JAMSHORO POWER COMPANY LIMITED

DETAILED ACCOUNT OF POWER PLANTS

Presentation

By

Muhammad Akram

Chief Executive Officer

12th November, 2010

JAMSHORO POWER CO. LTD.JAMSHORO POWER CO. LTD.

850 MW THERMAL POWER STATION JAMSHORO850 MW THERMAL POWER STATION JAMSHORO

JAMSHORO POWER CO. LTD (GENCO-I)

1. Installed Capacity TPS Jamshoro 850 MW

GTPS Kotri 174 MW

Total 1024 MW

2. Registered Office WAPDA House Lahore

3. Date of Registration 03.08.1998

4. Date of Commencement of Business

01.03.1999

5. Grant of generation License 1.07.2002

6. Authorized Capital Rs: 50,000 M

7. Application for Determination of Tariff date

27.03.2003 / 19.06.2006

8. Determination of Tariff by NEPRA.

31.03.2004 / 02.07.2007

BRIEF INTRODUCTION

Unit No:

Installed Capacity

(MW)Fuel

Commissioning Date

Project Cost

(Mil. Rs.)Contractor Manufacturer

M/s. Fuji Elect. & Co, Japan

M/s. Mitsui/ Riley Japan

ST - 2 200Dual

(Gas/FO)03.12.1989

ST - 3 200Dual

(Gas/FO)17.06.1990

ST - 4 200Dual

(Gas/FO)21.01.1991

Total: 850 15631

PROJECT DIGEST (COMPLEX-I)

6762M/s. Mitsui

& Co. JapanST - 1 250

Furnace Oil (F.O)

27.01.1990

T.P.S. Jamshoro

8869M/s. CMEC

China

M/s. Harbin Turbine, Boiler

& Electrical Machinery Co., Harbin China

Unit No:

Installed Capacity

(MW)Fuel

Commissioning Date

Project Cost

(Rs.M)Contractor Manufacturer

GT - 1 15Dual

(Gas/HSD)Dec. 1969

GT - 2 15Dual

(Gas/HSD)Jan. 1970

GT - 3 25Dual

(Gas/HSD)May. 1979

GT - 4 25Dual

(Gas/HSD)May. 1979

GT - 5 25Dual

(Gas/HSD)April. 1981

GT - 6 25Dual

(Gas/HSD)May. 1981

CCP-7 44

Through Heat

recovery boilers on

GT 3-6

Oct. 1994 1792.479M/s. HPEEC

China

M/s. HPEEC China

M/s. Chockerill Mech.

Industries, Belgium

Total: 174 2244.28

G.T.P.S KOTRI

PROJECT DIGEST (COMPLEX-II)

M/s. Thomassan BV Holland

184.018M/s. Thomassan BV Holland

CEM/BBC64.9M/s. CIE Electro Mech. (CEM) France

M/s. Hitachi Japan

202.878M/s. Marubeni

Japan

Unit # Type

Size (Capacity)

Fuel UsedCommissioning

DateAge

(Years)Installed (MW)

Dependable (MW)(IDC NET)

1 S/T 250 205 F. Oil Jan 1990 20

2 S/T 200 156 Gas / F. Oil Dec 1989 21

3 S/T 200 157 Gas / F. Oil Jun 1990 20

4 S/T 200 157 Gas / F. Oil Jan 1991 19

TOTAL - 850 675 - - -

GTPS KOTRI

Unit # TypeInstalled

(MW)Dependable (MW) Fuel Used

Commissioning Date

Age (Years)

1 G/T 15 8.5 Gas / HSD Dec 1969 41

2 G/T 15 8.5 Gas / HSD Jan 1970 40

3 G/T 25 18 Gas / HSD May 1979 31

4 G/T 25 18 Gas / HSD May 1979 31

5 G/T 25 18 Gas / HSD Apr 1981 29

6 G/T 25 18 Gas / HSD May 1981 29

7Steam

Unit (C.C.P)44 34.5

G/T Exhaust

/Flue GasesOct 1994 16

TOTAL - 174 123.5 - - -

GENCO-I TECHNICAL DATATPS JAMSHORO

POWER PLANT

INSTALLEDCAPACITY

(MW)

TESTED I.D.C

(NET)

(MW)

MAX: LOAD (MW)

GROSS

GEN:

(Gwh) GROSS

AVAIL: FACTOR

(%Age)

PLANT UTILIZ:

FACTOR (% Age)

LOAD FACTOR (% Age)

THERMAL EFFICIENCY

(% Age)

Design (% )

Actual

(% )

