JAMSHORO POWER COMPANY LIMITED

JAMSHORO POWER COMPANY LIMITED

LIST OF MAINTENANCE WORKS

AND

MODIFICATIONS CARRIED OUT

RECENTLY
BY JAMSHORO POWER COMPANY

AT

THERMAL POWER STATION JAMSHORO

AND
GAS TURBINE POWER STATION KOTRI

March 2006

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 JAMSHORO POWER COMPANY LIMITED
List Of Maintenance Works And Plant Modification, Recently Carried Out By
Jamshoro Power Company Limited.
A) THERMAL POWER STATION, JAMSHORO

Unit No.1 (250 MW Oil Fired).

INSTRUMENT SECTION
S.# Name of Maintenance and Date of Amount Remarks
Modification Works Completion
01 Solenoid Valves of Warm up Trip & Oil Feb-2003 60,000/- Efficient operation / Closing of
Fuel Trip replaced with new one. Trip valves ensured
02 5v,120 Amp: Logic Power Supply for Oct. 2003 80,000/- -
Auto Burner System(ABS) replaced.
03 Multi point analogue control card of March 2003 225,000/- -
Auto Boiler Control (ABC) replaced.
04 Single Board Computer Card SBC 02 May 2004 250,000/- -
replaced at Auto Burner System (ABS)
replaced
05 Input Card CA1*A replaced at Auto June 2005 150,000/- -
Boiler Control (ABC) replaced
06 Faulty Cable Connectors of C-Level Dec. 2005 34,000/- -
Burner replaced
07 Burner Control Keyboard of A Level Dec. 2005 700,000/- -
Burners replaced with new one.
08 Level Switch of HP Heater No.6 Jan. 2006 190,000/- -
replaced with new one and calibrated.
09 Centum Monitor of Auto Boiler Control Jan. 2006 960,000/- Efficient & reliable monitoring of
System replaced with new one. the Boiler Control System
ensured.
10 Bouncy Level Transmitter of Steam Jan. 2006 175,000/- -
Converter Tank Level replace with new
one and calibrated
11 Hard Chrome Plating and polishing of Jan. 2006 81,000/- Burners Control Operation made
pistons and cylinders of burners smooth and reliable.
pneumatic cylinders
12 Cable Connectors of Flame Detectors Dec. 2005 18,000/-
of burners replaced.
13 Replacement of modules CAI*A for Jun.2005 150,000/-
Auto Boiler Control System.
14 SBC-02 Card replaced at Auto Boiler May-2004 250,000/-
Control System.
15 MAC 3*B Card replaced at ABC March 2003 225,000/-
System.
16 Power Supply for ABS Logic Cabinet Oct. 2003 70,000/-
6V, 120 Amp: replaced.
17 Replaced flue gas temperature May 2003 52,800/- Without these thermocouples
thermocouples SCAH regulators can not be put
on Auto & even no monitoring of
flue gas temp: in C.C.R causing
difficulty in boiler operation.
18 Replaced position feed back April, 2004 250,000/- Make HP Bypass Valve operation
transmitter at HP Bypass Control valve satisfactory.
(PV04)
19 Replaced Electro Pneumatic Positioner April, 2005 132,000/- Make F.D Fan Regulator
of FD Fan Regulator operation on Auto which was
locally controlled.
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 JAMSHORO POWER COMPANY LIMITED
20 Replaced I/P transducer at primary Dec. 2005 220,000/- Without reliable operation of
spray regulator (TV-76) primary spray regulator MS
Temp: can not be controlled so
fault removed by replacing I/P
transducer.
21 Replaced R.O temp: controller (TC-26). Dec. 2005 254,000/- R.O temp; was controlled locally
so after replacing faulty
Temperature Controller now it is
controlled on Auto.

ELECTRICAL SECTION
Sr. Name of Work Date of Amount Remarks
# Completion
01. Replacement of 6.6KV Power Cable of December 2005 1188750.00 The reliability of said supply
Intake Pump House sources has increased as
insulation of originally installed
power cables was weak.
02 Installation of CVCF Equipment 9478600.00 The reliability of CVCF system
received on Dt: has increased has the spares
February 2006, of old CVCF Power Supply
installation is in system have become absolute.
process.

