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BEST AVAILABLE
DOCUMENT
In the Name of Allah,
the Beneficent,
the .Merciful
BESTAVAILABLE
DOCUMENT
THE LARGEST
THERMAL
POWER
STATION
OF PAKISTAN
00I,+,09.c/,Ogo,,e ,,l(Xa.t,
6c,,,.,,,,,
PREPARED & COMPILED BY
APPROVEDBY
Memcn Abdi Malik
Stn3Abid Ali
SENIOR ENGINEER
CHIEF ENGINEER
BEST
AVAILABLE
DO'UME"T
/1
0 CONTENTS
INTRODUCTION
* PhysicalLocation 1
PakistanWAPDA 5
ThermalPower62tations ofWAPDA 7
GudduMoves Ahead 9
SignificantTechnicalDataUnits I&II 13
* SignificantTechnicalDataUnitIII 21
* SignificantTechnical DataUnitIV 25
COMBINEDCYCLE-TILE NEWERA
600MWCombinedCycle PowerStation
* SalientFeaturesofGasTurbines 35
* GasTurbineDescription 37
* SignificantTechnicalData 44
* SalientFeaturesofSteamUnits 51
405 MWCOMBINEDCYCLEEXPANSIONPROJECT
* ScopeoftheProject 65
* SignificantTechnicalData 66
BEST AVAILABLE DOCUMENT
GENERAL
ChemicalSection 72'
Fuel 83
Training 90
Arboriculture 91
Colony 93
Education 94
*ecreation 95
lHealth 96
STATISTICS
OrganizationChart
PowerGeneratingUnits
UnitWisePlantPerformance
- SinceCommissioning
- DuringtheYear 1991.
BEST AVAILABLE DOCUMENT
/v
RIIYS I CAL L CAT ICN
Guddu ,the largestThermal PowerGenerationComplexof
Pakistan is situatedon the rightbankof river Indus
(Down Stream) at GudduBarrage, 10 K.M. ahead of
Kashmore, DistrictJacobabad in the provinceof Sindh.
Guddu is connectedwithrestof theCountry both by
Roadand Rail. Telex,TelefaxandTelephonic facilities
have connectedGudduwithrestoftheworld. A small
metaled airstripis alsoavailableforoperation of
small aircraft forVIPvisitorsand in emergencies.
BEST AVAILABLE DOCUMENT
THIE mAL POWER STA.TIOX N GUDIU
* The symbolicrepresentationof Pakistan.
* The jointventure ofPakistani Peoplecoming right
fromKarachi to Kaghan.
* A green Island, full *of love , peace and
brotherhood, alongriverIndus.
A bunch of dedicated & smiling Engineers,
AffectionateDoctors,and Lovingworkers.
* A lovesome spot in the desertedextremecorner of
Sind Province, rendering its services with
devotion to all mankindirrespective of caste,
creed andreligion.
* Where technology is activated, skillis motivated,
and servicesare dedicatedwithfunanu fantasy.
* Where everyone is busyto abide strictly the
QUAID's motto;"WORK,WORK,&WORK"for betterment
ofmotherland Pakistan.
2
BEST AVAILABLE DOCUMENT
TIEE LARCEST TIE IEMA.L COHWILI. AT GUDDU
BECAUSEOF
* MID COUNTRY PLACE .
*c AVAILABILITY
OF GAS FIELDS.
W AVAILABILITY OF WATER.
W AVAILABILITY OF 1200 BUILT-IN
RESIDENCES.
'V
3
BEST AVAILABLE DOCUMENT
(A LOGICAL CHOICE)
WAPDA in 1963 carriedout Powermarket-surveyandPower
systemanalysisto prepare integratedplanfor 10 years
developments. Itestablishedthe needof construction
of abig ThermalPowerStation (800-1000MW) in Upper
Sindh. Manysiteswereconsidered.Guddubeing A MID
COUNTRYplace wasone of themostunder-developedparts
of our Country, found to be ideallysituated on the
junction of Sind,BaluchistanandPunjab, flanked by
SUI and MARI GASFIELDS. PresenceofGudduBarrage with
an additional facilityof 1200 built-in Residences
vacatedby irrigationdepartmenton-completionofGuddu
Barrage ,made it A LOGICALCHOICEfor construction of
the proposedPowerStationwhichwas finallypicked up
by the Plannefs.
4
BEST AVAILABLE DOCUMENT
IPAKISTAN
WATER A""D VOWER DEVELOK'fENT
AUThOR 'r
(WAFDA )
The importance
of energy,key
to the,progress and
prosperity
canhardly be ignored .Particularly
in the
present desperate
strive of all under-developed
countriesof the World todeveloptheirpower resources
which is pre-requisite
for the nations march towards
the cherishedgoalof material,welfareandprosperity.
Power development-
is, therefore , an index of
Agricultural
and Industrial
development
ofacountry
Pakistan is makingsimilarstrides.
In thiscrusade,WAPDA,beingonthe vanguard,has been
contributing
to the Pakistan's
efforts.to make country
self sufficient
in this fieldof national endeavor.
With its vast networkof hydel and thermal power
complexesall overthecountry.The dedicatedteam of
Engineers
andTechnicians
ofWAPDAare engaged in a
gigantictaskofreconstruction
ofnation fora better
andhappierfuture.
To match the magnitude
or work required for the
BEST AVAILABLE DOCUMENT
5
developmentofwaterandpowerresourcesofthe country
on a multipurpose basis, the Water and Power
Development Authority was set up in 1958 as a
semiautonomousbody.
This institutionaldeviceaimed tocentralize planning
and designingofrelevant schemesandtheir execution
hither-todoneby the provincialGovernments ata pace
much slower than requiredby the exigency of the
situation.
Wapda took over generation, transmission
and
distributionofPower in the country(exceptin Karachi)
in 1959, andhas broughtabout big developments
in
these Sectors sincethen.
At the time of independence
in August 1947, the
Country's PowerGenerationcapacitystoodat a meager
13 Megawatts.
WhenWapdatookoverthe electricity
'in
1959, the powergenerating
capacitywas 119 Megawatts.
At present
(December
1991 ) the total installed
capacity
of Wapda system
(Excluding
Karachi)
has
reached
7005 MW whichcomprises
of4107 MWThermal
and
2898MW HydelGeneration.
6
BEST AVAILABLE DOCUMENT
hermal Power
tations.
-GudduSteam&
Gas Turbine
-Kot AdduGas
Turbine.
-MultanSteam
-Faisalabad Gas
Turbines.
i-Faisalabad Steam
3-ShahdaraGas
Turbines.
r-SukkurSteam
-KotriGas
Turbine
Yearof Generating Installed
Commissioning Units Capacity
(MW)
1974-88 Steam,Turbines
2x I10MW
2x 210MW
GasTurbines
4x 100MW
Combined
CycleSteam
2x 100MW 1249
1987-89 10 x100 MW 1000
1960-63 4 x65 MW
1 x5.7MW 266
1975 8x25MW 200
1967 2x66.MW 132
1966-69 2x 13.25 MW
4x 14.75 MW 86
1965-67 4x.12.5.HW 504
1970-81 2x15 MW 1
4x25MW 130
pTAVIANLA FDOCUMENT
7
9-Quetta
10-MESCO Steam
(Takenover)
1965-84
1981
Steam:
2x"7.5MW
GasTurbine:
1x 7.0MW
1x 12.25MW
1x25 MW
1x35MW
2x10 MW
94
20
13-JamshoroSteam 1990-91 1x250 MW
3x210 MW 880
Total: 4107MW
7..
8
BEST AVAILABLE DOCUMENT
GUDDU MOVES A-IEALD
STEP D SThP
STAGE-I
M/s SkodaexportofCzechoslovakiasupplied , erected
and commissionedthe first two biggestthermalunit of
110 MW eachandoneblackstartGasTurbineof9.0 M.W.
in 1974
Capacityof Plant
229000 K.Watt.
Total Cost
705.12 Million
Rupees.
ForeignExchange
153.1 Million
Rupees.
STAGE-II
M/s Technopromexport
ofU.S.S.R.supplied.and
installed
a Thermal Generating Unit of 210 MW which was
commissioned in 1980. Thisunit became the biggest
generating unitofthe Country.By adding thisunit ,
the installedcapacityofGudduThermal Power Station
was raised to 439 M.W.
Capacityof the Plant. 210000K.Watt.
9
BEST AVAILABLE DOCUMENT
Total Cost. 1905.910 Million
Rupees.
ForeignExchange 572.00Million
Rupees.
STAGE-KIII
M/sC.M.I.C.China ,supplied,erectedand commissioned
one 210 MW Unit. The unit was commissioned in
December,1985.The total installddcapacitywas raised
upto 649 M.W.
Capacityof the Plant. 210000 K.Watt.
Total Cost. 2040 Million
Rupees.
ForeignExchange. 716.00Million
Rupees.
STAGE- -IV
M/s G.Eof U.S.A.supplied, installedand commissioned
the CombinedCyclegeneratingunitsin the 4thphase in
which 4 x 100 MWGasTurbineswereinstalled in the
first stageand2x100 M.WSteamUnitswereadded in
2nd stage.
Capacityof the Gas
Turbine GeneratingUnits 4x100000 K.W.
10
BEST AVAILABLE
DOCUMENT
TutalCost
2318 Million
Rupees.
ForeignExchange
i306Million
Component
Rupees.
The second phase consists of 2 x 100 M.W. Steam
TurbinesGenerating
Units.
Capacityof theUnit
2x10000K.Watt.
ForeignExchange
1037 Million
Rupees.
STAGE-V
WAPDA has enteredin to aturnkeycontract
agreement
withthe consortium
ofM/s.SiemensofGermanyandH/s.
CMI ofBelgiumforthe design,supply,installation
and
commissioning
of 2x135 MWGasTurbineand 1x135 MW
SteamPowerGenerating
units.Theconsortium
is headed
by H/S Siemens . Contract
at the cost of DM
286,120,000/
plusPakRs.401,067,000/-
wasawarded on
December20,1989.
The under construction
combined
Cycle Power Plant
Expansion
PowerGenerating
Unitsareanticipated
to be
commissioned
forcommercial
operation
asper following
schedule:-
11
BEST AVAILABLE DOCUMENT
UnitNo. I(Gas)
March,1992
Unit No.11 (Gas)
May,1992
UnitNo.III (Steam)
March,1993
Capacityof thePlant
3x135000 K.W.
P.C.ICost (Total)
Rs. 2.57 Billion
ForeignExchangeComp.
Rs. 1.6 Billion
/
12
BEST AVAILABLE DOCUMENT
SIGNIFICANT
UNITS
TURBINE
Typeof steamturbine
Hfigh pressureturbine
Mediumpressure turbine
Lowpressure turbine
Ratedout put of the
steamturbine.
Rated Speedof the steam
turbine.
Ratedpressureof the
superheated steam
beforeH.P. stopvalve.
Rated temp.of the
superheated steam
beforeH.P.stopvalve.
