed at TPS Jamshoro. However, the case has been initiatedfor the procurement and installation of the Choromatograph and successful bidder hasbeen recommended for approval by the competent Authority and will be installed soon.

c. Heat rate and initial dependability test of each generating block will be carried out aftercalibration of fuel (Gas, Oil) flow meters. The case for calibration of fuel flow meters isunder process with USAID.

d. Gas supply agreement has already been signed with SSGCL on 10Apr 1995, whereas Fueloil supply agreement with PSO will be initiated shortly.

e. Power Purchase Agreement with the NTDC has already been signed on 26 November,2010.

f. Tender for all GENCOs was invited by General Manager (Thermal) office but only a singlebidder participated without furnishing the earnest money and the case couldn’t bematured. Keeping in view the Ministry of Water and Power (MoW&P) directions for hiringof independent engineer, USAID was contacted for provision of assistance in this case. Thesame will now be conducted by the independent engineer M/s PES as is appointed by theUSAID. Consent of NEPRA has also been taken on the issue.

g. After conducting the heat rate and initial dependable capacity modification in generationlicense will be applied and thereafter power purchase agreement will be signed with NTDC.




Guddu Power Plant (GENCO-2)


GENERATIONGENCO – 2 Guddu Power Plant

Unit Tech. Units DOC FuelInstalled capacity

Current capacity

Block 1 CCGT 11 - 13 1992 - 1994 Gas 415 MW 230 MW

Block 2 CCGT 5 - 10 1985 - 1988 Gas 600 MW 370 MW

Block 3 ST 3 - 4 1980 & 1985 Gas/RFO 420 MW 270 MW

Block 4 ST 1 - 2 1974 Gas 220 MW 110 MW

Total 1,655 MW 980 MW

Current Status: 13 Units

900-920 MW is available at Gas as a fuel.


GENERATIONGENCO – 2 Guddu Power Plant

BlockDesigned

%NEPRA

%Present

%Expected

%Current Capacity

Expected Capacity

Block-I(GT-11, 12 & ST-13)

48.20 40.00 36.32 40.00 230 385

Block-II (ST-5, GT-7 & GT-8)

44.36 36.00 32.69 36.00 370 570

Block-III(ST-3 and 4)

37.55 30.00 27.24 28.44 270 340

Block-IV (ST-1&2)

37.50 28.00 25.43 27.33 110 180

980 MW 1475 MW

Post major Outages & Rehabilitation: An expected gain of 495 MW



MW


MW


MW


Block No Before After Gain

1 60 90 30IV 23.05 23.05 00

2 50 90 403 140 170 30

III 27.26 28.44 4.154 130 170 405 0 80 80

II

32.71 36.00 9.137 0 100 100

8 80 100 206 75 75 00

37.58 37.77 0.509 105 105 0010 110 110 00

11 80 130 50

I 36.34 40.15 9.5012 80 130 50

13 70 125 55

Total 980 1475 495

THERMAL POWER STATION GUDDU

Note: 1. For modification of Unit No. 1 & 2 by the Russian company, the L/C has been established for carrying out Gas firing

improvement.2. At present Unit No. 5 is under Shutdown for want of repair of generator rotor at GE works Saudi Arabia. Rotor has reached at Port

at Karachi. The Unit will come back on bar in April, 2013 & take load 35-40 MW. 3. Unit No. 7 is under shutdown for want of new Torque Converter from M/s Voith Germany and is expected to be back on bar by

June 2013 & 90 MW load will be available on this Unit and Total gain at this block will be 125 MW ( ST 5 35 MW + GT 7 90 MW).

4. For Uprate/Upgrade of GE Units 5, 7 & 8, Purchase & Service Order has been placed on M/s GE USA. The job will be completed in 8-10 weeks as per schedule. 5. LOI in favour of M/s MAPNA Iran has been issued to carry out the overhauling job of the Siemens Units 11, 12 & 13. Service order yet to be issued. The job will be carried out one by one on each Unit in 105 days starting from mid April, 2013 .