BOILER SECTION
Sr. Name of Work Date of Amount Remarks
# Completion
01. Replaced the air preheater side-A May 2004 Rs.1160690 Fault removed and unit made
lower support bearing by new one. reliable
02. Replaced the complete hot reheater Dec.2005 Rs.26600000 Boiler reliability and loading
tubes / coils increased
03. Replaced the heating elements of Air Rs.28000000 Loading of the unit improved
preheater elements both sides Dec.2005
04. About 1369 M² area of Air preheater Dec.2005 Rs.1120000 Flue gas leakages points
hopper and exhaust flue gases duct attended.
was repaired by patch work
including insulation and cladding.
05. All the 38 Nos soot blowers were Dec.2005 Efficiency and reliability
completely overhauled improved.
06. Complete water washing of heating Dec.2005 -do-
tubes
07. Main ceiling ring of isolating device Dec.2005 -do-
for main steam line was replaced
08. Replaced the damaged flexible gear Feb.2005 -do-
coupling and taper roller bearing of
F.D Fan B-side

(TURBINE SECTION)
Sr. Name of Work Date of Amount Remarks
# Completion
1 High pressure water jet cleaning of May 2004 Condenser vacuum improved.
condenser tubes
2 Condensate pump-B diffusers and May 2003 Rs.300000 At 125 MW two CPs were in
impellers manufactured from local operation to maintain the
market level. After said work one CP
is maintaining the level.
3 Seats of min. flow recirculation July 2003 Nil Amperes on electric motor
valves of BFPs repaired in workshop reduced. Aux consumption
saved
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 JAMSHORO POWER COMPANY LIMITED
Unit No.2 (210 MW Gas / Oil Fired).
(INSTRUMENT SECTIOIN)

S.# Name of Maintenance and Date of Amount Remarks

Modification Works Completion
01 Complete 3-Way Valve assembly Sep. 2003 6000000/- Operation of the Oil Burners of
including hydraulic actuator replaced at 2nd elevation ensured.
2nd elevation.
02 Transceiver cables and 9IIC Card Dec.2004 110,000/- Safe & reliable operation of the
replaced at furnace safeguard and Furnace Safeguard Supervisory
supervisory system (FSSS) and System (FSSS) of Boiler ensured.
simulation test performed.
03 Magnetic operated switches of seal oil July, 2004 80,000/- Safe & reliable operation of the
tank level replaced and circuit seal oil tank level ensured.
modified.
04 Fault attended on C-2 Burners by Feb. 2006 80,000/- Long time out of order burner
replacing the Transceiver Cable and brought into service and hence
repairing the Transceiver Card. loading of the unit increased.
05 Level Vessel with Level Switches at Feb. 2006 230,000/- Safe & reliable operation of the
Stator Cooling Water Tank completely stator cooling water tank level
modified by replacing the vessel and monitoring and control ensured.
magnetic operated switches with better
quality (European make)
06 Replaced Reheat Steam Temperature Feb. 2003 120,000/- Fault rectified
Transmitter
07 Replaced H.P. Oil Servomotor travel Aug. 2003 18,206/- Without H.P Turbine Valve
Sensor. Position at C.C.R the locally
unloading of turbine becomes
difficult so faulty one replaced by
new one.
08 Replaced faulty ZJM Pneumatic R.C Oct. 2003 9,00,000/- Without GRF Regulators it is very
Fan Regulators. difficult to control R.H.S
Temperature by replacing these
regulators now RHS
temperatures are controlled on
Auto from C.C.R

(ELECTRICAL SECTION)
S.# Name of Maintenance and Date of Amount Remarks
Modification Works Completion
01. Installation of D.C Batteries January 2002 Reliability of DC system after
3400000.00 replacement of 12 years old
batteries.
02. Replacement of 6.6KV Power Cable of December 1981250.00 The reliability of said supply
Demi-Plant & Intake Pump House 2005 sources has increased as
insulation of originally installed
power cables was weak.