Ratedpressureof the
reheatedsteambefore
M.P.turbine.
Rated teiap. of the
reheated steambefore
M.P.turbine.
TECHNICAL
DATA
I & II
Tendomcompoundturbine.
Curtiswheels+8actionstages.
12 actionstages.
4action stages indouble'flow
arrangement(i.e.8
actionstages)
110 MW
3000 r.p.m.
130 atabs.
5350C.
32.5atabs.
535
0
C.
13
BEST AVAILABLE DOCUMENT
Rated temp.of the
primarycoolingwater 33
0
C.
Max. temperatureof the
primarycoolingwater. 36
0
C.
Numberof Steam
Extractions from
turbine. 8
Numberof H.P.Turbine
regulatingvalves. 4
NumberofM.P.Turbine
regulating valves. 2
Numberof turbineoil
coolers. 5'
FirstOil filling of
turbine. 19400Liters.
Oil systemofGenerator 4400 Liters.
Consumptionof additional
oil. 0.38Kg/hour.
C *NIRATOR
Typeof turbo-alternator 3-Phase,Hydrogen
Cooled.
Ratedout put 110MW,137.5HVA.
Ratedvoltageat
terminals 10.5KV +5%,-10%
Frequencyspeed 3000 r.p.m.
Hydrogenpressure 1000m.m.w.c.and
2 Kp/cm
400
Hydrogen
temp.
14
BEST AVAILABLE DOCUMENT
Temp.of Secondary
Coolingwater
Number ofHydrogen
Coolers.
Ratedout putof
Exciter
Exciter speed.
CONDENSERS
No. of condensersfor
one unit.
Cooling surface of
condenserson steam
side.
No.ofPrimaryCooling
Water routes.
Resistanceof Condenser
onWater side.
Coolingwaterconsumption
for one condenser.
Numberof tubes in each
condenser.
Length of condenser
tubes.
STARTINGOILPUMPS
Q
H
33
x 2
3x 2
700,,KW.
1000 r.p.m.
2
3380 s.q.m.
3 m.w.c.
7700cu m/hr.
6800
7500m.m.
2NO.
2100 lit/min.
125 M.W.C.
BEST AVAILABLE DOCUMENT
15
-----------
34
_____ CE. Wc 125
I I
1
7--2
.... ...
............
+ , i r
"~- 00 I
L-J
_ _ _ _I_"__ _ _
I I -,.. . 5 ;-., .
CLNP
CONDENSATE* FLOW
BESTIAVAILABLE DOCUMENT DIAGRAMUNIT NO: 1 &,2
R.P.M. 1475
ElectricalMotor 100 KW,400/231V,
50 C/s.
HIGHPRESSUREOILPUMP
Drivenby 30 KW,1460 r.p.m.,400/231V,50c/s.
group electricmotor.
"O I .Elr
Max. continuous ratingofBoiler 375'tons/hour.
Economical rating ofBoiler. 330 t/hr.
Rated out let steampressure 139 Kp/cm
2
168 Kp/cm
2
DrumOperating
Pressure.
177 Kp/cm
2
Boilerdesignpressure
RatedSteam temp. at super
heateroutlet. 540C+ 5C,- 10
0
C
Rated feed watertemp. 240C
Ratedquantityof reheatedsteam 323 tons/hr.
Temp.of steamat the inletof
reheater. 360 0C
Ratedtemp. of the reheated a?
steamat the outlet of
reheater.
5400C+5
0
C,-10
0
C
Steampressureat the inlet of
reheater.
33.5 atg.
16
BEST AVAILABLE
DOCUMENT
Steampressureat the out letof
reheater.
Total areaof evaporation.
a- areaof Ist stageof
evaporation.
b. area of 2nd stage of
evnporation.
Total surface of superheaters.
a. Area of 1st Superheater
1). Area of convection
superleater No.2
c. Area of Superheater No.3
d. Area of superheater No.4
Surtion Head
Pump Speed
Out put of intermediate
Extraction
Manometric Head of intermediate
extraction
Bearing lubricationoil pressure
Max. bearing temp.
Type of Hydrauliccoupling
Transmitted out put
Speedof Electricmotor
32.5 atg.
9047 Sq.m.
7877 Sq.m.
1170 Sq.m.
26912Sq.m.
7022 Sq.m.
8060 Sq.m.
4600 Sq.m.
7230 Sq.m.
21.m
2910 r.p.m.
25 t/hr.
40 Kp/cm
2
2
0.5-0.6Kp/cm
70
0
C
RS630 C
1200-2000 KW.
2980 r.p.m.
BEST
AVAILABLE
DOCUMENT
17
Slipof coupling 3-5 %
Range of regulation 2910-2400 r.p.m.
Weightof coupling 2813 Kg.
Coolingareall.C. Cooler 25 Sq.m.
Coolingwater consumptionat
33 C. 60 Cum/hr.
Lubricationoil watercooler 2.1 Sq.m.
Coolingwaterconsumption 5Cum/hr.
Coolingwaterpressure
2-4 Kp/cm
2
Oil quantity 700 liters including
25 Sq.m.cooler.
Weightof theH.C.Cooler
withoutoil. 1200 Kg.
Weightof the lubrication
coolerwithoutoil. 205 Kg.
REDUCINGSTATIONNO.2
Capacity 12-24 tons/hour.
Inlet pressure 8-11 at abs.
Outlet pressure 6at. abs.
Inlet temp. 3400- 360
0
C
Out let temp. 150 C.
18
BEST AVAILABLE
DOCUMENT
PROPANE
BUTANE
GASFORIGNITION
BURNERS
ONLY
Pressure
of P.B.
gas before
ignition
burner.
INDUCED
I)RAUGIT
FAN
Type.
Din meter
of the fan
Q
Driven
by electric
motor
FORCED
DRAUGHT
FANS
Type
Diameter
of the fan
Q
Driven
by Electric
Motor
RECIRCUILATION
FAN
Type
Q
Electric
Motor
Hydraulic
coupling
type
FEEDTANK
Capacity
0.7 - 1.1 kp/cm
2
2 Nos.
C41
2000
m.m.
102 Cum/Sacat 150 0 C
700 KW.
2 Nos.
C43
1800 m.m
60 Cum/Sacat 50 C
430 KW.
DL12
- 2000
50 Cu m/Sec.
190 KW.
750 SvNL11
120 Cu. m.
BEST AVAILABLE DOCUMENT 19
I.
- 4
-
1~\71
-,C
-, -: ---..
_ _ -
co
I I
-
--
--."
-,!
2 --
H P.--
I-
--
T
- -
'-
I'
.......- .. -;-- --
-.
"
AIN STEAM CYC "-
UNiT NO, 1 &,2
BES AVAILABLE DOCU.MENT
SIGNIFICANT
UNIT
YEAROFMANUFACTURING
MAKE
CLASSOF INSULATION
Full power- KVA.
ActivePower-KW
Voltage- V
StatorCurrent- A.
PowerFactor
Efficiency%
Static over loading
Statorwinding phase
interconnection
Numberof Stator winding
out-going leads.
FrequencyHz
Speed- rpm
Flywheel moment tm
2
Critical Speeds rpm
HydrogenPressure.
TECHNICAL
DATA
NO.111
1975
ELECTROSILA,USSR
'B'
233500
210000
17750
8550
0.9
98.6
1.5
DoubleStar.
9
50
3000
21.1
1370/3400
3.5 Kgf/cm
2
BEST AVAILABLE DOCUMENT 21
RatedTemp: of cold
gas0
0
C.
RatedGauge Pressureof
distillate in the stator
winding.
TEMPERATURE TOLERANCES (MAXIMUM)
Statorwindings
Rotorwinding
Stator active iron
Hotdistillateat stator
windings outlet.
Hot gas inGenerator
T UlRNtflM
Typeof Turbine
Ratedoutput
Superheated steamabsolute
pressure before H.P.
Superheated steamtemperature
before H.P.
+ 50
3.0 Kgf/cm
105
0
C Measuredby
R.T.D.
115
0
C
105
85
0
CMeasuredby
mercury thermometer.
750C
K-200-130-3
Singleshaft-three
Cylinders
210 MW
2
130Kgf/cm
540
0
C
BESTAVAILABLE DOCUMENT 22
Absolutesteampressureat
H.P.C.Exhaust at rated output
SteamTemperatureat II.P.C.
Exhaust at ratedoutput
Absolute steamPressure after
reheater&beforeM.P.
Steam temperatureafter
reheater&beforeM.P.
Absolute pressure in Turbine
Condenserat ratedoutput
CoolingWaterTemperature
Q
MaximumSteamFlow
Turbine rotor speed
II()I ][ It
29.3 kgf/cm
2
339
0
C
25.6 kgf/cm
2
450
0
C
0.078 kh/cm
2
27
0
C
27500m
3
/h
670 t/h
3000 r.p.m.
Boiler plantTIM -104 is designedforproducing steam
of high pressure in burningnatural gas and oil and
operating in blockwith turbineK-200-130.
670
Nominal rating, t/h
Workingpressure in drum ,ata
15.5
Workingpressureof primary
steamatboileroutletata
140
Temperature of superheated
primary steam,C
545
23
BEST AVAILABLE DOCUMENT
........... .
I
*
0
E "0
.- ' r. , -:F
learn',iGa, -~
-.
U))
Basic ,
"*
-
I ILM
._,.--,-
*,
*
'
-,.o * .*~, .
"" -
, - I- - - -
I - r - - - - " I, .--. :
-a i F-ow Dag a - .- ,t,_
L ,, -
-
Consumptionofsecondary
steam,t/h
590
Pressureof secondarysteam
at boileroutlet,ata
25,0
Pressureof secondarysteam
at boiler inlet ,ata
27,0
Temperatureof secondarysteam
at inlet,
0
C
333
TempErature of secondarysteam
at outlet,C
545
Feedwatertemperature,C
243
A
BESTAVAILABLECOPY
24
SIGNIFICANT TEC[INICAL DATA
UNIT NO- IV
TURD INFE
Model: N210-130-535/535
Manufacturer HarbinTurbine Works
Ratedspeed 3000 r.p.m
Ratedpower
210MW
Rotary directionof the
rotor
Clockwise (viewedfrom
the turbinehead).
Live steampressure 130ata (beforenozzle)
Live steam temperature 5350C
Exhaust steam pressure
of Hl.P.cylinder
25.5 ata
Exhausted steam
temperature of H.P.
casing
312.50
C
Reheat steam
22.5ata
pressure
Reheat steam
535C
temperature
Exhaust back
0.0729ata
pressure
25
BEST AVAILABLECOPY
Mainoil pump Centrifugaloil pumpwithoil
enteringat two sidesdriven
by the mainshaftthrough
pectinatedcoupler.