PARAWISE REPLY OF NEPRA’s QUERRIES CPGCL (GENCO-II)

a. Fuel flow meters have already been installed on steam units and gas turbines of Power Complex Guddu.

b. The tender invited fifth time for the procurement of gas chromatograph that was opened on 19-02-2013 and is in evaluation process. The same will be installed / commissioned in next 4-6 months. The previously called tenders could not be matured due to bid did not received.

c. Heat rate and initial dependability test of each generating block will be carried out after calibration of fuel (Gas, Oil) flow meters. The case for calibration of fuel flow meters is under process with USAID.

d. Fuel Supply Agreement (FSA) with supplier (PSO) and Gas Supply Agreement with Pakistan Petroleum Limited (PPL) and Sui Northern Gas Pipeline Limited (SNGPL) are in process.

e. Draft Power Purchase Agreement between NTDC and CPGCL has been submitted to NTDC on 05-10-2012. Articles 1 to 7 of the Agreement have been discussed and remaining articles will be discussed on 14-03-2013 as meeting date conveyed by the NTDC.

f. Tender for all GENCOs was invited by General Manager (Thermal) office but only a single bidder participated without furnishing the earnest money and the case couldn’t be matured. Keeping in view the Ministry of Water and Power (MoW&P) directions for hiring of independent engineer, USAID was contacted for provision of assistance in this case. The same will now be conducted by the independent engineer M/s PES as is appointed by the USAID. Consent of NEPRA has also been taken on the issue. .

g. After conducting the heat rate and initial dependable capacity modification in generation license will be applied and thereafter power purchase agreement will be signed with NTDC.




Muzaffargarh Power Plant (GENCO-3)


GENERATIONGENCO – 3 Muzaffargarh Power Plant (1/5)

Unit Make DOC FuelInstalled capacity

Current capacity

Unit 1 Russia 1993 RFO/Gas 210 90



Unit 4 China 1997 RFO/Gas 320 160



Total 1370 MW 750 MW

Current Status


GENERATIONGENCO – 3 Muzaffargarh Power Plant (2/5)

BlockDesigned

%NEPRA

%Present

%Expected

%Current Capacity

Expected Capacity

Unit 1 36.77 33.00 30.41 32.41 90 165

Unit 2 36.77 33.00 31.97 32.66 160 170

Unit 3 36.77 33.00 31.26 32.12 160 170

Unit 4 36.70 33.00 28.80 34.02 160 210

Unit 5 31.65 29.00 24.55 26.60 100 140

Unit 6 31.65 29.00 25.01 26.55 80 120

750 MW 975 MW

Post major Outages & Rehabilitation



MW


MW


MW


Before After Gain

1 90 185 80 30.41 32.41 6.57

2 110 185 70 31.97 32.66 2.15

3 110 185 70 31.26 32.12 2.75

4 160 280 100 28.80 34.02 18.12

5 100 170 70 24.55 26.60 8.35

6 80 170 90 25.01 26.55 6.15

Total 650 1175 525 28.66 30.72 7.18

THERMAL POWER STATION MUZAFFARGARH

PARAWISE REPLY OF NEPRA’s QUERRIES NPGCL (GENCO-III)


a. Fuel flow meters have already been installed at units of Power Complex Muzaffargarh.b. No chromatograph meter is installed at TPS Muzaffargarh. Calorimeter is installed by Sui

Northern Gas Pipelines Limited (SNGPL) at their gas Station TPS Muzaffargarh. The monthly calibration of the Calorimeter is carried out by the joint metering Committee of SNGPL and TPS Muzaffargarh. Procurement case for chromatograph meter is in process.

c. Heat rate and initial dependability test of each generating block will be carried out after calibration of fuel (Gas, Oil) flow meters. The case for calibration of fuel flow meters is under process with USAID.

d. Fuel Oil Supply agreement has been signed between NPGCL and Pakistan State Oil Company Limited (PSO) on dated 16.09.2009. Request of Gas Supply Agreement between NPGCL (GENCO-III) and SNGPL has been made several times. SNGPL rejected the request for GSA of even 10 MMCFD with TPS Muzaffargarh due to their system constraints. GSA already exists between WAPDA and SNGPL to supply 25 MMCFD gas to Gas Turbine Power Station Faisalabad, however, GSA is not being implemented on part of SNGPL.

e. Power Purchase Agreement was signed in 1999 but expired. The restated PPA is in the process of finalization and Draft PPA is in the process of finalization with CPPA. The finalization of PPA will be after Heat Rate/CDC test.

f. Tender for all GENCOs was invited by General Manager (Thermal) office but only a single bidder participated without furnishing the earnest money and the case couldn’t be matured. Keeping in view the Ministry of Water and Power (MoW&P) directions for hiring of independent engineer, USAID was contacted for provision of assistance in this case. The same will now be conducted by the independent engineer M/s PES as is appointed by the USAID. Consent of NEPRA has also been taken on the issue.

g. After conducting the heat rate and initial dependable capacity modification in generation license will be applied and thereafter power purchase agreement will be signed with NTDC.


Genco Holding Company Limited

THANKS

gencos rehabilitation 27.03.2013

Documents