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 JAMSHORO POWER COMPANY LIMITED
(BOILER SECTION)
S.# Name of Maintenance and Date of Amount Remarks
Modification Works Completion
01. i)Replaced all 40 No coils of primary
supper heater, 80 Nos coils of
secondary super heater including their
inlet and outlet headers Nov.2003 44.34 Million Boiler loading on gas and
ii) Installation of additional spray reliability improved
injection attemperator for platen super
heater outlet header.
02. Furnace support beam refractory Nov.2003 2.97 Million -
works and masonry work at bottom /
hopper of furnace
03. Replaced the pressure control March 2004 0.149 Million To maintain the lube oil
regulator of boiler I.D.Fan-A by new pressure.
one

(WATER TREATMENT SECTION)

S.# Name of Maintenance and Date of Amount Remarks
Modification Works Completion
01. Rehabilitation / Replacement upriser Dec.2004 Rs.4824354 Performance of cooling tower
pipes and hot water distribution pipes has improved
alongwith related accessories of
cooling towers
02. Safety hand rail of cooling tower Dec.2005 Rs.286567 Personnel safety of working
persons in operation and
maintenance ensured.
03. Installation and modification of 8” dia June 2005 Rs.1569463 The frequent leakages in original
M.S. pipeline for feeding clear water installed underground piping
from pretreatment plant to demi plant required replacement.

(TURBINE SECTIOIN)

S.# Name of Maintenance and Date of Amount Remarks

Modification Works Completion
1. Major overhauling carriedout May 2002 30 Million -
2. Chemical dozing pumps replaced with May 2005 2 Million Failure of pumps and loss of
prominent Germany pumps chemicals decreased.
3. Retubing of condenser tubes Nov.2003 40 Million Improvement in vacuum and
problem of tube leakages
attended.
4. L.P heater drain pumps replaced with Nov.03 1.47 Million Reliability increased
KSB Drain pumps
5. Bearing cooling water pumps taken in Sept.03 Boiler feed pump bearings
service (Chinese had not taken these temperature decreased due to
pumps into service) cooling
6. Carbon bushes fixed on the shaft May 05 JPCL Frequent damage of gear
motor of feed water pump near Workshop decreased
bearing No.3.

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 JAMSHORO POWER COMPANY LIMITED
Unit No.3 (210) MW Gas / Oil Fired).
(INSTRUMENT SECTION)
S.# Name of Maintenance and
Modification Works
01 Replacement of Temperature
Indicating Switches of Double Contact
Type) on Boiler Feed Pump No. 1, 2 &
3 for sealing water Return Oil
Temperature Bearing No. 5 & 6 and
Drain Oil Temperature of Booster Side
of Thyoda Japan make.
02 Replacement of ZJM Pneumatic
Actuator on Secondary Spray A&B,
Gland Sealing & Condenser Level
Regulator.
03 Rehabilitation work on MZ-III Auto
Regulation System including
replacement of Chinese Components
with USA / Japan make Industrial
Standard Components, Exhaust
Cooling Fans etc.
04 Replacement of Instrument Air Line
Header of Boiler Front.
05 Installation of Motorized Actuator On
Load Feed Water.
Date of Amount Remarks
Completion
Dec. 2005 629,979/- Previously single contact direct
type temperature including
switches were installed on Boiler
Feed Pumps causing frequent
tripping of the pumps without
indication ultimately effecting the
load reduction. After replacing
these switches with double
contact type Thyoda Japan,
these unnecessary tripping has
been avoided resulting plant
efficiency and reliability
improvement.
Dec.2005 4085858/- These Regulators shifted to local
mode frequently due to complete
their useful life, ultimately very
difficult to control parameters.
After replacing these regulators
are controlled from A.C.C.R even
Gland Sealing and Condenser Level
Regulators are working on Auto.
Dec. 2005 500,000/- Most of the regulators working
on Auto mode like Feed Water,
Condenser level, Gland Sealing,
H.P Auxiliary frequently shifted
from Auto to “Manual” mode
due to malfunctioning of the
System’s module because of low
inferior quality components. By
replacing this compound now the
regulators are working more
efficiently on “Auto” mode
improving plant efficiency.
Dec. 2005 5070000/- A complete header of Instrument
Air line on boiler front of ¾” ∅
and 250 ft. length replaced with
new S.S pipe as the originally
installed M.S air line became
corrosive from inside. From this
header air supply to gas
regulator, G.R fan (A&B),
primary and secondary sprays,
SCAH and H.P Aux. Header
regulators. Moreover the
distribution air lines of ¼” ∅ and
100 ft. length of all these
regulators also replaced with
new S.S pipe.
Dec. 2005 124734/- Originally ZJM4 DBKIY
Pneumatic type regulator is
installed for low load feed water.
This regulator is used during
start up of unit. Some time due
to moisture in Instrument Air or
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 JAMSHORO POWER COMPANY LIMITED
due to trouble in any part like
torque motor, pilot valve of
regulator, this actuator not
operate properly causing delay in
the start up of machine. Keeping
in view the importance of this
regulator, a new motorized
actuator typeDKJ-4100 with
position feed back installed in
parallel to old type Pneumatic
actuator. Along with this
motorized actuator a local T.B
and Auto / Manual Station in
C.C.R also installed. This
actuator checked / tested and
took into operation. The
performance of the newly
installed Motorized Actuator is
much more time better than the
Pneumatic Regulator.

