technical audit of gencos - final report april 27

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

Technical Audit Study of GENCO Power Plants

Hagler Bailly Pakistan Executive Summary

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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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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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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


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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Installed Capacity

MW

Present Gross

Capability MW

Present Net

Capability MW


Design Heat Rate

Design Net

Efficiency

Gross Heat Rate

Gross Efficiency

Net Heat Rate

Net Efficiency



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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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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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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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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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.


Hagler Bailly Pakistan Contents

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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


Hagler Bailly Pakistan Contents

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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


Hagler Bailly Pakistan Exhibits

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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


Hagler Bailly Pakistan Exhibits

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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


Hagler Bailly Pakistan Introduction

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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.



R1V02TAG: 04/27/11 1-2

Exhibit 1.1: Locations of Power Stations Studied



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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.


Hagler Bailly Pakistan Methodology

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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.



R1V02TAG: 04/27/11 2-2

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.



R1V02TAG: 04/27/11 2-3

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



R1V02TAG: 04/27/11 2-4

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


Hagler Bailly Pakistan Description of GENCO Plants

R1V02TAG: 04/27/11 3-1

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



R1V02TAG: 04/27/11 3-2

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.



R1V02TAG: 04/27/11 3-3

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



R1V02TAG: 04/27/11 3-4

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.



R1V02TAG: 04/27/11 3-5

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,



R1V02TAG: 04/27/11 3-6

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



R1V02TAG: 04/27/11 3-7

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.



R1V02TAG: 04/27/11 3-8

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.



R1V02TAG: 04/27/11 3-9

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



R1V02TAG: 04/27/11 3-10

Exhibit 3.10: Oil Storage Tanks at TPS Muzaffargarh


Hagler Bailly Pakistan Maximum Present Capability

R1V02TAG: 04/27/11 4-1

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


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%



R1V02TAG: 04/27/11 4-2

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



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%


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.



R1V02TAG: 04/27/11 4-3

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



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%


Hagler Bailly Pakistan Heat Rate Analysis

R1V02TAG: 04/27/11 5-1

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



R1V02TAG: 04/27/11 5-2

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.



R1V02TAG: 04/27/11 5-3

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.


Hagler Bailly Pakistan Heat Rate Analysis R1V02TAG: 04/27/11 5-4

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.



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



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.



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.




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.



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

technical audit of gencos - final report april 27

Documents

jamshoro power company

power plant availability

units tps jamshoro units

summary of units

combined cycle power

state owned power plants

thermal power stations

number of units