Inletoil pressure:
1kg/cm
2
2
Outlet oil pressure
20kg/cm
The first oil injector
2
Outletpressure
0.8-1kg/cm
Flow 2840.1L,/min
The SecondOil Injector
2
Outlet pressure 2.8kg/cm
Flow 2700L/min
THERMALCHARACTERISTICSOFTURBINE
There are 32 stages for the fluxpartof the turbine,9
thatare ,singlespeedgoverningstageand 11 pressure
stages in theH.P. cylinder, tenpressurestagesin the
I.P. cylinder and five pressure stages at each
symmetrical sides in the L.P.cylinder.Theheightofthe
laststageblade is 710 mm.
The turbine haseight non-governing extract stages
which are appliedto heatthe feed water, condensate
and thedeaerator.
27
BESTAVAILABLECOPY
DO XLP.I
Type
Manufacturer
Date of manufacture
Installationdate
Rating
Drumpressure
Superheat steam
pressure
Superheat steam
temperature
Reheat steam flow
Reheat steam temperature
Reheatsteam inlet
temperature
Reheat steaminlet
pressure
Reheat steamoutlet
pressure
Exit flue gas
temperature
Feedwater
temperature
Hotair temperature
DG680/140-10
DongfangBoilerWorks,China
1984
1985
680 T/H
157 kg/cm
2
140 kg/cm
2
540
0
C
589T/H
540
0
C
315
0
C
26.2 Kg/cm
2
2
24.2 kg/cm
133
0
C
2500
2430C
28
BESTAVAILABLECOPY
Airtemperature
at
600C
preheater
inlet
63239Nm3/H
Fuel consumption
(gas)
93.17%
Efficiency
Furnaceoutlet
13120C
temperature
G ENERATOR
QN-210-2
Type
210 MW
Activepower
247 MVA
Ratedcapacity
15750V
Ratedvoltage
9056A
Ratedcurrent
0.85
Powerfactor
3
Phase
50 Hz
Frequency
3kg/cm
2
Rated
hydrogen
pressure
water-hydrogen-hydrogen
Cooling
mode
MAUI EXCITOR
JL-1165-4
Type
1650kva
Ratedcapacity
431/249v
Rated
voltage
BESTAVAILABLE
COPY
29
Ratedcurrent
1562A
Frequency
100 l1z
Power factor
0.91
Phase
3
PERMANENTMAGNETICEXCITOR
Type
,TFY-46-500
Ratedcapacity
46 KVA
Rated1 voltage
161/93 V
Ratedcurrent
165 A
Phase
3
AUXILIARYEQUIPMENTS
CONDENSER
Type
N-13490
The condenser has double shells, circulation water
systemhas double flow channels.Eachof the shellscan
are
be free fromoperation for cleaning. Thetwo shells
m
2
7.7
connected
witha flexible
joint
which
areais
and the steamcommunication
pipemakesthemasawhole.
Inside the condenser,
the brass tubes arranged
in
is provided
bundle. The accumulator
ofthe condenser
with dripsand splashing
deviceso as to deaerate
the
condensate
and collect the heat.
30
BESTAVAILABLE
COPY
CONCRETE
DATA OF THE CONDENSER
13490m
2
Total
cooling
area
436 t/h
Condensed
steamrate
Inlet temperature
of the 6ooling
water
270C
0.0729ata
Pressure
in the condenser
1580C
Working
t.emperature
140 m3
Water
tank
capacity
700 t/h
Output
THE FEET) WATER PUMP GROUP
3 Nos.
BOOSTER
PUMP
YNKN300/200
Model
(single bladewith
doubleextracting).
330 t/h
Fl ow
77 in 112 0
l,ift i .n.t.
121 m112 0
outlI.et
1485 r.p.m.
Speed
1610C
Waater temperature
56.4 kw
Shaft Power
3Nos.
FEEDWATER
PUMP
40C11TA
Mode].
325 t/h
Flow
31
BESTAVAILABLE COPY
11.6 kg/cm
2
Inlet
pressure
172.5
kg/cm
2
Outlet
pressure
4950 r.p.m.
Speed
Feed water temperature
161/165.6
0
C
2041 kw
Shaftpower
68 kg/cm
2
Tappressure
92.5 t/h
Minimum flow
6
Stages
MOTOR
Y800-11-4
Model
6600V
Ratedvoltage
3200 kw
Ratedpower
Ratedcurrent
329A
Rated speed
1485 r.p.m.
Phase
3
Pole
4
The cooler is installed
at the topofthe motor.
CIRCULATING
WATERPUMP
Bankside pump
50ZIQ-50
Model
Flow
1746m
3
/h
BEST AVAILABLE
COPY
32
Outlet.pressure
Speed
Shaft Power
Motor
Model.
P'ower
Voltage
Current
C. W. PUMP
Model
Flow
Outlet pressure
Speed
Shaft.power
Motor power
Voltage
TheCondensatePump
Model
Intake bore/out take bore
1ift
14.3mH20
485 r.p.m.(whenthe blade
wheel is -20)
775 KW
JSL-1000-12
1000kw
6600V
118A
50ZLQ-54
20800m
3
/h
22.5m1120
*. 584 r.p.m.
(Whenthebladewheel is
-20)
1570 KW
1600KW
6600V
7LDTN-6-1000
350/250 mm
162mH20
33
BESTAVAILABLECOPY
Flow
Motor
Model
Power
Revolution
Frequency
Voltage
ClosedCircuitC.W.Pump
Pump
Model
Flow
Head
MOTOR
Model
Speed
Voltage
Frequency
Current
350m
3
/h
YL-355-4
225 KW
1460 r.p.m.
50H1z
6000V
20 St1-13
2016 m
3
/h
35.1 M112 0
JS-148
990 r.p.m.
6600V
50 H1Z
34 A.
BEST AVAILABLE COPY
34
600 MW COM3INED CYCLE
SALIENT FVAkWXTRES DF GAS TURDINES
Gas Turbine is modern speedtronic.type and has
the remotestarting, synchronizingandloading in
addition to local autostarting.
The excitationsystemis purelystaticandmodules
(IC) are used.
All the necessary parameters (temperature,
pressure, vibration) of the compressor, turbine
and generatorare monitoredby the Microprocessor
computeranddisplayedonthe screennamed as ITS
(IntegratedTemp.System).
Each gas turbine has its own logprinter, the
parameter of the unit can bM printed. The
conditions half hour before tripping can be
printed.
The air filterunit of compressor comprises of
1280 elements , with the provision of self
cleaning, cartridges,has two yearslife.
The automatic purging of 112 and fillingof C02 in
emergencyhas beenprovided.
35
BESTAVAILABLE COPY
s
S
s
e
o l
I
0
eS
a
i I I I IS a
*
I
Us I i
OII &
I
I
* I S . .SSSI
S ISS*I'
BEST
AVAILABLE
COPY
Each unit has provision for diverting its
exhaust gases fromatmosphere t.o heat recovery
boilerof the steamturbine.
Automatic fuel change overi.e. gas to distillate.
Generators havebeen provided with necessary
synchronouscondenseroperationfacilityto boost
up local voltage system and also decrease it
whenever necessary.
t 11 w
sI I
r
III !
I I |
: II
I,
It
I,
iI
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II
wl
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I llt51 I mutI a, II StIll3511p 111
Il155 litIIWI VVIIlPI'lI'SIPI
IVIUWIII I II'IIIIIIIU|P
36
BEST AVAILABLE COPY
GAS TURBINE DESCRIIOxN
COMPRESSOR
ROTOR
The compressorrotoris anassemblyof-15 individual
wheels , two stub shafts each- with an integral
wheel,speed ring, tie bolts and compressor rotor
blades.
STATOR
The stator (casing )of compressoris composedof four
majorsections.
A- Inlet Casing.
B- ForwardcompressorCasing.
C- A.F.T. CompressorCasing.
D- CompressordischargeCasing.
These sections in conjunctionwithturbine shall forms
a primary structureof gasturbine .Theysupport the
rotor at the bearingpoints and constitute the outer
wall of gas path annuals. Inlet casing, supports
bearing No.1 and variable inlet guide vanes. Forward
37
BEST AVAILABLE COPY
casing contains fourcompressorstator stages.
The AFT Compressor casing contains fifth to tenth
stages while discharge casing contains final seven
compressor, stages. It also joins, the compressor and
turbine stators and provide support for bearing No.2
COMBUSTIONSYSTEM
The combhustion system is of Reverse flow type w-ith
fourteen combustion chambers arranged around the
periphery of compressordischargecasing. The system
also iticludes fuel nozzles ,Two spark plugs, Two
flame detectors arid cross fire tubes.
TURBINESECTION
Energy in the form of hightemperaturepressurized gas
is converted into mechanicalwork throughthree stage
turbine hiaving parts; rotor, casing, exhaust frame,
exhaust diffuser,nozzlesand shrouds.
G.ENERAT~lR DF.SCRIIT ION
Generator packageconsistsof the generator, hydrogen
control equipment C02 control equipment and the
collectorring compartment.
38
BEST AVAILABLECOPY
The generator is designedto operatecontinuously and
provisions are made for maintaining the hydrogen
pr.-ssure and purityand for supplycooling water and
ubricating oil., circulationof hydrogen is provided by
the rotor fans.
GENERATOR PROTECTION & CONTROL
I)i fferential Protections
Generator only.
Generator and transformer
St at.or Earth fault, Negative sequence, Over excitation,
Field ground, Reverse power (for turbine). Automatic
/Manual synchronizingarrangementsare provided.
EXCITATION SYSTEM
ITt is generally known as potential source excitation
system . This systemcontrolsAC terminal voltage, or
reactive volt-amperes of the generator, by controlling
its field excitationsystem,usesa power Potential
Transformer (PPT) connected to the generator line
termina]Is as a Powersourcefor the excitation. The
1111T secondary voltage is rectified and controlled by
diodes and thyristors (SCR's) to furnish DC for the
39
BEST AVAILABLE
COPY
generator field, Since the generator is self excited,
that i? fieldpower is obtainedfrom the generator,
the exr' itat.i.on systemis selfcontained in that no
e:terna l power is required, other than DC control
power. However , the regulator power supplies are
etergize(d by the 120 VAC stationsupplyuntil the unit
i s at rated speed.
E ItAN. ; F'(> I MER'
Unit Transformer - 125 MVA -- forced air cooled type
with off load tap changer. It stepsup the generated
vo]tlage from 11.5 KV to 220 KV.
Roserve s.tation supply transformers20 MVA (2Nos.) one
of them stepsdown 220 KV /6.6 KV theother 132 KV/6.6
KV. These are forced air cooled and with ON-Load
automatic tap changer fromH/s MRWest Germany, while
the transformersare of M/s FUJI - ElectricJapan.
220 KV SWITCIYARD
For Gas Turbine No. 1 & 2 andReserve Station Supply
Transformer 220/6.6 KV, Airblastcircuitbreakers are
ult.i.ized fromPhase-II existing 220 KVSwitchyard.
BEST
AVAILABLE
COPY
40
Gras Tirhine 3 & 4 - three 220 KV lines namely Guddu
N'ow Hii] taii, (Cuddiu-ladut and Giiddu-Sibi are connected to
the n .: I nv t.flsructed 220 K. V. Switchyard.