06 Work on Control cable damages due October 2003 500000/- All the Controllable repaired &
to fire incident on 19.10.2004. tested for proper alarms,
interlocks / protection.
07 Level switch with thermo state replace Sep. 2004 250000/- LP Bypass Start permission made
at LP Bypass Unit # 3 MRS No. 1849 healthy to avoid any damage.
dated 07.09.2004
08 Stator Cooling Water make-up August, 2004 230000/- To ensure reliable operation of
solenoid valve replaced and modified solenoid valve.
from 220V DC to 220V AC
09 Oil Gun Cylinders, Tilt/Secondary Air December 90,000/- To ensure smooth operation.
Damper piston rods hard chrome 2003
plated and galvanized.
10 Control cable for HPH replaced with Dec. 2005 1,20000/- HPH Protection made healthy.
new one.
11 H2 purity analyzer replaced with new Dec.2005 2,50000/- To ensure efficient monitoring.
one.

(ELECTRICAL SECTION)
S.# Name of Maintenance and Date of Amount Remarks
Modification Works Completion
01. Installation of D.C Batteries April 2003 Reliability of DC system after
3500000.00 replacement of 13 years old
batteries.
02. Replacement of 6.6KV Power Cable of December 1585000.00 The reliability of said supply
Pre-treatment Plant 2005 sources has increased as
insulation of originally installed
power cables was weak due
many joints.

(BOILER SECTION)
S.# Name of Maintenance and Date of Amount Remarks
Modification Works Completion
01. a) Replaced all 40 Nos Coils of primary Nov.2002 44.34 Million Boiler load on gas and reliability
super heater, 80 Nos Coils of 2ndary improved.
super heater including their inlet and
outlet headers.
b) Installation of additional injection
spray attemperator for platen outlet
header.
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 JAMSHORO POWER COMPANY LIMITED
02. a)Complete overhauling of boiler was
carried out I.DFan bearings, F.D.Fan 1.8 Million
bearings. Motorized valves, steam coil
air heater water washing, refractory Dec.2005 Reliability improved.
works, burner compartments, soot
blowers of A.P.H, all kind of pumps.
Expansion joints, Dampers etc.
b) Replaced the cold end elements of 7.8 Million
A.P.H.Both side.
03. 20 Tons boiler self auxiliary steam Feh.2005 Rs.1,35,00/- Leakages of aux.steam stopped.
motorized valve HS-395 (dia 3”) was
replaced.

(WATER TREATMENT SECTION)

S.# Name of Maintenance and Date of Amount Remarks

Modification Works Completion
01. Rehabilitation / Replacement upriser 2005-06 Rs.6549106 Performance of cooling tower
pipes and hot water distribution pipes has improved
alongwith related accessories of
cooling towers
02. Safety hand rail of cooling tower Feb..2006 Rs.293960 Personnel safety of working
persons in operation and
maintenance section ensured.
03. Replacement of Common blow down Jan.2006 Rs.1876724 Underground leaked pipe
piping 16” dia for cooling tower units- replaced.
1-4.
04. Modification of 10” dia M.S waste Dec.2005 Rs.2565166 Underground spreading waste
water piping for units-2,3 & 4 at water stopped.
pretreatment plant

( TURBINE SECTION)