ST-1 BLOCK-I

250 205 200 955 73 50 50 36.63 32.92

ST-2 BLOCK-II

200 156 180 1118 88 75 71 33.89 29.39

ST-3 BLOCK-II

200 157 180 1026 85 69 65 33.89 28.71

ST-4 BLOCK-II

200 157 175 1182 91 79 77 33.89 29.70

GT-3 BLOCK-III

25 18 22 135 84 62 70 27.85 21.51

GT-4 BLOCK-III

25 18 23 111 81 51 55 27.85 21.50

GT-5 BLOCK-III

25 18 23 140 99 64 70 27.75 21.47

GT-6 BLOCK-III

25 18 19 84 96 38 51 27.75 21.40

CCP-7 BLOCK-III

44 34.5 38 185 90 53 56 - -

GT-1 BLOCK-IV

15 8.5 10 14 99 11 16 24.50 15.36

GT-2 BLOCK-IV

15 8.5 9 13 99 10 16 24.50 15.37

Overall GENCO-I

1,024 798.5 879 4,963 90 65 68 - -

JAMSHORO POWER COMPANY LIMITEDCRITICAL / SIGNIFICANT PERFORMANCE INDICATORS

July-2009 to June-2010

POWER PLANT

INSTALLED CAPACITY

(MW)

TESTED I.D.C

MAX: LOAD (MW)

GEN:

(Gwh)

AVAIL: FACTOR

(%Age)

PLANT UTILIZ:

FACTOR (% Age)

LOAD FACTOR (% Age)

THERMAL EFFICIENCY

(% Age)

Design (% )

Actual

(% )

BLOCK-I JAMSHORO

250 205 200 955 73 50 55 36.63 32.92

BLOCK-II JAMSHORO

600 470 535 3326 87 71 71 33.89 29.82

BLOCK-III KOTRI

144 106.5 125 655 92 67 67 27.80 29.91*

BLOCK-IV KOTRI

30 17 19 27 100 30 31 24.50 15.36

1,024 798.5

JAMSHORO POWER COMPANY LIMITEDCRITICAL / SIGNIFICANT INDICATORS

July-2009 to June-2010

* Overall Efficiency of Block-III with CCP

FUEL SUPPLY SYSTEM

FUELS TPS JAMSHORO GTPS KOTRIFuel Oils R.F.O H.S.D

SourceOn fortnight basis from

PSO-

Mode of Supply Tank Lorries -

Oil Decanting Capacity 5000 M.T / Day

-

Oil Storage Capacity 100,000 M.T 6, 600 M.T

Average Stock 30,000 M.T NIL

GAS SUPPLY SYSTEM

Source M/s SSGC Ltd Hyd M/s SSGC Ltd Hyd

Mode of Supply Through 16” Pipeline Through 12” Pipeline

Gas Allocation62 MMCFD

(53 MMCFD Guaranteed))

15-20 MMCFD

(10 MMCFD Guaranteed))

Average Gross Calorific Value (Btu/Cft)

925-1030 925-1030

THERMAL POWER STATION JAMSHOROMAXIMUM LOAD SHARED (MW)

775 760 730 730700

0100200300400500600700800900

2005-06 2006-07 2007-08 2008-09 2009-10

MW

GAS TURBINE POWER STATION KOTRIMAXIMUM LOAD SHARED (MW)

149146

141 144 136

0

30

60

90

120

150

180

2005-06 2006-07 2007-08 2008-09 2009-10

MW

THERMAL POWER STATION JAMSHOROAVAILABILITY & UTILIZATION FACTORS

77

65

75

64

7461

68

47

81

62

0102030405060708090

100

2005-06 2006-07 2007-08 2008-09 2009-10

Availability (%) Utilization (%)

GAS TURBINE POWER STATION KOTRIAVAILABILITY & UTILIZATION FACTORS

92

59

88

63

95

64

94

64

94

54

0

20

40

60

80

100

120

2005-06 2006-07 2007-08 2008-09 2009-10

Availability (%) Utilization (%)

THERMAL POWER STATION JAMSHOROENERGY GENERATED (MKWH)

FUEL MIX

1628

2718

4346

1723

2505

4228

1446

2453

3899

1342

1709

3051

2493

1788

4281

0500

100015002000250030003500400045005000

2005-06 2006-07 2007-08 2008-09 2009-10

F.O GAS TOTAL

THERMAL POWER STATION JAMSHOROFuel Cost (Paisa/KWH)

499

256

347494

304

381

1446

2883899

884

417

623

1117

422

827

0

150

300

450

600

750

900

1050

1200

2005-06 2006-07 2007-08 2008-09 2009-10

F.O GAS TOTAL

THERMAL POWER STATION JAMSHOROOverall Cost (Paisa/KWH)

385 416486

685

865

50

150

250

350

450

550

650

750

850

950

2005-06 2006-07 2007-08 2008-09 2009-10

Overall Cost

GAS TURBINE POWER STATION KOTRIENERGY GENERATED (MKWH)

