kapco internship report
Post on 13-Jan-2016
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DESCRIPTIONKAPCO field study of six weeks.
Kot Addu Power Plant (the "Power Plant") was built by the Pakistan Water and Power
Development Authority ("WAPDA") in five phases between 1985 and 1996 at its present
location in Kot Addu, District Muzaffargarh, and Punjab. In April 1996, Kot Addu Power
Company Limited ("KAPCO") was incorporated as a public limited company under the
Companies Ordinance, 1984 with the objective of acquiring the Power Plant from WAPDA.
The principal activities of KAPCO include the ownership, operation and maintenance of the
Kot Addu Power Company Limited ("KAPCO") was incorporated in 1996 with the purpose to
contribute economic power to the national grid. KAPCO has shown exceptional results in the
area of plant maintenance, availability, quality standards and financial performance. In April
2005 KAPCO was formally listed on all the three Stock Exchanges.
KAPCO is committed to contributing to Pakistan's economy by powering the lives of its
people by continuously improving its performance through efficient systems, capable
workforce and good governance.
Kot Addu site is situated in District Muzaffargah, 100 KM north east of Multan on the left
bank of river INDUS at a distance of 16 Km from TAUNSA BARRAGE. The area is surrounded
by agricultural land stretched on the north and west side of Kot Addu. There are some
adjacent areas covered with wind blown sand dunes which were formed with the passage of
time. These sand dunes too are being gradually converted into agricultural land.
Apart from above, there were very little educational facilities available in the area prior to
setting up of this Power Station which has now almost been doubled and some of the
School has been upgraded. The essential amenities are also now made available to the
1.2 BRIEF HISTORY OF POWER HOUSE COMPLEX The complex comprises three blocks, 1, 2, and 3. Each block is independent in it and can be
considered a separate power station. There are 2 combined cycle modules in each block no.
1 and 2 whereas block 3 has only one module. This is the physical distribution. For the
commercial purpose the complex is divided into three blocks called Energy block 1, 2, and 3.
The power purchase agreement provides different energy charges for the electricity
generated and dispatched from each block. The energy block 1 (plant block 3) is the latest
and was in commissioning stage when NP took over management in June 1996 whereas
other blocks were completed and commissioned between 1986-1995. The plant block 3,
being latest, is the most efficient plant and provides the cheapest electricity to customer. Its
total capacity is 397 MW. In order of priority, whenever there is generation demand from
the customer, this block is run first. When the demand exceeds then only other plants are
run. The complex history over past 4 years shows that plant block 3 runs round the clock
throughout the year at maximum capacity. In case this plant can not run at full capacity due
to any fault or break down of machines, the customer need is made up from other available
plants that are relatively expensive but the customer pays lowest energy charges (of block
3) for the deficit generation. This results in significant loss. Therefore this block is the most
valuable asset of the company.
1.2.1 HEAT RECOVERY STEAM GENERATING SYSTEM
The gas turbines, despite of their low installation cost, easy and speedy erection and high
loading rate could not win the deserving popularity over the steam turbines due to the poor
efficiency of the former. In the conventional gas turbine unit, substantial amount of heat
energy was lost through the turbine exhaust gases which leave the turbine at about 580
Deg. Centigrade. To make use of this wasteful energy, an innovative concept of combined
cycle plant, now has been introduced by the gas turbine manufacturers. Under this design,
the exhaust of the gas turbine is made to pass through a conduction type boiler (commonly
called as HEAT RECOVERY STEAM GENERATOR). High-pressure steam so generated is then
used to run the steam turbine, which thus produces power without any fuel. This raises the
plant efficiency to nearly 49 % against the 28 % of the conventional gas turbine.
1.2.2 AGREEMENTS BETWEEN WAPDA & KAPCO
WAPDA entered into an agreement with KAPCO for the purchase of the power for next 25
years from this plant. The tariff covered two kinds of payments viz. capacity and energy
payment. The capacity payment is made on the available capacity of the plant and is mainly
used by the company to meet the fixed expenses and 756 million dollar debt liability that it
inherited from WAPDA. The energy payment is done on the actual dispatch from the plant.
It covers the fuel cost and there is hardly and saving from this part.
The agreement allows 36 complex days for the scheduled outages and 500 complex hours
for the unscheduled / forced outages. In case the accumulated outage period over the year
exceeds the agreed allowance, the company is liable to pay the liquidated damages at a rate
of 1.6 times of what it gets as capacity payment.
The first year of the business went very well. WAPDA was prompt in making payments, but
it did not lost very long. WAPDA as well as Govt. of Pakistan were in financial crises because
of corruption and in efficiencies. Ultimately WAPDA engaged KAPCO and National Power in
a complicated legal battle over the tariff issue by filing petitions in the high court. The court
finally passed an interim order in October 1998 that restricts KAPCO to receive Rs. 1.98 per
KWh of electricity. The objective behind this legal wrangling was to pressurize KAPCO /
National Power to agree and out of court settlement for deduction of tariff. With the
incoming of present Govt. the matters have been solved to fair extent.
1.2.3 VISION STATEMENT
To be a leading power generation company, driven to exceed shareholders expectations
and meet customers requirements.
1.2.4 MISSION STATEMENT
To be a responsible corporate citizen
To maximize shareholders' return
To provide reliable and economic power for our customer
To excel in all aspects relating to safety, quality and environment
There are three blocks in the power plant.
GT 1,2,3,4 and ST 9, 10
GT 1, 2
Manufacturer Siemens, Germany
Base load rating of GT at 15 C 125 MW (HSD)
Base load rating of GT at 50 C 96 MW (HSD)
GT 3, 4
Manufacturer GIE, Italy
Base load rating of GT at 15 C 96 MW (HSD)
Base load rating of GT at 50 C 73 MW (HSD)
ST 9, 10
Manufacturer ABB, Germany
Rated power Steam turbine 112 MW with 2 HRSGs
GT 5,6,7,8 and ST 11, 12
Manufacturer Alstom, France
Base load rating of GT at 15 C 106 MW (HSD)
Base load rating of GT at 50 C 81 MW (HSD)
ST 11, 12
Manufacturer RATEAU, France
Rated power Steam turbine 103.4 MW with 2 HRSGs
GT 13, 14 and ST 15
GT 13, 14
Manufacturer Siemens, Germany
Base load rating of GT at 15 C 139 MW (HSD)
Base load rating of GT at 50 C 108.6 MW (HSD)
ST 11, 12
Manufacturer Siemens, Germany
Rated power Steam turbine 148.6 MW with 2 HRSGs
The basic need of the safety is to prevent human being from any type of injury.
2.1 General Safety:
Security is first stage of safety.
When we working in the plant area we should use PPEs (Personal Protection Equipments)
They are mention as below:
Ear plug/ muff
It prevent us from the head injury.
Its a special type of dress and this dress is fit to body. Loose dress may be cause of any
They are prevent us from slipping and if something fell down they can bear 25kg weight by
its toe and prevent us by feet injury.
It is used to save our eyes from dust.
An earplug is a device that is meant to be inserted in the ear canal to protect the user's ears
from loud noises produced by the heavy machines, dust or excessive wind.