S.# Name of Maintenance and Date of Amount Remarks

Modification Works
1 High pressure water jet cleaning.
a. Condenser tubes.
b. Heat exchangers.
2 a. Condensate pumps gland bushes
modified.
b. Re-routed the condensate pumps
gland sealing water pipe line.
c. Re-routed the condensate pumps
vent system.
3 a. Rehabilitated BCW system, which
was out of service since
commissioning of unit.
b. Strainers of BCW system modified.
Completion
a.Vacuum improved from 610
Dec.2005 mmHg to 640 mm Hg at 180
MW>
b.Over all thermodynamic
efficiency of turbine increased.
Nov. JPC Workshop a. Eliminated the chance of
2002 condensate ingress into 6.6 KV
driving electric motors.
b. No vacuum drop from the
glands.
c. No wastage of demi water
which was previously supplied
into the drip tray for sealing of
glands by Chinese
Nov. Nil Cooling water pressure boosted
2002 from 1.8 to 3.5 Kg/cm²,All the
Aux. equipments are running
within safe limits of temp.
a.Tripping of BFPs minimized.
b. Unit is now capable to be

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 JAMSHORO POWER COMPANY LIMITED
operated at
150 MW, with one CW pump in
operation(in case of emergency).
Practically it was done in March.
2005
c. Frequency of back washing of
heat exchangers are minimized

4 Turbine high pressure Chinese origin Nov. 0.80 a. Turbine heat loss minimized.
drain valves were replaced with 2003 million b. Over loading of condensers
Japanese Okano valves class 2500 restricted.
c. Erosion of turbine flash tank
and drain lines minimized.
5 Chinese chemical dozing pumps April 2.00 a. Equipment down time
replaced with Prominent German 2005 million minimized.
pumps. b. Trouble free operation.
c. Oil consumption minimized.

6 LPH # 2, drain pumps replaced. June 1.40 a. Load reduction on machine

2003 million minimized.
b. Hazards of LP heaters level
high minimized.
c. Safe and reliable operation of
regenerative cycle.
7 2nd Major overhauling of turbine & Dec. 30.00 a. Safe and reliable operation of
Aux. 2005 million turbo unit.
b .Turbine efficiency increased.
c. Machine down time reduced.

Unit No.4 (210) MW Gas / Oil Fired).

(INSTRUMENT SECTION)

S. Name of Maintenance and Date of Amount Remarks

# Modification Works
01 Replacement of Temperature
Indicating Switches of Double Contact
Type) on Boiler Feed Pump No. 1, 2 &
3 for sealing water Return Oil
Temperature Bearing No. 5 & 6 and
Drain Oil Temperature of Booster Side
of Thyoda Japan make.
02 Replacement of ZJM Pneumatic
Actuator on I.D, F.D Fans, Secondary
Spray A&B, Gland Sealing & their useful life, ultimately very
Condenser Level Regulator.
Completion
July, 2003 629,979/- Previously single contact direct
type temperature including
switches were installed on Boiler
Feed Pumps causing frequent
tripping of the pumps without
indication ultimately effecting the
load reduction. After replacing
these switches with double
contact type Thyoda Japan,
these unnecessary tripping has
been avoided resulting plant
efficiency and reliability
improvement.
July, 2003 5,548,746/- These Regulators shifted to local
mode frequently due to complete
difficult to control parameters.
After replacing these regulators
are controlled from A.C.C.R even
Gland Sealing and Condenser
Level Regulators are working on
Auto.