A dohI(- bus bar systLem is provided for export of
i,',norat.od( eer-gy to the Load Centre.
S)u Iphe 'r 1exaflour-ide (SF6) Breakers are installed for
:V%'i t.ch itlif .
A IJX 1. 1. 1 ARC T V.:;
A. C .SYSIEIMH
TI r-e Ar'e two reserve station supply transformers,
20
MVA e;uir, one transformer for two units . Two 6.6 KV
i,( torr- , one for c:ranking the turbine and the other" is
fo. syn,}'rnoiis condenser operation of the unit.
D).C. S N, FIM:
TbI r( r, three separate I).C. Systems, one for Gas
T', rbin ,,,'ond for 6.6 1KV Subi Station and the third for
... K... i ttchyard wit.h the r chargers.
(C)N'IZOI, ANI) PROTECTI.TtON SYSTEIM
Th}- in:st lled Generpal Electr'ic Gas Turbines have been
BESTAVAILABLECOPY
GT/HRSG 1
OVERVIEW
COMBINED CYCLE
" GT/HRSG 2
24--5CE
C 12.MT/HR
l
.
..
...
FUL T
I -.....IGEN
Ll i
.IILTUR
B
i f
.-
I__FE
COMP< ,L,
w
co
CIO
COEc \~VGEN
equipped with "Speed-Tronic,Mark-II,!. with Integrated
TemperatureSystem,so itconsists.of twoportions:
SPEEDTRONICMARK-IISYSTEM
Speed tronic is the registeredtride-name of General
Electric Electronics control for gas turbines. The
SpeedTronicMark-IIusedmore integratedcircuits and
replacedmuchof the relayswithdigital logic. The gas
turbine is controlledby changingthe'amount of fuel
sent to the combustionchambers.Ins'peed tronicsystem
a variablecontrolvoltage (VCE)represents the 'Set
point' or 'Called for amount' of.fuel. The fuel
metering element, Gas orliquid ,'is. moved to the
'Called for position' by high.pressure hydraulic
pistons actuated byServovalves..controlled by the
Speed Tronic system.Positionsensingdevices on the
fuel elementprovideafeedbacksignal to the control
system.
INTEGRATEDTEMPERATURESYSTEM (ITS)
The ITS is a microprocessor based system which
integratesmost ofthetemperaturedependent functions
of the gas turbine. Thermocouples are connected to an
42
BESTAVAILABLE
COPY
Analog input rack (withthe exceptions of the over
temperature thermocouples). These Thermocouples are
scanned periodically,covered to digitalnumbers, cold
junction compensatedandstored in the microprocessor
memory . Similarly selectedhighlevel signals (e.g.
VCE, OTA, OTB,OTC)are also connectedto the analog
input rack, periodicallyscanned convertedto digital
numbers and stored in the microprocessor
memory. The
control and protection functionsare all implemented
by
programme if the programmable readonlymemory (PROM).
Thissystem has following maincontrol:sub-systems;
1-
Startupcontrol
2-
Speedcontrol
3-
Temperature
control
4-
Protectionsystem
5-
Sequencing
system.
BEST AVAILABLE
COPY
43
STATION BATTERY SINGLE LINE DIAGRAM
MCC BAEAI.C FRCM PCC RE.KrR NC-7 600 MW PC*CF
FROM NC. -7 I
1225 AH
92 CELLS 2
t25V1 BEST AVAILABLE cOPY
-BATTE Rf
CONTACLCOWPT
4- --
125 VOC PCC- MCC T 125V DCPAINE._ PCARO)
3c) FRAME.
'2
ALE POL
:so ti K )01 )(60) )(O1 )(30) 50)
ALL 2 POLE BREAKRS TYPE )"2SC15O)
3 5 /77)C-2 /27MCI
TO CON- CCmPT STANOBY LTG CONTROL FIRE
PWR POWER PRCTECTICN
85 Q;E-i 18 QE..2
EMERGENCY EER,LUSE &SEAL
LUSE PkiP OiL PUUL M.TCR
MC7CRCCT) (GEN'
TURBINE C:NTRC. PANE' IN CONIR:tL C MPT-, C!NTPC.PANELIN CCHTrZLCMI,.
CCNTRCLFIRE PRCTZ:TKtNS,.0 GENERAICR EXCITATION COMP&RTM4ENT OCF BASE.
0 ACCESSCR' BASE OEVICE
CCNTR.L CCMPARTMENT
C) COPITR-L CO PA.':EN' PCwE~z C::L C:MPAR:IMEN' (PC.1ONACCE5-.B-SE
0 TC'r CCNTRCL CENTRE IN P cC. fENERATCA. C*OPART"EN7
F- LUBE CIL SKIO GEN) C
r "
F BASE
RatedAmperes
Substransientreactance
Transient reactance
Synchronous reactance
Poles
RPM
Excitationvolts
Field current
240 KVVOLTAGETRANSFORMER
Manufacturer
Type
RatedVoltage
Primary
Secondary
Tertiary
Secondary
Tertiary
SimultaneousBurden
240 KVLIGHTENINGARRESTER
Manufacturer
Type
6320,Peakcapability6471A
0.162perunit
0.227 perunit
1.794 perunit
2
3000
500V
1103A
AlsthomAtlantique,France.
UHC-245"
220/13KV
110 /13KV.
110/13KV
220VA
.25VA-
200VA'
ASEAABSWEDEN
XAQ245A3
COPY
BEST
AVAILABLE
Voltage rating 240KV
Dischargecurrent rating 10 KA
Type ofoperating counter TXB
UNITTRANSFORMER
Manufacturer FujiElectricCo.Ltd.
Type ThreePhaseOilImmersed
Outdoor.
Rated output(ONAN/ONAF1/ONAF2) 75/100/125MVA
Vectorgroup
Nominal ratio transformation
at no load.
Rated current (H.V)
Rated current (L.V)
Type of cooling
Ynd11.
11.5"KV/220 KV
197/262/328
3936/5249/6561
ONAN/ONAF1/ONAF2
RESERVESTATIONSUPPLYTRANSFORMER(132/6.6KV)
Manufacturer
VoltageRatio
Type
Rated PowerOutput
(ONAN/ONAF1/ONAF2)
Current RatingHV
Current Rating LV
FujiElectricCo.Ltd.
132KV/6.6KV
ThreePhase,Oil immersed
12/16/20 MVA
52/70/87 A
1050/1400/1750A
BEST AVAILABLE:COPY 46
PowerFreq TestVoltage(K.V)
275 forAV
20 for LV
Insulation
class
F
Typeof cooling
ONAN/ONAFI
220 KV SWITCHGEAR
EQUIPMENT
240 KV CIRCUITBREAKER
Manufacturer
Sprecherand Schuh
(Switzerland)
Typedesignation
HFG114/lA
Ratedvoltage
245 KV
Rated continuous
current
2000A
Ratedcontinuous
current
40 KA
Typeof operating
Mechanism
FKF1.2motorwoundspring
240 KVISOLATORSANDEARTHINGSWITCH -
Manufacturer
EGIC/MG.
Type
DR245
RatedVoltage
245 KV
Ratednormal current
2000A
240 KVCURRENTTRANSFORMER
Manufacturer
AlsthomAtlantique,France
Ratedprimarycurrent
2000A
47
BEST AVAILABLE
COPY
Numberof cores
Current
Rated burden
For metering service
Forrelayingservice
Vectorgroup
Nominal ratio of transformation
at no load.
Typeof cooling
5
o00/i
1500/1
.1000/1.
750/1
.500/1
30 VA
30 VA
Ynd11.
'132/6.6KV.
ONAN/ONAF1/ONAF2
RESERVESTATIONSERVICETRANSFORMER (220KV/6.6KI)
Manufacturer
Standard
Type
Rated/Output
(ONAN/ONAN1/ONAF2)
Vectorgroup
Nominal ratio of
transformationat
no load.
Type ofcooling
Fuji ElectricCo.Ltd.
.IEC
Threephase,oil immersed
outdoor.
12/16/20 MVA
Ynd11
220/6.6 KV
ONAN/ONAFI/ONAF2
48
BESTAVAILABLECOPY
A.C.SYSTEM
StartingMotor
Synchronouscondensers
AuxiliaryHydraulicPump
AuxiliaryLub Pump
Exhaust frame blower (2Nos)
Watercoolingpumpmotor
ExhaustPlenumcoolingair fan
GeneratorLub /Seal Oil Pump
(2Nos.)
Fuel forwardingpump (2Nos.)
Coolingwaterfanmotor
(3Nos.)
Accessorycompartmentheater
Generatorspaceheater
Turbinecompartmentheater
Lub tankimmersionheater
Lub tank immersionheater
(Gen.)
Gen.bearing oil liftpump
(2Nos.)
Atomizing air booster
Torqueadjusterdrivemotor
1250HP
900 HP
20 HP
100 liP
100 HP
150 HP
05 HP
75 HP
40 HP
50 HP
3KW
5XW
3KW
24.4 KW
25.5 KW
: HP
20 HP
1.5 KW
BEST AVAILABLE COPY
49
Gen. seal fluidpump
Compressormotor (C02Fire
Protectionskid)
Pressurizing fan access
turbine loadexcitation
compartment.
Vapourextractormotor
D.C.SYSTEM
EmergencyLub PumpMotor
(Turbine)
EmergencyLub/SealOil Pump
Motor (Gen.)
GasTurbineBattery
Rating
Voltage
BatteryCharger
Capacity
Input voltage
Input current
Outputvoltage
Output current
75HP
0.75 HP
125/37.25
1HP
10 HP
20 HP
1225 All, 7hour
1.25 Volt.
6.25 KW
400 VAC, 1Phase.1z
76 A
153.9 VDC
100 Amps.
50
BESTAVAILABLE COPY
SALIENT FEATURES OF STEAM UNITS
600 k-l C. zc
Four GasTurbineof100 MWeachweIrept in operation
in 1985-86, theseunits areutilizingthe fuel in the,
for: ofeitherMariGas,Kandhkot;Gas,.SuiGasor HSD
Oil. Ahigh temperatureexhaustof these,Gas Turbine
was wastedin atmospherewhich isnowutilizedby the
two CombinedCycleGeneratingUnits."
General ElectricCompanyofU.S.A.hassuppliedthe,
two STAG 209ECombinedCyclephase-II *Power Plants,
each of 100.56MWcapacity.Themajoritems of this
Plant include:
HeatRecoverySteamGenerators :04 Nos.
SteamTurbo Generators :02.Nos.
Plant supportsystems forcirculating cooling water,
water treatment , condensate,steam,.. air,and fuel.
Electrical PowerSystems forFeedingPlantauxiliaries*
The Plantdesignis basedonthe GeneralElectric MS-
9001 Gas Turbine Generators, with matching heat
recoverysteamgeneratorsandsteamturbine generator.
Each STAG209EPlant canbe rapidlybrought on line.
