PNABU386

UNITED STATES AGENCY FOR
INTERNATIONAL DEVELOPMENT
PRIVATE SECTOR POWER PROJECT
JAMSHORO POWER STATION
TECHNICAL DUE DILIGENCE
PERFORMED FOR
INTERNATIONAL RESOURCES GROUP, LTD.
NOVEMBER 1993
BEST AVAILABLE DOCUMENT
EXECUTIVE SUMMARY
The Jamshoro Thermal Power Station (JPS) consists of four steam turbine generating
units with a total installed capacity of 880 MW. These units were commissioned
between 1989 arid 1991.
The JPS nas been the subject of evaluation as a preliude to either commercialization
and/or privatization. This report includes the Technical Due Diligence analyses that
have been conducted at this facility.
The initial report, entitled Equipment Condition Assessment
November 1991. The purpose of this study was to provide
the major systems, components and structures necessary
generation of electricity. The findings of this report are as
Report was completed in

an overall assessment of
for the safe and reliable
follow:
1)
The systems and components reviewed at the Janshoro Power Station should
be suitable for contintied operation for the next 20 years.
2)
In general, Unit No. 1 appears to bQ of superior quality and exhibits better

overall workmanship with fewer current problems than Unit Nos 2, 3 and 4.
3)
It is assumed that all equipment currently in place was designed, manufactured

and installed in accordance with applicable code and standards arid are of
power house quality.
The second report, entitled Final Technical Due Diligence was completed in September
1992 and was conducted to update the previous study and investigate any new
issues that might have arisen. The principal findings of this study are as follow:
1)
Fundamentally, the major components and systems at the plant are sound and
incorporate proven design concepts and technology.
2)
The plant support equipment and facilities are adequate in design and number,
although a few prublems remain to be resolved.
3)
Based on appearance, operational records and staff testimonials, it appears that

Unit No. 1 is the best designed and constructed unit.
4)
The units were built to currently applicable codes established in the country
from which the unit was purchased.
5)
The single largest area for improvement is in the area of site facilities and
personnel management, a situation most likely related to the newness of the
plant and the relative inexperience of the technical staff.
In February 1993 a follow-up Site visit was made by the author of the September
1992 report. The observations are included in this report. Responses from plant
management to these observations are also included.
In October 1993 a third Technical Due Diligence analysis for Jamshoro was
completed. Its purpose was to review the findings of the previous reports and to
provide an update to their findings. This information was required to expedite the
privatization of the Jamshoro Power Station. The conclusions of this report are as
follow:
1)
The plant was found to be in generally good condition and was operating in a
normal fashion for a plant of its relative youth.
2)
One area that needed attention is the recurrent plugging of steam generator
components caused, in part, by the high levels of sulphur and vanadium in the
furnace oil.
3)
A second identified problem was the overflow of plant waste water into
neighboring fields caused by the undersizing of plant settling ponds.
4)
The plant staff has programs underway which are designed to alleviate each of
these problem areas.
al
UNITED STATES AGENCY FOR INTERNATIONAL DEVELOPMENT
PRIVATE SECTOR POWER PROJECT
TECHNICAL DUE DILIGENCE UPDATE
JAMSHORO POWER STATION