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 JAMSHORO POWER COMPANY LIMITED
03 Repairing of APH (Air Re-heater)
Control Device Wy-2
04 Rehabilitation work on MZ-III Auto
Regulation System including
replacement of Chinese Components
with USA / Japan make Industrial
Standard Components, Exhaust
Cooling Fans etc.
05 Replacement of Instrument Air Line
Header of Boiler Front.
06 3-Way Valves of 2nd Elevation replaced
with new one during Major
Overhauling (These 3-Way Valves
were shifted to Unit # 2).
07 FSSS 32 Pin Pg-Connectors replaced.
Important Scan Power Supply sub-
divided into six portions for ease of
fault detection and trouble shooting.
08 Stator Cooling Water make up
Solenoid Valve modified from 220V DC
to 220V AC.
09 Oil Gun Cylinders, Tilt/ Secondary Air
Damper Cylinders hard chrome plated
July, 2005 20,000/- APH Control device WY-2
installed on Boiler Auxiliary Panel
was out of order since 1993. This
device is used for monitoring
support and guide bearings
temperature of APHs and also
control of lube oil motors for the
same. This device was procured
vide tender No. T-988 and the
rates quoted were US $
27,675.00. Now the same has
been repaired at our own during
this major overhauling.
July, 2003 500,000/- Most of the regulators working
on Auto mode like Feed Water,
Condenser level, Gland Sealing,
H.P Auxiliary frequently shifted
from Auto to “Manual” mode
due to malfunctioning of the
System’s module because of low
inferior quality components. By
replacing this compound now the
regulators are working more
efficiently on “Auto” mode
improving plant efficiency.
July, 2004 5,70000/- A complete header of Instrument
Air line on boiler front of ¾” ∅
and 250 ft. length replaced with
new S.S pipe as the originally
installed M.S air line became
corrosive from inside. From this
header air supply to gas
regulator, G.R fan (A&B),
primary and secondary sprays,
SCAH and H.P Aux. Header
regulators. Moreover the
distribution air lines of ¼” ∅ and
100 ft. length of all these
regulators also replaced with
new S.S pipe.
During M.O.H 400,000/- R.O Burners can not be ignited
July, 2003 without these 3-way valves. All
the 16 nos. R.O Burners made
ready.
May, 2004 2,00000/- FSSS caused false tripping due to
five incidents on unit logic
cabinet on 06.09.2000. 2A.C. Bs
installed to monitor any
malfunction.
July,2003 2,30,000/- To ensure safe and reliable
operation.
July,2003 90,000/- To ensure proper and smooth
operation
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 JAMSHORO POWER COMPANY LIMITED
(ELECTRICAL SECTION)
S. Name of Maintenance and Date of Amount Remarks
# Modification Works Completion
01. Installation of D.C Batteries December 3400000.00 Reliability of DC system after
2005 replacement of 14 years old
batteries.
02. Installation of UPS March 2005 2273600.00 The reliability of UPS system has
increased as the spares of old
UPS Power Supply system have
been obsolete.

(BOILER SECTION)
S. Name of Maintenance and Date of Amount Remarks
# Modification Works Completion
01. Modification and modernization of Boiler load on gas and reliability
boiler Unfit No.4 improved.
a.Replaced all 40 Nos coils of primary April 2003 44.34 Million
and platen super heaters, 80 Nos coils
of 2ndary super heaters including their
inlet and outlet headers.
b.Installation of additional spray
injection attemprator for platen outlet
header.
02. Repaired the 3D burner (RO) Sept.2005 Rs.23700 Improvement in burner
alongwith their all accessories like, air
compartment, pipes diffuser etc.
03. Furnace bottom hopper supporting Sept.2005 1.42 Million Leakage of flue gases stopped.
beams 02 Nos refractory work
carriedout.

(WATER TREATMENT SECTION)

S. Name of Maintenance and Date of Amount Remarks
# Modification Works Completion
01. Modification of umbrella M.S sheets at Jan.2006 Rs.1699960 Quality of clarified water
Coagulator sedimentation takes –B&C produced by the coagulator
improved .
02. Utility water piping 6” dia (G.I Feb.2006 Rs.368463 Wastage of service water over
Material) rehabilitation / replacement come.
with related accessories.

( TURBINE SECTION)
S. Name of Maintenance and Date of Amount Remarks
# Modification Works Completion
01 Major Overhauling Carried out. June-2003 30.00 Over all reliability and safety
increased.
02 Chemical Dosing Pumps replaced with Oct. 2003 2.00 i) Equipment down
Prominent Germany Pumps. time decreased.
ii) Loss of chemical
decrease.
03 L.P Heater Drain Pumps replaced with July 2003 1.4 i) Equipment down
K.S.B Drain Pumps. time decreased.
iii) Reliability of
plant increased.
04 Jet cleaning of Condenser carried out August 2005 - Vacuum improved efficiency of
condenser increased.
05 06 Nos. Main Steam drain valves of August 2005 0.7 Leakages on drain header
drain header replaced with Okano decreased.
Volvo Japan.
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 JAMSHORO POWER COMPANY LIMITED
06 Bearing Cooling Water Pumps taken July 2003 - 1. Reliability of cooling water
into service. These pumps were not increased resulting availability of
taken into service by Chinese. Feed Water Pumps ensured.
2. Frequent Tripping of Feed Water
Pump minimized.
07 Carbon Brushes fixed on the shaft of August 2005 - 1. Frequent Gear damage
motor of Feed Water Pump near decreased.
Bearing No. 4. 2. Equipment down time
decreased.
3. Reliability of Feed Water Pump
increased.