BEST AVAILABLE COPY
51
TheGas Turbinegeneratorscanprovideupto 73% of the'
Plantout put inlessthan30 minutes.Dependingon the
steamequipment temperatures,
therestofthe Plantcan
be on line in one to threehours.For typical daily
start applications,
the totalplant output would be
available inless thanonehour.
HEATRECOVERYSTEAMGENERATORS (HRSG)
The HRSG is unfired and functions only when the
associated
Gas Turbine is operati-ng.
Each HRSG
operates independently
and provides a proportional
shareof the steamflow forthe steamturbineunit. The
HRSG steamcapacitywillbe controlledbya modulating
damper located intheGasTurbineBy-pass stack. The
majorcomponentsofHRSGare:
HRSGDRUM- ECONOMIZER- EVAPORATOR- SUPERHEATER
TECHNICALDATA
HRSG
Manufacturer
General'Electric
52
BEST AVA1LABLF COPY
Type
ForcedCirculationwith
economizer
evaporator,
superheater
and exhaust
gasby-passdampers.
NumberofUnits
Four
PerformancewithBaseLoad
TURBINE

InletAirTemp.
80F-80.4
0
F-104 F-122 F
MaximumSteamFlow
Lbs
6302-5.982 - 5868 -5717
SteamTemp. at
Superheater
outlet ,PSIG
936- -942 - 930 -909
Steampress, at
977 -991
Superheater
936 - 965 -
outlet
O
F
FeedwaterTemp.
167 - 171 - 172 -172
at Economizer
Inlet ,OF
HRSGExistGas
360 - 356
Temp.OF
361 - 361 \-
HRSGDESIGN
OutletDimensions
67.6x 16.4x69.9 feet
(Lengthxwidthxht)
DesignMaximumpressure
1166psi
971,303 lbs
Approximate
EmptyWeight
BESTAVAILABLE COPY 53
SuperHeater
a. TotalHeatingSurface
b. TubeMaterial
c. TubeDiameter
d. FinMaterial
Evaporator
a. TotalHeating Surface
b. TubeMaterial
c. TubeDiameter
d. FinMaterial
Economizer
a. TotalHeatingSurface
b. TubeMaterial
c.TubeDiamet,--e
d.FinMaterial
HRSGCirculating
Pump
Manufacturer
Type
Numberof Units
RatedCapacity
TotalPumpHead
61t215 ft
2
SA-209-TI/SA-213-T22
1.25 in.
SA-240-Type
409
144.216 ft
2
SA-192
1.25 in.
SA-283-C
112,355 ft
2
SA-192
i.0 in
SA-283-C
Worthington
Horizontal,
RadiallySplit,
Single-stage,Centrifugal
OneperBoiler
4403 gpm
92 ft
54
BEST AVAILABLE COPY
PumpSpeed
980 rpm
Design BrakeHorsepower
110 hp
CoolingWaterFlowrate 3.5 gpm
MotorManufacturer
Loher
Motorhp/V/Hz/Phases
177hp/380V/50HZ/3-Ph
STEAMTURBINE
The STAG209Esteamturbine is a'straight condensing,
double flow,non-reheat,tendomcompound, with down-
wardexhausthaving 23" laststagebucketsdesigned to
utilizeall steamgeneratedatanyambient temperature
in the Plant operating range at variable steam
temperatureahdpressures.
Recognizing
the uniqueability'of STAGPlants' to be
started and stopped easily and quickly,the
steam
turbine forthe STAG209 incorporates
special design
features
for suitability
to cycle duty without
compromising
baseloadcapabilities.
STEAMTURBINEDESIGNFEATURES
StraightCondensing-
TURBINETYPE:
DoubleFlow.
55
13EST AVAILABLE COPY
DrivingPerformance 118,306KVAq11,500VHydrogen
CooledGenerator,500VStatic
Exciter.
Rating 95,700 Kw
Designsteamconditions
Initial pressure 850PSIG
Initial temperature 949.5 FFT
Backpressure
2.5 inchesHgAbs.
Speed
Rated
3000 rpm
Primarytrip
3360 rpm
Emergencytrip
3420 rpm
TURNINGGEAR
It is motoroperatedwith provisions for automatic
engagingand manual crankingincluding:
Crankingdevice
Lowspeedsensingdevice
Solenoidfor localorremote engagement.
Pushbutton forsolenoidengagementsignal lights
Bearingpressureinter lock.
56
BLSf AVAILALE COPy
GENERATOR
The Generator is completelyenclosedhydrogen cooled,
synchronous unit, lubricationfor the generator is
supplied fromtheturbine lubricrlionsystem.Generator
cooling system includinghydrogencoolers which are
verticallymountedin the coolertowerslocatedat the
four cornersof the frame.
NOMINALRATINGS
KVA
ArmatureAmps.
FieldAmps
ExciterVolts
ExciterVolts
PowerFactor
DESIGNDATA
Gas 98% Purity (PSIG)
MaximumKVAOneCooler
Outof Service
No. Load FieldCurrent
ThreePhase Armature
WindingCapacitance
118,306
5,939
11,500
942
500
0.85
30
94,645
348 A
0.947uf
0
57
BESTAVAILABLE COPY
ArmatureWindingDC
Resistance(perphase)
0.00258 2at 1000C
FieldWindingDC
Resistance
0.555 2at 1250C
EXCITATIONSYSTEM
Theexcitationsystemusedoneachturbinegeneratoris
the current state of the art' in A.C. Generator
excitation system.This systemcontrolsA.C. terminal
voltageor reactivevolt-amperesof thegenerators, by
controlling
its filedexcitationsystemuses a Power
PotentialTransformer (PPT)connectedto the generator
for the excitation.
line terminals as a power dource
ThePPTsecondaryvoltages rectifiedandcontrolledby
diodes andthyristors
(SCR's)to furnishD.C. for the
excited,-
generator
field. Sincethegenerator
is self
generator,
the
i.e.field
power isobtained
fromthe
excitation
systemis selfcontained
inthatnoexternal
energized
by the 120V.A.C.station
supply
power is required,
other than D.C. Control
Power.However,
the regulator
power supplies
are
until the
unit is at ratedspeed.
58
BEST AVAILABLE COPY
TRANSFORMER
MAINSTEP-UPTRANSFORMER
DESCRIPTION
Stepup'transformer that
stepsthe steamturbines
generator voltage of 11
KV upto'"the utility
voltageof 220 kv.
Manufacturer FujiElectricCo.
Installation
Outdoors
AmbientTemperature 00C to500C,
40C".AJrge
Coolant Oil (i0
0
0)
Oil PreservationSystem Conservator
CoolingClass OA/FA/FOA
No.of Windings Two(2)
Frequency
50 Hz
'
MVA Rating
73.2/97.6/122MVA@ 400C
averageambient
TemperatureRise
5500 winding Rise by
Resistance above40
0
C
averagedailytemperature
with500 maximumambient
temperature
and 650C
hottest spotrise.
HighVoltageWinding
Rated
Voltage
220
KV":
59
BESTAVAILABLE COPY
Connection
BIL
LowVoltageWinding
RatedVoltage
Connection
BIL
VectorGroup
TransformerImpedance
UNITAUXILIARYTRANSFORMER
Description
Manufacturer
Installation
Coolant
Oil PreservationSystem
CoolingClass
No.Windings
Material
No.Phases
Solidlygroundedwye
1050 KV
11KV
Delta
110 KV
YNd ii
10% onFOA base
Auxiliary Step-down
transformerthatsteps
thegeneratedvoltage
of11KVdownto6.6.KV
which supplies the
auxiliaryofthesteam
turbine.
Fuji ElectricCo.JAPAN
Outdoors
Oil(10
0
C)
Conservator
OA/FA
Two(2)
Copper
Three(3)
60
Bt3.1, \A,!.10,11COPY
Frequency 50 Hz
MVARating 10/12.5MVA@400C
average ambient
Temperature Rise 55
0
CWindingRiseby
Resistanceabove40
0
C
averagedailytemp.
with500Cmaximum
ambienttemp.and 65
0
C
hottest spotrise.
HighVoltageWinding
Rate Voltage 11-KV
Connection Delta
BIL 110KV
VectorGroup Dynl
Transformer Impedance 5.75% onOAbase
Highvoltageair-fil'.ed terminalboxfor isolatedphase
bus connection.
Lowvoltage air-fille6terminalboxandconnectors for
terminating 15 KV shieldedcable.
CONDENSERCOOLINGWATERSYSTEM
Normally the condensercoolingwateris river water
61
BEST / .!,... COPY
from the Irrigation
CanalnamedB.S.Feeder.
The raw
water from thisCanal is circulated
bytwo' circulating
pumps
(the third one is standby),-
in the condenser
tubes,
to condense
steam.
Acooling
towerandcooling
pumphouseis alsoprovided
as a secondary
circulating
water supply
for plant
operation
when the canalcannot:'supply
circulating
water.
Thecooling
toweris of the mechanical
induced
draft type.
62
BLST AVAILABL.F COPY
405 MW OMBNED CYCLUE
Ecxs scon Procjc~t
Upon instructions of FederalGovernment , WAPDA planned
to install 3moreUnits 2x100 MWGas Turbines and
i00 MW SteamCombinedCycleUnitas anexpansionof
one
existing 600 MW (4x 100 MWGasTurbinesand 2x100 MW
SteamCombinedCycle) ,to meet the risingpower demand
of the countryand in orderto bringlotofdirect and
PC-I
local benefits. The Federal Governmentsanctioned
for atotal costof Rs.2.57 Billion including Rs.1.6
Billion ForeignExchange .International
Tenders were
invited andafter the evaluationof the bidsthe offer
of M/s. Siemens Germanywas found to be the most
2x 135
attractive
and economical.
According
to which
MW Gas Turbinesand Ix 135 MWSteamTurbinehas to be
installed.
with
WAPDA therefore
entered into aTurnKeyContract
consortium
of M/s Siemens of Germany and Mi's CMI
, installation
and
Belgium for the design,supply
total value of the
commissioning
facilities.
The
Contract
isDM 286,120,000/-
plusRs.401,067,000/=.
The
BEST AVAILABL.ECOPY
63
date of awardwas December20,1989.
Thesethree machines oftotal capacity405 MWarebeing
installed on the northwest of the existing Combined
Cycle Units & have been separated, by the 500 KV
Switchyard.
Natural gas is the primaryfuel forall the existing
steam as well as the running combined cycle units,
although the steam unitboilers can be fired on
furnaceoil and the combinedcycle gasturbines can be
operated onHighSpeedDieselOil.NaturalGases from
Sui, Kandhkot andMari fields are supplied to Guddu
where a gas mixing station is already in use to
allocate the gasestovariouspowerplantunits.
Consequent upondecisionof installing'2 x135 MW Gas
Turbines in expansion project, there will be an
additional.
requirement
of 90 MMCF gas/day,, but
not
unfortunately
Ministryof Petroleumhas approved
this extra quantity of gas. It has therefore been
Furnace oil in the boilers of the
planned to use
existing steam units 3 &4 and divert
saved the
quantity ofGas for operationofnewlyinstalled 2 x
135 MWGasTurbines.
BEST
AVAILABLE
DOCUMENT
64
WIE SCOPE O THE PROJECT
405MWCCP
Two gas turbine andgeneratorunitseachratedat
135 MW capacity,completewith,iauxiliaries and
local panels.