741 791 810 785

683

50

150

250

350

450

550

650

750

850

950

2005-06 2006-07 2007-08 2008-09 2009-10

GAS

GAS TURBINE POWER STATION KOTRI Fuel Cost (Paisa/KWH)

245296 288

411 433

50100150200

250300350400450500550

2005-06 2006-07 2007-08 2008-09 2009-10

GAS

GAS TURBINE POWER STATION KOTRIOverall Cost (Paisa/Kwh)

295347 336

461 496

50100150200250300350400450500550600

2005-06 2006-07 2007-08 2008-09 2009-10

Overall Cost

Future Plan for the Repair and Rehabilitation of Jamshoro Power Plant

For the rehabilitation of Units 1,2,3&4 of Jamshoro, a Fixed Amount Re-imbursement Agreement (FARA) has been signed on 20.05.2010. Under this agreement, the USAID will provide US$ 18.36 million for the repair & rehabilitation.

The following table summarizes the proposed rehabilitation works and the associated costs.

Sr. No.

Unit No.

Details of Works/Spares Estimated Cost (US$)

Planned Completion

date

1- 1 Rehabilitation of air Pre-heater Side-B Rotor

500,000 30.11.2011

2- 1 Replacement of Final Super Heater Coils

1,000,000 -do-

3- 1 Complete replacement of Flue Gas Duct & Air Pre-heater Bottom hoppers

600,000 -do-

4- 1 Complete Rehabilitation of Cooling Towers

500,000 -do-

Sr. No.

Unit No.

Details of Works/Spares Estimated Cost (US$)

Planned Completion

date

5- 1 P-Gradation/Replacement of Auto Burner Control System & Data Acquisition System

300,000 30.11.2011

6- 1 F.D. Fan duct up to Steam Coil Air Heater

200,000 -do-

7- 1 Major Overhauling 1,650,000 -do-

8- 1 Soot Blower Spare Parts 100,000 -do-

9- 1 Tube Bundles of Steam Converter 250,000 -do-

10- 1 Spares for Oil & HSD Burners & Igniters

200,000 -do-

11- 1 Air Pre-heater Elements & Seal 670,000 -do-

12- 1,2,3&4

Use of fuel oil additives to prevent soot buildup and cooling water treatment chemicals to prevent scale buildup

1,000,000 -do-

Sr. No.

Unit No.

Details of Works/Spares Estimated Cost (US$)

Planned Completion

date

13- 2,3&4 Replacement of HP Heaters along with the valve and controllers including Rehabilitation of Instrument Control & Protection System

3,450,000 30.11.2011

14- 2,3&4 Complete Rehabilitation of Cooling Towers

750,000 -do-

15- 2,3&4 Modification/Rehabilitation of Electro Hydraulic and Mechanical Hydraulic Governing System

900,000 -do-

16- 2,3&4 Complete Rehabilitation of Drain Valves

300,000 -do-

17- 2,3&4 Rehabilitation of soot blowing system

600,000 -do-

18- 2,3&4 Replacement of Coagulator Agitators

1,200.000 -do-

Sr. No.

Unit No.

Details of Works/Spares Estimated Cost (US$)

Planned Completion

date

19- 2,3&4 Replacement of Data Acquisition System (DAS-100), Auto Regulation System (MZ-III) & Temperature Scanners for Generator Winding Temperature, Super Heater/Re-Heater Temp:, Boiler Drum Metal Temp: FD, ID Fan Motor Temp: Boiler Feed Pump Temp: with latest Distributed Control System (DCS)

900,000 30.11.2011

20- 2,3&4 Replacement of Existing FSSS along with Furnace Flame Monitoring

390,000 -do-

21- 2 Procurement of Boiler Feed Pump Motor Complete

100,000 -do-

22- 3 Replacement of Final Super Heater Coils

1,000,000 -do-

23- 3 Three Way valve of Oil Burner 200,000 -do-

24- 3 Spares for Overhauling of Turbine 500,000 -do-

Sr. No.

Unit No.

Details of Works/Spares Estimated Cost (US$)

Planned Completion

date

25- 2 & 4 Replacement of Turbine Vibration System with ViBro-Control-4000 Schenk

200,000 30.11.2011

26- 4 ID Fan Impellers 500,000 -do-

27- 1,2,3 & 4

Off-line Efficiency Monitoring System & Training

400,000 -do-

Total Cost (US$) 18,360,000

Targeted load after Rehabilitation

The targeted rehabilitation of the four Units will re-capture 95MW of the de-rated capacity. The MW recovered after targeted rehabilitation as under:-

Unit # Installed Capacity

(MW)

Declared De-rated

Capacity (MW) Gross

Present Operational

Capacity (MW) Gross

Gain After Rehabilitation

(MW)

Capacity after Rehabilitation

(MW)

1 250 225 190 35 225

2 200 170 170 20 190

3 200 170 170 20 190

4 200 170 170 20 190

Total 850 735 700 95 795

Critical Issue

Serious Problem due to saline River Water of high conductivity (1,200µs/cm against designed 500µs/cm).