UNITS 1-4
CONTROL WORKPLAN 2.33.0
FINAL REPORT
PERFORMED FOR
INTERNATIONAL RESOURCES GROUP, LTD.
SUBMITTED BY:
DENNIS W. EVANS
JOHN T. BOYD CO.
AND
DR. J.D. GUY
I.R.G.
OCTOBER 1993
SECTION
TABLE OF CONTENTS
SECTION
DESCRIPTION
TABLE OF CONTENTS
II
PROJECT TASK AND DESCRIPTION
III
FINDINGS
IV
PLANT OPERATING AND PARAMETERS AND ACTIVITIES
UNIT 15
VI
UNIT 2, 3 & 4
VII
PLANT COMMON FACILITIES
VIII
MAINTENANCE PRACTICES
IX
STAFFING
PAGE
PROJECT TASK AND DESCRIPTION
The purpose of this work effort is to review the findings of the two
previous Technical Due Diligence reports and to provide an update to
their findings. This update is required to expedite the privatization of the
Jamshoro Power Station on a fast-track as directed by the Privatization
Commission of the Government of Pakistan.
A team composed of Dennis W. Evans of John T. Boyd Co. and Dr. J.
D. Guy of IRG Ltd. visited the power station beginning on September 25,
1993 and lasting through September 28, 1993 to conduct the
evaluation. This time was spent touring the plant facilities, holding
discussions with key plant staff and reviewing and analyzing plant
operating data supplied by the staff.
The team also undertook a review of previous Due Diligence reports
provided by Ebasco Services, Inc. in 1991 and by John T. Boyd Co. in
1992. These two reports provided a background and a framework for
the update contained in this report. For that reason some of the detailed
plant descriptions are riot included in this report arid can be found in one
or both of the other reports.
The team was able to observe the responses by plant management to
the recommendations suggested by the previous reports. The team also
evaluated any additional problems that may have arisen since the last
previous report had been completed.
FINDINGS
The team found the plant to be in generally good condition and operating
in normal fashion for a plant of its relatively young age. There are two
areas which need attention: (1) d( to the high Stlphulr and vanadium
content of th oil b)urned in Unlit 1, aind in Units 2, 3, and 4 when gas is
unavailable, there is considerable )ltjgi (ig of many of the steam
generator components iMithe furnace, and (2) due to the undersizing of
the settling porids, there is a discharge of waste water from the plant
inIto surrounding fields.
Normal mainternance activities are undertaken at the plant for all four
units and there does not appear to be other problems of an, significance.
PLANT OPERATING PARAMETERS AND ACTIVITIES
The table below summarizes the Jamnshoro Power Station with regard to installed units
and includes various relevant operating data for the past two years. The operating
statistics were taken from Form E reports provided by the plant staff; however, the
capacity factor information was recalculated to reflect the methods which are in more
common usage in the West.
PLANT DESIGN DATA
Unit 1
Unit 2
Unit 3
Unit 4
Design Capacity (MW)
250
210
210
210
Maximum Operating Capacity (MW)
250
200
200
200
Date Commissioned
1/90.
12/89
6/90
1/91
Country of Origin
Japan
China
China
China
Fuel Type(s)
Oil
Gas/Oil
Gas/Oil
Gas/Oil
Design Heat Rate

(Btu/Kwh)
9,063
10,254
10,254
10,254
PLANT OPERATING DATA (ANNUAL)