(WORKSHOP)

S. Name of Maintenance and Date of Amount Remarks

# Modification Works Completion
01. Manufacturing of grating of air Dec.05 Rs.272000/- Used on Unit-1
preheater A&B side (01 set)
02. Manufacturing of expansion joint Dec.2005 Rs.152000/- Rehabilitation of Boiler
partially from air preheater to Chimney
about 10% work carriedout.
03. Manufacturing of trolley for shifting the Jan.06 Rs.551850 To use during major overhauling
turbine rotors having max: loading
capacity of 60 Tons

( COMMON)

S. Name of Maintenance and Date of Amount Remarks

# Modification Works Completion
01. Installation of 6.6 KV Intake overhead June 2003 Rs.2311286 Reliability of water supply from
line intake pump house has been
increased for Units-1,2,3 & 4.

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 JAMSHORO POWER COMPANY LIMITED
B) GAS TURBINE POWER STATION KOTRI

List of Maintenance Works and Plant Modification carried-out at GTPS Kotri

15 MW Unit No.1

S.No. Name of Maintenance Date of Amount Remarks

& Modification works Completion
1. Generator Rotor July 2004 Rs.1,179,547.00 The Rotor was damaged
during operation. It was
repaired at Central Work
shop Faisalabad and the
Unit was restored into
commercial operation.

25 MW Unit No.3
S.No. Name of Maintenance Date of Amount Remarks
& Modification works Completion
1 11 kV Generator Jan.2004 Rs.828,000.00 The Minimum Oil Circuit
Breaker Breaker modified at
Alstom Factory Karachi,by
using Vacuum
Chambers,due to
Non availability of spare
parts and frequent
problems of oil leakage on
the breaker.
2. Generator Control Nov.2004 Rs1,023,303.00 The spare parts of the
Panel. existing system phased-out
Signal Limit Monitor and were no more available
Cards so the modification of the
signal limit monitors cards
carried-out by using TSX
Modicon Micron PLC
System.
3. Inlet Guide Vanes Apr - 2005 Rs.2,953,657.00 Modified type Inlet Guide
Vanes installed on the
machine. The out put
capacity of the unit
increased 1 to1.5 MW
4. Cranking Motor May 2005 Rs.3,087,678.00 The Faulty motor replaced,
with a new motor

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 JAMSHORO POWER COMPANY LIMITED
25 MW Unit No 4
S.No. Name of Maintenance Date of Amount Remarks
& Modification works Completion
1 11 kV Generator Breaker July – 2004 Rs.695,000.00 The Minimum Oil Circuit
Breaker modified at Alstom
Factory Karachi,by using
Vacuum Chambers,due to
Non availability of spare parts
and frequent problems of oil
leakage on the breaker
2. Spare 11 kV Generator July – 2004 Rs.695,000.00 -Do-
Breaker
3. Turbine Components
Modified type Inlet Guide Sep– 2004 Rs.2,953,657.00 Modified type Inlet Guide
Vanes installed Vanes installed on the
machine. The out put capacity
of the unit increased 1 to1.5
MW.
Turbine Bearings No.1 Sep– 2004 Rs65,520.00 Replacement of worn-out
&2 replaced with new bearings during inspection of
ones the unit.
Ist & 2nd Stage Buckets Sep – 2004 Rs.3,506,541.00 Replacement of Buckets
replaced with new ones. during inspection of the unit
carried-out
4 Generator Control Panel. Nov – 2004 Rs1,023,303.00 The spare parts of the existing
Signal Limit Monitor system phased-out and were
Cards no more available so the
modification of the signal
limit monitors cards carried-
out by using TSX Modicon
Micron PLC System.