This has badly affected the operation of the Power Plant and caused high consumption of Chemicals, resulting increase in per unit cost

SolutionInstallation of Reverse Osmosis Plant

Thank you

29

ORGANIZATION STRUCTURE

Internal Audit

Company Secretary

Board of Directors

Chief Executive Officer

Finance Director

M.I.S. Director

HR &Admn. Director

Technical Director

Jamshoro Plant

Kotri Plant

BOARD OF DIRECTORS

Private SectorPrivate Sector PEPCOPEPCO WAPDA/JPCLWAPDA/JPCL

Prof. Dr. Khawaja Amjad Saeed, Chairman

Mr. Salman Iqbal

Executive Director (L&CA)

Syed Wajid Ali Shah

Chief Engineer, GSO, Lahore

Mr. Ashfaq Ahmed Waraich,

GM,Wazir Ali Industry Hyd

Mr. Muhammad Mumtaz

Chief Engineer (WPPO)

Mr. Mohammad Akram, Chief Executive Officer, GENCO-I

Mr. Yousuf Suleman

Ex-President Hyderabad Chamber of Commerce & Industries, Hyderabad

Total Land of JPCL = 800 Acres

JAMSHORO POWER COMPANY LIMITEDEnergy Generation

Since Commissioning up to June 2010T.P.S Jamshoro

Unit No Date of Commissioning Operation Hours Energy Generated (MKWH)

ST-1 27.01.1990 123074 20092

ST-2 03.12.1989 116366 17081

ST-3 27.06.1990 110537 16311

ST-4 21.01.2991 108584 15918

458561 69402

G.T.P.S Kotri

Unit No Date of Commissioning Operation Hours Energy Generated (MKWH)

GT-1 Dec-69 104730 896

GT-2 Jan-70 125540 1021

GT-3 May-79 164438 2923

GT-4 May-79 186340 3305

GT-5 Apr-81 160377 2878

GT-6 May-81 163089 2864

CCP-7 Oct-94 117441 2910

1021955 16797

A- Present De-rated Load

This Power Plant comprises four conventional Steam Power Units with a total capacity of 850MW. The Units have been de-rated to a capacity of 675 MW. The Unit wise configuration of this Power Station along with the de-rated capacity is enumerated as under:-

Unit # Installed Capacity

(MW)

Declared De-rated Capacity

(MW)

Make Year of Commissioning

01- 250 205 Fuji Japan 1990

02- 200 156 CMEC China 1989

03- 200 157 CMEC China 1990

04- 200 157 CMEC China 1991

Total 850 675

C- Reasons of De-ratingi) Unit-1

a) Aging Factor

b) Damaged APH Elements

c) Damaged Steam Coil Air Heaters

d) Condenser Choking

e) Frequent leakages in Final Super Heaters

f) Frequent leakages in Re-heaters

g) Low Efficiency of Cooling Towers

h) Leakages from Air Pre-Heaters

i) Damaged flue Gases duct

ii) Unit-2,3&4

a) Aging Factor

b) Outage of HP Heater

c) Frequent choking of APH Elements

d) Condenser Choking

e) Low Efficiency of Cooling Towers

KEY PERFORMANCE INDICATORS

1. Plant Availability Factor (%)

2. Plant Utilization Factor (%)

3. Plant Load Factor (%)

4. Plant Heat Rate (Btu/kWh)

5. Thermal Efficiency (%)

Rehabilitation of Jamshoro Power Plants

Recovering the lost output of existing power plant is the dire need of PEPCO’s system to bridge the gap to some extent between demand and supply and reduce the generation cost per Kwh. It has therefore been planned to regain the lost capacity of Jamshoro Power Plant by rehabilitation. Keeping in view the present power crises in the country, US Government plans to assist the GoP and resolving the power crises through Repair & Maintenance measures to improve the operating capacity of the Jamshoro Power Plant.

Rehabilitation of old Units means to refurbish or upgrade the components in order to recapture the lost capacity and bring the performance near to the designed capacity. Despite proper operation & maintenance, aging is a major factor causing higher generation cost due to excessive forced outages period resulting less availability, loss of output and increase in heat rate. Rehabilitation of old steam power units is not only a financially viable option but also shorter in implementation period as compared to installing a new power unit.