One steam turbine andgeneratorunit.of 135 MW
capacity,completewithallauxiliaries.
Two units of heat recovery steam
generators (HRSG), completewithauxiliaries.
ta
Step-upand service transformers,switchgears and
associatedelectricequipment forthe transportof
electric powerfrompowerplantto the electric
grid.
Associatedcivilworks.
Training to WAPDApersonnel.
ProvisionofConsultancyservices.
65
BEST AVAILABLE DOCUMENT
405COMBINEDCYCLEPROJECT
PLANTDESCRIPTION
Numberof Units Two
Gas TurbineGenerators: Two (2)
GasTurbines : HeavyDutySingleShaft
GuaranteedNetOutput
at Base Load. 136,070 KW at 30 0C
(Ambient).
Generator
GeneratorVoltage 11,000V
Frequency 50Hz
PowerFactor 0.85
Generator Speed 3,000RPM
SteamTurbines
Generators one (1)
Steam Turbine
CombinedCycleUnit
GuaranteedNetOutput : 147,218Kw at 300C
(Ambient)
Speed
3000RPM
Numberof stages
5/26
Highpressure/
Lowpressure
66 BEST AVAILABLEDOCUMENT
Generator
Speed
3,000RPM
Phases 3
Frequency 50 Hz
VoltageRating 15,750V
Power Factor 0.85
Guaranteedoutput 153,000 Kw
at 0.85 and43
0
C
cold gas temperature.
HR SG
TwoNos.
Max. SteamFlow'at
30 C Base
65,48Kg/Sec.
SteamPr. at
30
0
C Base.
60 Bar
SteamTemp. at
30
0
C Base :.'5300C
Feedwater Pumps
Three (3)
Type BarrelTypeMulti-stage
(Horizontal)
Capacity
98.2Kg/Sec.
Total Head
: 880Meters
Motorkw/v/Hz/phases
1400/6,600/50/3
Speed
:
2,976RPM
BEST AVAILABLE
DOCUMENT
67
CondensateFeedwaterPumpsThreeNos.
Type
CanType (vertical)
Capacity
98.2 Kg/Sec.
Total Head
116/90Meters
Motor kw/v/Hz/Phases :132/400/50/3
Speed
1,480RPM
MainC.W.Pumps
Design Flow
16,776cu. meter/hour
DesignHead
13 meters
MaximumSpeed
490 RPM
CoolingTower
14
Number of Cells
34,848cu meter/hour"
DesignWaterFlow
InletWaterTemp.
45
0
C
Outlet WaterTemp.
37
0
C
259.2x 106 kcal/hour
Heat Removed
WaterTreatmentPlant
Demineralizedwater
666 litersperminute
FlowRate
Anion,Cation,andMixed
Type
BedExchanger.
EnergyGeneration
415,342kw
68
BEST AVAILABLE
DOCUMENT
Max/Min Load
Capability From0to 100% load.
PlantHeatRate
onCombinedCycle 7,335 kj/kW-Hr
Number of Normal Normal,300 startsper
and Fast Starts 5,000 firedhours,and
Fast',-600startsper
5,000 firedhours.
Fuel consumptionat 30 0C
FuelGas 28 Kg/Sec
FuelOil = 19.0Kg/Sec.
PlantLoad Factor 70%
V. A4:'. .,L. ..j.
. . . . . . . . . . ...U., . ..
69
BEST AVAILABLE DOCUMENT
TheChemical water treatment is ofvital importance in
asteam powerplant.- Theuntreatedwaterwhichcontains
silica and othermineral contaminations becomes very
harmful to the metallicsurfacesofboilerand turbine
when heated up to high pressure and temperatures.
Thence a chemical-section
withskilled chemists and
modern equipmenthas beenestablished.
WATERTREATMENTPLANTUNITS I&II
ClarifyingReactor
2Nos.
dia 4200 mm
Ratedcapacity
63 Cu.m/hour(each)
Minimumcapacity
26 Cu.m/hour (each)
Maximumcapacity
70 Cu.m/hour
PressureFilter
Dia3000mm
Operatingoverpressureof 6Kp/Sq.Cm
Fillingunderlaying bed quartz sand
D 2/4 ,2.5 Cu.m
Filtering Fillingquartz sand VP-2 11.7 Cu.m
AirReceiver
Dia2000 mm
70
BEST AVAILABLE DOCUMENT
Volume
Operating overpressure
OperatingTemperature
Ferric ChlorideDissolvingTank.
Dia 1600mm
Volume 2Cu.m for 20% FeC1 3
Measuring vat of dia
Volume of
Operating temperature
Rotary limeslakingapparatus
dia800 mm
Maximumdailycapacityof
Stirrerof dia
Volumeof 1.5 Cu. m for
Iydrocyclone
of 6Cu.m/hourfor
StorageTankdia
Volume
Stirrerofdia
Volumeof
10 Cu.m
6Kp/Sq.Cm.
4r"C
1000 mmwithworking
0.6 Cu.mfor 10% FeCl 3
450C
4.5 tons.
1400 withworking
20% CaO
20% CaO
2800mmwithworking
25785 Lit. for 20% CaO
1400mmwithworking
1.5 Cu.mfor 3%CaO
71
BEST AVAILABLE DOCUMENI
HYDROGENPRODUCTIONPLANTUNITSI&II
BAMAGELECTROLYSER
MaximumVolt
MaximumAmp.
112 gasoutlet pressuremmW.C.
02 gas outlet pressuremmW.C.
H2 gaspurity
02 gas purity
112 gasMax. capacity
Feed Waterrate
Compressors
Ist stage pressure
2nd Stage pressure
3rdStage pressure
Maximum rate
76V
0
560 A
200
200
99.9 +0.1% Vol.
99.5 + 0.3% Vol.
9m
3
/hour
0.9-1.0 litreper
2Nos.
5.7Kp/cm
2
n p 2
39.0 Kp/cm
.175.0K.p/cm
2
14 litre/minute
DEMINERALIZATIONPLANTUNITSI&II
WeakCationExchanger
Numberof filters
Chargematerial
Functionalgroup
2Nos.
CC-3
R-COOH
BEST AVAILABLE DOCUMEN4'7 2
Bed depth
Water treated
Flow rate
StrongCationExchanger
Number of filters
Charge material
Functional group
Bed depth
Water treated
Flow rate
WeakAnionExchanger
Number of Filters
Charge material
Functional group
Bed depth
Water treated
Flow rate
StrongAnion Exchanger
No. of Filters
Chargematerial
Functional group
iST
1470 mm
5000 m
3
20-45 m
3
/hr.
2Nos.
C-20
-S03-H
1270 mm
3
1406 m
20-45 m
3
/hr.
2 Nos.
A-30-B
- NR2
1270mm
1406 m
3
/hr.
20-45 m3/hr.
2Nos.
A-1O1-D
-NR3
1VL )3 0 DCUtIME N
Beddepth 1270mm
Water treated 2343m 3
Flowrate 20-45m
3
/hr.
StrongAnionExchanger
No. of filters 2Nos.
Chargematerial A-101-D
Functionalgroup - NR3
Beddepth. 1260mm
Watertreated 75000m
3
Flow rate 20-45 m
3
/hr.
MIXEDBED
No of Filters. 2Nos.
Chargematerial C-20,A-101-D
Functionalgroup S03,-HNR3
BedDepth 360 mm,720
3
12000 m
Watertreated
Flowrate 20-45 m
3
/hr.
SOFTENER
No of filters 2Nos.
ChargeMaterial C-20
Functional group S03-Na
77h'~~ BEST VAj:; 7
74
Bed depth 1380 mm
Water treated
360 m
3
Flow rate 3.5 - 14 m
3
/hr.
WATERTREATMENTPLANTUNITSIII & IV
The watertreatment plantincorporates the following
principal equipment.
TwoNos.Clarifiers. 180m
3
/hrCapacity
each.
OneNo. Clarifier is as stand-by,
operation.
Max.pressure 6.0 Kg/cm
2
FourdoubleChamberfilters(three
operational filtersand onefor
hydraulic overloading).
Diameter 3400.mmLoadedwith
anihracite.
Bed Height. 0.9m ineachchamber
6.0 Kg/cm
2
Max. pressure
FourH-Cationicfilters
(Twosets of H-cationic filter)
Diameter 2600mmloadedwith
C-20 tothe height
2.OmandC-433 in
thepreceding filter
to 1.5m.
Height
accordingly
:max.pressure
6.0 Kg/cm
2
BEST AVAIL' 1:. ' "
:max.flowrate 80.Om
3
/hrs
TwoFirst stageAnionfilters
Diameter 26mm filled with
A-30-Bdoulite
resin,to the
height0.8 m.
2
Inletmax. pressure
6.0 Kg/cm
max. flow rate 80.0m
3
/hr
Decarboniser
The chargedmaterial is Reaching 3
Rings output.
150m/hrs.
H-Cationic filterIIndstage 3Nos.
The three filter chargedwith C-20resins
Diameter 2600 mmloadwith
-C-20to the height
0.Sm
ThreesecondstageAnionitefilters
Diameter 2600mm filledwith
A-101-Bdoulite
resin to the height
of 0.81 meter.
OneNo.H-Cationitefilterthirdstage
Diameter 2600mmfilledwith
C-20 douliteresin
76
BEST AVALL
One thirdstageAnionitefilter
Diameter 2600mm filledwith
A-101-BBoujite
resinto the height
0.8m.
The tanks associatedwith the water conditioningplant
are as follows.
Coagulated andlime watertank
Blow down tank forclarifier
Decarbonized
watertank
Settling tank for backwashing
water from mechanical filter
TwoNos demi watertanks
Tankofauxiliaryclarifiedtank
Tank ofAux.Demi watertank
Tank for repeateduse of Sodium
hydroxide
Clarifiedwater storagetank
oneNo.
DEMIWATERPRODUCTION
Demiwaterproduction/hr.
Storage tanksatW.T.Plant
Contaminated tank
200m3K?
30m
3
x1
10Om
3
2x100
400m
3
x1
400m
3
x1
100
3
x1
.
50m.
3
5000m
80m
3
/hr
800m
3
1000m
3
each
77
BES AAII~u DIJ~\
Purecondensatetank 1000meach
TotalStorage
Capacity
3800m
3
ChemicalStorageTanks
Ammonia sol storagetank. 30m
3
Caustic SodasolutionStoragetank30m
3
x2
SulphuricAcidStoragetank
2Nos.
Clarifiedwaterproduction
H2PLANTUNITSIII &IV
Hydrogen plant consists of
equipments.
Electrolyser
Maximumampere required
Maximumampere required
Max.
production
ofeach
electrolyser
Maximumpressureofelectrolyser
Maximumoperatingtemperature
RECTIFIERS
InputMax. volts
Max.Amp.
