Pakistan Steel Mills (PSM) is to seek Japanese funding through Economic Affairs Division (EAD) for revamp and rehab of its power generation plant, official sources told Business Recorder. Pakistan Steel - a financially empty national asset - operates its own captive power generation plant which uses exhaust gases generated at its blast furnaces and coke oven batteries as fuel. It has a capacity of 2X55 MW working and 1X55 MW standby turbo generators. Excess electricity is sold to K-Electric (Karachi Utility Company) as per agreement.
The sources said, due to ageing of machines and lack of funds for maintenance the generating capacity has come down to 25-30 MW requiring immediate re-habilitation. With the envisaged expansion of Pakistan Steel 2X125 MW additional Turbo Generators shall be required for the combined Cycle Power Plant to cater for the power needs of steel making.
PSM argues that it has become imperative that the present generational capacity be restored to its designed capacity of 110 MW in the first phase; to enhance capacity upto 165 MW in the second phase by revamping and modernisation of present thermal power plant; and finally increase the power generating capacity by constructing a new thermal power plant with two condensing turbine generators of 125 MW each (Combined Cycle) and two boilers of 420 tons per hour each with complete auxiliary and ancillary facilities in the final phase.
According to sources, PSM has forwarded its project proposal for re-habilitation of existing power generating capacity, its enhancement and for undertaking energy conservation in the plant/facilities to Economic Affairs Division for availing funds from Japan International Co-operation Agency (JICA). They maintained that there are four boilers of 220 Ton/Hr production capacity provided at TPP. The condition of major parts of boilers specially heating surfaces, boiler drum, regenerative air heaters, stop valves etc are severely deteriorated, that may lead to very critical and alarming situation and could result in either sudden damage of equipment or a fatal accident.
The main operative parts of turbines, turbo-generators like moving blades, guiding blades of the baffle, satellite plates and regulating valves are badly deteriorated, moreover, Turbo Generator Nos. 2 and 3 is operating with missing blades of two stages each. The condition of parts has attained a very unreliable and unsafe condition and therefore needs immediate attention.
Repair/replacement of slip rings, brush assembly of turbo generators and radiators of power transformer are considered essential for a reliable and stable power supply, the sources continued. The basic process equipment has worked over 25 years and its proper overhauling during last 10 - 15 years has not been carried out. Frequent shutdowns during operation are a cause of serious concern as automatic control systems, including ignition control for boilers, are not available. Besides, C&I instrument installed at TPP in 1979-80 is out of production, and no spares are available, therefore a complete replacement is required.
Recently, Pakistan Steel planned a project for rehabilitation of its Thermal Power Plant (165MW) for obtaining sustainable power generation of 100 - 110 MW with the aim of exporting surplus/balance power to M/s K-Electric, but the rehabilitation work could not materialise due to paucity of funds available with Pakistan Steel. The sources said PSM is also considering establishing a new power plant with two identical units to generate gross power of 200 MW.
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