25 MW Unit No.5
S.No. Name of Maintenance Date of Amount Remarks
and Modification Completion
works
1. Expansion Joints of Sep.2003 Rs.767,820.00 The Damaged Expansion
HRSG Generator Joints replaced with new
ones to prevent hot gases
from the worn-out Expansion
Joints..
2. Inlet Guide Vanes Sep-2003 Rs.2,953,657.00 Modified type Inlet Guide
Vanes installed on the
machine. The out put
capacity of the unit increased
1 to1.5 MW

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 JAMSHORO POWER COMPANY LIMITED
3. Turbine Components
Aug-2005 Rs.3,490,412.00 i) 120 Nos. 1st stage moving
blades replaced with
new one.
ii) 05 Nos. 1st stage shroud
replaced with new ones
iii) 10 Nos. Transition
pieces replaced with
new ones.

25 MW Unit No.6
S.No. Name of Maintenance Date of Amount Remarks
and Modification Completion
works
1. Inlet Guide Vanes Jan.2003 Rs.2,953,657.00 Modified type Inlet Guide
Vanes installed on the
machine. The out put
capacity of the unit increased
1 to1.5 MW

44MW Combined Cycle Unit 7

S.No. Name of Maintenance Date of Amount Remarks
and Modification Completion
works
1 Major overhaul of the Dec.2003 to - The damaged components,
Steam Unit carried-out Feb.2004 replaced with new ones:

i) Generator bearings 3&4

ii) Turbine Thrust Pads.
iii) H.P & L.P Side
Labyrinth seals
2 Control and Dec.2003 to Rs.1,401,587.00
Instruments Feb.2004

Replacements of Parts Achieved the reliability of

the control system
i) Pressure Gauges.
ii) H.P Drum Electrodes
iii) Thermocouple of Steam
Turbine
iv) H.P Gland Spray Valve
Actuator.
v) RTD for Pads of Bearing
No.4 of Steam Turbine
Generator.
vi) Smart Transmitter STG 110
for Hydrogen side Seal Oil
Pressure of Steam Turbine
Generator.
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 JAMSHORO POWER COMPANY LIMITED
vii) Digital Input Module Card
JD IMOO for Hi-way No.2.
viii) Digital Out- put Module
card JDOM20 for Hi-way
No.1,BoxNo.5 of AMC-
105
ix) Faulty Push Buttons of
PLC- Panel replaced with
LED based lighted push
buttons
3. Boiler Feed Nov.2003
PumpMotor (3.3
kV,285 kW)
4. Chinese Feed Pump
Motor Repair
5. Boiler Feed Pump March 2005
Motor (3.3 kV,285 kW)
6. Up-gradation of TDC- July-2005
3000 on LCN level
Rs.1,749,228.00 The Chinese Feed Pump
Motor were subject to
frequent problems of bearing
failure, so Oil Bathed type
bearings motor installed to
overcome the failure of
bearings.
July 2004 Rs.258,755.00 01 No. Chinese motor
modified after replacing the
aluminum conductors with
copper conductors in its
squirrel cage rotor
July 2004 Rs.580,000.00 The stator of the Chinese
Motor repaired and rewound
which was damaged due to
fault on the Rotor
Rs.1,749,228.00 The Chinese Feed Pump
Motor were subject to
frequent problems of bearing
failure, so an Oil Bathed type
bearings motor installed to
overcome the failure of
bearings.
Rs.12,554,143.00 Up-gradation of TDC-3000
on the combine cycle plant
carried out replacing the
main components on LCN
level, to increase the
reliability and performance
of the distributed control
system.
a) Universal Station Modules
b) History Modules.
c) Application Modules.
d) High-way Gateway
Modules
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 JAMSHORO POWER COMPANY LIMITED

Installation of New Energy Meters on all Generating Units and 132 kV Outgoing Feeders

S.No. Name of Maintenance Date of Amount Remarks

& Modification works Completion
1. New Energy ‘Meters June 2004 Rs.1,577,538.00 05 Nos. new PRI Meters
(PRI) installed on 132 installed on the 132 kV
kV outgoing feeders. Feeders, emanating from
the GTPS Grid.
2. New Energy Meters Feb.2005 Rs.2,704,037.00 New Meters Installed to
(CEWE) installed on read the energy fed to 132
132 kV side of all the kV Bus Bars
Generating Units

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