Outputmax.volts
max.Amp.
3
30mx2
180m
3
/hr
following principal
2-Nos.
72,Volts.
330 Amp
4.3 m
3
/hr
10.0 Kg/cm
2
800C
2Nos.
220 V
330 Amp.
72 V
330Amp
BEST AVAILABLE 1'10C . ,78
DRYERS
Dryers are charged with
rcgeneratedwithsteam.
RECEIVERS
Eachset consistsof twoNos.
receivers Filledat maximum
pressure
Eachreceiver
capacity
Safetyvalve setting
Diameter
CarbonDioxidereceivers
Capacity
Total capacity
Safety
valve setting
Designpressure
WATER TRE IENT PI.NT
2Nos.
Silica gel which are
10 Kg/cm
2
3
10.0m
11.5 Kg/cm
2
1516mm
2Nos.
1Om
3
each
3
20 m
1.1 Kp/cm
2
13.0Kgfrm
2
AT 600 W C. C. V
Rawwatersuppliedfromthe canalis pumpedto a water
pre-treatment ,where it is clarified, filtered and
stored in two filteredwater storage tanks. Three
filtered wate: transferpumps takesuction from the
filtered waterstoragetankandprovidewaterfor the
makeup demineralizer, the servicewater system, the
1EST AVAILE!L
potable watersystemandthe existingwater treatment
system.
Two treatedwatertransferpumpsareprovidedto supply
filteredwaterto the filteredwaterstorage tanks from
the existingwater treatmentsysf
Adual train,threebeddemineralizerwillbe supplied
to provide cycle makeup to the STAG units.
Demineralizer waterfromthe outletofthe mixed bed
'iange units willbe stored in- the demineralized
r storage tank.Twodemineralized
transfer pumps
will be provided to the two STAG unit condensate
storage tanks ortheexisting powerplant.The existing
demineralizer"
system can alsosupply water to the
demineralizedwaterstorage tank.
The servicewatersystemconsistsof a service water
tank, two servicewaterpumpsanddistributionheader.
HYDROGENGENERATINGPLANTAT600MWC.C.P
Theplantconsists oftwoelectrolytic
generating
sets
1& 2having gas generating
namely as CellBankNo.
rapacityof 11.2cubicmeters perhoureach.
80
BEST AVAILMWLA '
CILLERPLANT
Three units forairconditioningof Central Control
Room buildingandAdmn.Block,having provision for
heating as well has been supplied by M/s Trane
Engineering Co., U.S.A.Thesingle stage absorption
couldgeneratoris designedto use 12 psigsteamorhot
water upto 270
0
F.Workingfluids.inthe machine are
lithium bromide, the absorbent , aDd water the
refrigerant.The steamorhotwaterisusedto reclaim
refrigerant fromthelithiumbromide, the absorbent,
and water the refrigerant.Thesteamorhot -water is
used to reclaimrefrigerantfromthe lithium bromide
solution to sustain the refrigeration
cycle. Each
machine has fourinternal sections,the
concentrator,
condenser, evaporator and absorber. Additional
components include heatexchanger,electronic control
panel , .neumatic control panel, operating
valves,solution
pumpandpurgepump.
BEST AVAILi'J_ r,'
TheunitsI&II useGasasFuel , whileIIIandIVare
provided- withdual fuel firingarrangements.The four
gasturbines runonNaturalGas/H.S.D.oil.
All the threegasesare intermixedwitheachother and
then supplied to thevarious Generating units. The
following is theallocationofGasfor Thermal Power
StationGuddufromvariousGas fields:-
1- Sui 110 MHCFD
2- Mari 100 MMCFD
3- Kandhkot 75 MMCFD
Whenall the tengeneratingunits-areoperatedon full
load, theabovegasquotafromallthe fields is not
sufficient andhence oil firinghas to be carried out
presently2elevationof boilerofunit4are operated
on FurnaceOil to utilizefull capacityof the Guddu
power generatingcomplex.
As this quota shall remain the same even after
commissioning of theTwoGas turbines of the under
constructionexpansionproject.Hence it is planned to
BEST AVAILABLE s8
run units 3&4on furnaceoil for regular operation
and the amountof the NaturalGas so saved shall be
diverted to thenewlycommissionedGasturbines.
OILSTORAGE
The details ofoilstorageTanksandtheir capacities
areelaboratedhereunder :-
TANKNO. CAPACITY FUEL
1
5500 M.T FurnaceOil
2
5500M.T
3
3500M.T
4
3500M.T
5
3800M.T
6
3800M.T
7 3800M.T
8
12055550 LTS
9
12055550 LTS
10
12055550 LTS H.S.D. Oil
11
1345894
LTS
"
"
12
1345894
LTS
of
10222870 LTS
16
83
BEST AVAILABLE
DOCUMENT
CHEMICAL
ANALYSIS
I1 S). OIL
SpecificGravityat 15
0
C
0.82-0.87
ViscosityKinetic at 38
0
C 1.6 - 5.5 CS
Sediment (%Wt)
0.01
Ash (%wt)
0.01
Carbonresidue, conradsion (%wt) 0.1
Sulphercontents (%wt)
Less than 1.0
Water (%wt)
0.05
FlashPoint,penskymarten
650
Higherheatingvalue (KJ/kg)
46,000
NAT U]RAL CAS
MARI SUI KANDHKOT
(Raw)
Methane (%volume ) 71.2 88.52 79.2
Ethane (%volume)
0.2 0.89 1.1
Propane (%volume)
- 0.26 1.1
Butane and higher
(%volume)
- 0.37 0.4
Nitrogen (%volume) 19.5 2.46 16.6
Carbondioxide (%volume) 9.0 7.35 2.5
Hydrogensulphide
Gr/100 cmft) 0.1 92.2 30.8
84
BEST AVAILABLE DOCUMENT
Mercaptansulphide
3.8 1.2
Higherheatingvalue
(KJ/NM
3
) 26,940 34,74031,350
FW 1NAC E OD L

Flashpoint,C(F ) 66 (150)
Viscosityat 500C
(122 UF) Min. 11.8
Max.
75
Su'.p'ier , % byweight,
Max%
3.5
Water,% by volume,
max.
M
Sedimentbyweightmax.
0.12
Pourpoint0C
.(OF)Max.
.24(75)
Calorific valueKCal/kg
10000
(BTU)/lb)Gross,Min.
(1.8000)
Specificgravityat
15.5 oC(60
0
F)Max.
0.96
GAS PIPELINEANDDEHYDRATION
As stated inearlierparagraphs,
Gasis supplied
to
fromthreegas fieldsaroundthis station.
All
Guddu
the three gas lines are beingmaintained
byWAPDA.
The
Sui andMarl are also being
Dehydration
plants at
lookedafterbyWAPDA.
BEST AVAILABLE DOCUMENT
85
Since these linesareburied atadepthof 3ft. from
averagegroundlevel henceinvolve cathodic protection
systemto avoidcorrosioneffectsonpipesurface.
Mari Guddu Gas pipeline was commissioned in
February,1986,but theC.P.Systemwascompleted later
and handed to thisofficeon 18-11-1986 . 5 Nos.
Transformers Rectifiersof 24 VDC/50ampwere installed
at fiveplaceson theentire linetomaintainmax PSP
value as -1.5 Vatdrainpointsandmmn-0.85 V on
remaining portion. Butdueto laying of circulating
water lineandKandhkotGasLine, anodegroundbed of
C.P. StationNo.5wasdisturbedandMariGas Line near
Gudduend is unprotected.Atpresent.C.P.station No.5
hasbeen shiftedto otherlocation.
A dehydrationPlantsuppliedbyM/sSiirtec Italy has
beeninstalledatMari andSui GasFieldto reduce the
water contentinthe gasto 7Lbs/ MMSCF.. Triethylene
glycol is usedas absorbentforthispurpose.
ThePlantcomprisesof:-
- Reboiler
86
BEST AVAILABLE DOCUMENT
- Absorber
or contact
tower.
- GasCooler
Glycol
/Glycol
heatexchanger.
-
ondenser
- Anoverhead
- A stillcolumn.
- Aglycol filter.
- A glycol
purifier.
- Kimray
Pumps.
- Corrosion
Inhibiter
pumps.
GASMIXING
STATION
viz
Since
theGas received
from
three
different
fields
Mari,
Sui andKandhkot
have
different
analysis,
hence
a
all
Mixing
Station
hasbeen
installed
to intermix
Gas
the gases
before
combustion.
Highlights
of Gaslines
DIAOFPIPELINES
GAS
DISTANCE
Sui
60 K.M.
16" Dia
Mari
60 K.M.
20" Dia
Kandhkot
50 K.M.
16" Dia
BEST AVAILABLE
DOCUMENT
87
ARBORI(GUL
1
TURE
Arboriculture sectionwasestablishedin'1972. At that
time area ofPowerHouseandResidential Colony was
totallybarren/desertedandunderconistruction.
Total area of PowerHouseandresidential colony is
about 903 acres. In1973 a qualified Arboriculturist
was appointed as Arboriculture Superintendent for
developing the areabytreeplantationand parks to
improve the environmentalconditionsbecauseclimateof
District Jacobabad is veryhotandheavy storms are
blowing during majorpartofyear.
area
Now-a-days the residentialcolonyandPowerHouse
is developedwithgrassygrounds,parksand thousands
of trees, shrubetc.Therearewell developed grassy
play groundsi.e. Cricket,LawnTennis, Golf, Hockey
and Foot Ball.
Thedevelopments
ofArboriculture
sectionhas improved
reducing
the environmental
conditions
of theareaby
its ambient temperature
byapproximately
5
0
C Moreover
BEST AVAILABLE DOCUMENT
89
the quantity of dust blown with the air has
considerably
beencontrolled,
consequently
improving
the lifeof thepowerplantequipment.
The lush greenviewof theareaproduces
a pleasant
effect
to the viewersandhasagreatpositive
effect
onthe healthofthe inhabitants.
90.
BEST AVAILABLE DOCUMENT
CO L O N
Guddubeing in theextremedesertedcornerofthe Sind
Province andbeing farofffromanycity/town , Wapda
has to provideliving facilitiesto all the employees
engagedon the complexforsmoothworkingof the power
station.Keeping inviewthis factsufficientnumberof
residential units ofvariouscategories , a 50 Bed
Hospital , an IntermediateCollege,Two High Schools
(Boys and Girls) ,FourMosques , Community Centre,
Club,Market,Bank ,PostOffice,Telegraphofficeetc.
all areaccommodatedin theColony.
The Colony is situatedat adistanceof2KM from the
Power Station,theareaof colonyis about500 Acres.
About2600 residencesofdifferentcategorieshavebeen
constructed
in fivestagesof construction
of Power
well planted, giving
Station The colonyisvery
pictureof anymoderntown.
BEST AVAILABLE DOCUMENT
91
Wapdahas furnished adequateeducational
facilities
for
the wards of the employees,
workingat Guddu
One
Intermediate
ScienceCollege,TwoHigh Schools,
(One
for Girls and the otherfor Boys) and one Primary
School are functioning
at Guddu. Wapda College and
Schools have.shown distinguished
and meritorious
performance
in' theeducational
level throughout
the
Districtand Board.
92
BESTAVAILABLE DOCUMENT
For recreational activitiesofemployees, Wapda "has
establishedonecommunitycentreforlabourhavingan
auditorium whichhasmultiferoususessuchas meeting
hallandCinemahall , besidesotherLabour functions,
Readingrooms, Indoorgamesetc. arealsoprovidedat
thisCentre.
An officersClubof-the standardofA Class Gymkhana
has been establishedwithvarious sports facilities
such as Badminton ,Squash,HardandLawn Tennis
Golf, SwimmingpoolandanAuditorium.Oneplay ground
where arrangementsofoutdoorgameslikeVolley Ball,
Hockey, Cricket, Football etc. also exists. Guddu
producesteamsatDistrict/Divisionlevel in allgames
vizCricket,Football,
VolleyBalletc.
93
BEST AVAILABLEDOCUMENT
IEALTI
Health is one ofthe basic rights of human being.
Wapda,keeping inviewthisnecessity
hasprovideda 50
Bed centrally
Air conditioned
Hospital
for its
employees.
This Hospital iswell equipped with all
necessary
modernequipment
likewise,
X-rays, E.C.G.,
Ultrasound
etc. The Clinical
Laboratory
is also
functioning
forcarryingoutalltheessential
medical
tests. Theoperation
Theateris equipped
with modern
Surgical equipments
wheremajorsurgicaloperations
are
being carried out. Theconsultation
and Medicare
is
provided in all the basicspecialities
viz Surgery,
Medicine,
Gynae,Dental, EyeandE.N.T. Indoor Wards
are fully equipped and are also air-conditioned.
Authority
has allowedemergency
treatment
including
hospitalization
and
to surgery
non-wapda
patients
living in thenearbyvillagesonnominal charges as
that of Govt. CivilHospital
rates. This generous
gesture ofAuthority
hasearnedawillandblessings of
the poorpeoplearoundGuddu . TheHospital is headed
byMedicalSuperintendent
withacrewof 8 specialists
Doctors,OneDentalSurgeon, 6MedicalOfficers,
3lady
MedicalOfficersandnecessary
paramedical staff.
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COMPUTERISED
MAINTENANCE
MANAGEMENT
SYSTEM
GudduThermal
PowerStation
haibeenselected
as pilot
station
for the introduction
of a Computerised
Maintenance
Management
System.
Its objective
is tooptimise
theeconomics
of carrying
workwithinthe accepted
limits
of
out maintenance
safety
and operational
needs
thereby
improving
andreduction
in the 'down
availability,
e~ficiency
time' of thethermal
powerplant.
The Maintenance.Management
Systemwillincludc:-
1) Planned
Maintenance
andWorkControl.
2) Outage
Planning
andControl.
3) Stores
Management
Control.
1) PLANNED
MAINTENANCE
ANDWORKCONTROL
SYSTEM
SHORTTERMPLANNING
plant
The objectives
ofaP.M.System
aretokeepthe
concerned
inacontinuous
reliable
condition
capable
of
carrying
outthetaskforwhich
itwasdesigned.
It is not intended
to evaluate
theeconomics
of planned
presently
maintenance
systems
butit should
bethata
whether
the
designed
programme
will
show
benefits
accrued
bythereduction
of maintenance
savings
are
or increased
availability
of plant
by the
costs
BEST
AVAILABLE
DOCUMENT
95
reduction in breakdowns or an increase in plant
efficiency.
- Acomputeraidedmaintenance managementsystem known
as T.I.M.S. will be used to supply immediate
information to enableengineeringstaff to plan an
effective work programme for each maintenance
departmentanaDayto Daybasis.
- The computersystemwillhavefacilities to store
pre-definedworkin routinemaintenanceform, standard
trouble report rectification,normal unit Off Load
work.
- Aworkbankconsistingof jobs inprogress, awaiting
assessment orawaitingresourcesandmeans of showing
progressof jobs throughtheWorkControlsystem.
- Recordingofcompleted jobs. i.e) HISTORYFILING
WORKSPECIFICATIONS
- willbe preparedoneachitem of
equipment.
job
The workinstructionwillsetoutindetailhowa
is to- be performed and will provide precise
instruction,
stepbystep inthecorrectsequence.
- Such detail as drawings showing assembly, etc.
clearancesetc.
96
- Typeandsizeof bearings.
BEST AVAILABLE
DOCUMENT
- Liftingandslingingmethods andweightof equipment
to be lifted.
The above information will be stored in the
computerisedsystemT.I.M.S.
SPARESMATERIALSANDSPECIALTOOLS
It is obviouslyundesirable toplanor start a Job
withoutensuringthatthespare partsorspecial tools
requiredto do the Jobare available.
The computerised systemto be installedwill have a
terminal link between theWork-Control Office and
Stores, therebyhavingthe facilitytocheckthat items
are available.
2) MAJOROUTAGEPLANNINGANDCONTROL
This section known as Long Term Planning has the
followingobjectives:-
out
i) To -ensure unit overhaul
are carried
effectively
but in the minimum time, thereby
unit costs an improving
plant
reducing
availability.
ii) EnsuringthatStatutoryrequirements
are being
met:
NETWORKS ANDWORKLISTS
large projects
suchasmajor overhauls
of main
For
plant,itwillbe necessaryto preparemasternetworks,
BESTAVAILABLE DOCUMENT
97
work lists,sub-networksetc.
A worklistwillbepreparedforeachmaster activity
andwillconsistof alistofdetailedjobs which will
successfullycompletethatmasteractivity,fromthisa
sub-networkcanbedrawn.
A computerised systemknownas ARTEMIS7000 will be
used to inputthis informationand with approximate
durationsshowntodoeachjob.
Atimeanalysis andresourceanalysisschedulewill be
produced usingCRITICALPATHANALYSIS. Hence duration
of unit outage will be determined, together with
resources neededtodo the work.
STORESMANAGEMENTCONTROL
The initialstage willbe to identifystores items and
produceastorescatalogueshowingallconsumables and
spares used. Thiswillbestored ina data bank an
T.I.M.S.softwarepackage.
recognised
A classification
andcodingsystemusinga
method, namelyauniversalcommoditycodesystem will
beadopted.
The systemdefinesconsumablesandplantspares items
and will identifyduplicatedstockandgivea logical
sequenceof stockingarrangements
and layout.
98
BEST AVAILABLE DOCUMENT
Level of controlof stockie)maximumandminimum re-
order levels will beassignedto each commodity in
order to minimise capital investment in stock yet
satisfy the demandsfromstock using pre-determined
levels.
A bonding systemwill beimplemented whereby spares
will be identifiedtoensurethatbefore work on a
particular jobonitemof plantisstoredthe necessary
sparesto do this workareavailable.
Computerised Maintenance Management is now being
set up andworkhas beentakeninhand-withateamof
WAPDA EngineersandBEIconsultants.
The timescale allocatedisaperiodof twoyears.
99
BEST AVAILABLE DOCUMENT
ONE LINE DIAGRAM
(ELECTRICAL SYSTEM)
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BESTAVAILABLE DOCUMENT
STAFF (8)
POWER GzENERATT NG UN ITS
T_ P_S GUDDU
(SIGNIFICANT
UNIT CAPACITY MAKE
NO. (MW)
1 110 CZECH
S
2 110 CZECH
- T
3 210 USSR
E
4 210 CHINA
A
5 100 U.S. A
6 100 U.S.A
7 100 U.S.A
8 100 U.S.A
9 100 U.S.A
10 i00 U.S.A
DATA UP TO 31. 12. 1991)
D.O. C GENERATION RUNNING HRS
' (Mkwh)
30.03.74 9414 118237
06. 10.74 8002 102186
07.11.80 13926 79294
29.12.85 6121 35124
18. 12.87 2128 29382
22.03.88 1818 30298
20.12.85 3542 39286
01.04.86 3868 I 42311
06.03.86 3833 43013
12.04.86 3140 35382
BEST AVAILABLE
DOWY
UNIT WISE PLANT PERFORMANCE
SINCE COMMISSIJONING
UP TO
31-.12.1991
UNITS IN MKWH
5.63%
16.57%
6.93%
6.35%
14.34%
3.81% L')
24.96%
.........
SUNIT_ 1 U UNIT-2 El UNIT-3 UNIT-4
U UNIT-5 E--
UNIT-7 II UNIT-8
UNIT.-6
lUNIT-9 [[IUNIT- 10
BEST AVAILABLE DOCUMENT
UNIT WISE PLANT PERFORMANCE
SINCE COMMISSIJONING UP TO
31.12.1991
UNITS IN MKWH
1326
14000
12000
10000
0414
8002
8000
6121
6000
4000 36 3833
3140
.2128
2000 1818
0
UNIT- UNIT- UNIT- UNIT- UNIT- UNIT- UNIT- UNIT- UNIT- UNIT-
1 2 3 4 5 0STAVILABLLDOCUNAENT Jo
I.iNI'I
1
WISE PLANT PERFORMANCE
SINCE COMMISSIONING
UP rl'O
:31. 1. 1.991
(RUNNING HOURS)
G.30
'
6 21.32%'
.....
X)XX;;... L.. ..
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JUNIT-9 19 UNIT- 10
BEST AVAILABLE DOCUMENT
UNIT
WISE PLANT
PERFORMANCE
SINCE
COMMISSIONING
UP TO
31.12.,1991
(RUNNING.
HOURS)
"-120000
-118237
102186
100000
79294
60000
40000-"
"."" 423ij
43013
40000 - 35382
29382
30298
20000."--
UNIT-
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UNIT',-.
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UNIT-
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9
1 2. 3 4
BEST AVAILABLE
DOCUMENT
0
10
UNIT
WISE
PLANT
PERFORMANCE
FOR THE YEAR
1991
(RUNNING
HOURS)
IO~l 9.91.

A1
' ii 7.517
10.60% .......
,':: .'', ........... ... ..
..,...........
10.297
10.72%w
10.93%
10.66-
10.78%
lgUNIT-4
MUNIT-5
[5UNIT-I
:UNIT-Z
RUNIT-3
UNIT- 10
*UNIT-7
ULUNIT-8
.uNIT-9
UNIT-6
BEST AVAILABLE
DOCUMENT
/o
UNIT WISE PLANT PERFORMANCE
FOR THE YEAR 1991
(RUNNING HOURS)
9000
8000
800 --
7986 7040 8005 1417
7662 7006
7304
7000
6239
6000
5595
5000 t
4000 -
3000
2000
1000
0-
UNIT-
UNIT--
UNIT-
UtIT- UNIT- UNIT- UNIT- UNIT-
UNIT-
UNIT-
1 2 3 4 5 6 7 8 0 10
BEST AVAILABLE DOCUMENT
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DOCUMENT

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