Units
Y (a
A h) l 1h~l
'41/2
12/93
91/92
Q2193
91192
.3S2
10.)4(0
().002
9.Q-)3
9.500
9F2/93
1).063
4
91/92
92/93
95.S5
9.937
RaIc (lit/Kwh)
A% I:lui)
caII t
kIct
:lr( 'g
(1
901
65.2
77.4
59.0
74 6
57.0
55.3
6137
701
48.8
Ss 9
47.0
is'
44 4
38.0
The chart shows that all of the units at the plant are relatively new, the oldest is not
yet four years old. On': '.would expect the performance parameters shown in the
operating data table to improve considerably as the plant staff moves Up the learning
curve and the normal to-be-expected unew construction problems are resolved.
HEAT RATES -- The actuial heail
rato for Unit# 1 is on average about 7 % higher than
wh a t has been described as the; design heal rate while the actual heat rates for the
other tuits are oii average alri rust 5% less tha the design values. The team was not
able to review thu Uti # 1 icceptiace report to reterjirie if the unit had achieved
the design heat rate at the 11011! Of the !st. It should be noted that the actual heat
rate (Jata are calculated tsisg aveir ! operatling data over an entire year, which will
include the entire raige of Linit operations. Ho wever, the design heat rate would likely
reflect a specific set of controlled operatirg conditiois and may also be at a specific
point of IlWLe unil's operatingq cu rve. It would be desirable that each unit be subjected
to a heat rate test to (lt. ri iie the actual h eat rates at various points on the
operating curve. These data wonld provide a better basis for comparison to the design
criteria.
AVAILABILITY --The low availabilities of Units 2, 3 and 4 are accounted for by
extended outages related to r guired scheduled inspections. In particular, Unit# 4 was
out of service for about five monr1ths in 1992 for its first inspection. Ordinarily these
inspections are of 90 day duration but in this case it was longer due to the
unavailability of reguired replace(?iCut parts. This extended outage adversely affected
the unit's availahility in b)ot the years for which data are reported.
CAPACITY FACTOR --The capacity factor results are determined by: (1) the
availability of the units to be operated arid (2)the actual dispatch decisions of the
system dispatcher at N.C.C. in Islamabad. The last factor is beyond the control of the
Jamshoro plant management and should not be considered necessarily reflective of
the plant's potential performance. The actual dispatching decisions are driven by
relative unit fuel costs, overall system load requirements, arid individual unit response
rates.
UNIT 1
This unit has a nominal rating of 250 MW and was designed and constructed by
Tokyo Electric Power Service, Ltd. It was commissioned on January 27, 1990. The
unit appears to well designed and constructed and the operating records bear this out.
The major problem associated with this unit is caused by the poor quality of tile
furnace oil that is burned ii the boiler. This fuel contains high levels of sulphur arid
vanadium and the exhaust from the conbustion of the fuel causes excessive plugging
of the boiler componens. There was no provision in the unit's design for automatic
washing of these components which means that the unit must be taken out for
service for an extended time for washing by hand. The plant engineers are evaluating
the Use of a fuel additive which should reduce the rate of pluggage of the unit. That
evaluation has not been concluded at this time. It may also be possible to modify the
unit by installing an a u toniat ic washing system which has been included on similar
Japanese units of th e sane design.
It is also possible To convert the ln it to burh gas if that fuel is available in sufficient
quantity. This conversioni would completely mitigate the plugging problem. However,
an estimate provided by the constructor of tile cost of conversion was approximately
equal to the cost of an entire new boiler. It may be desirable to have the constructor
re-evaluate this estimate.
UNITS 2, 3 &4
These units, all 210 MW each, were designed and constructed by North East Electric
Power Design Institute, Ministry of Water Resources and Electric Power, ChangchuPeoples Republic of China and were commissioned on December 9, 1989, January
27, 1990 and January 21, 1991, respectively. These units to riot appear to be as well
designed and constructed as Unit II 1 arid the operating data bear this out, at least in
the first years of operation. These units also require frequent shutdowns to manually
wash the boilers wheii bnirninq furnace oil.
These units are highly labor intensive since they are currently incapable of operating
in a completely autoriated mode because of the unreliable instrumentation. The
operation arid maintenance Manuals supplied by the constructor are not as complete
as those provided for Unit 1 aid staff training has suffered due to communication
difficulties. Similarly, riaiiteriince activities have been made more difficult due to the
lack of as-built drawings.
Many of the deficiericies noted inthe previous due diligence reports are still prevalent
and will contribute to higher nuainitenance costs inthe future unless corrected. Some
of these, such as open cable trays arid exposed wiring on instrumentation, could be
ameliorated with expanded efforts during planned overhauls.
PLANT COMMON FACILITIES
WAREHOUSES AND STORES -- The warehouse for Unit 1 contains an adequate

Supply of most required spare parts which were supplied by the constructor. Some of
the large items, such as intake water pumps, have yet to be delivered. The spares for
the other units are located in a second warehouse and appear to marginal at best. No
one seemed to know if additional spare parts are scheduled for delivery. All inventory
accounting is currently done niinlually; however, when the Maintenance Management
System is installed at Janshoro, the inventory will be maintained on a computer based
system. That process is already underway and is scheduled for completion within the
next two years.
WATER HANDLING -- As discussed in previous reports each unit at Jamshoro has
adequate capacity to supply its demineralized water requirements. Additionally, the
water chemistry and control systems appear to be in line with generally accepted
practi(-(;s.
However, as mentioned earlier, there is a major proLlem in the handling of waste
water from the plant. This effluent, arising principally from boiler and cooling tower
blowdowns, is ordinarily pUnilped to settling ponds for evaporation. However, the
ponds are undersized and are insufficient to handle the effluent flow. Consequently,
the overflow from the ponds drain onto local fields adjacent to the plant. The solution
proposed by the plant engineers is to construct an open channel from the ponds
directly to the Indus River.
WORKSHOP-- In the last Due Diligence Report (10/92) it was noted that there existed
a large workshop building but that it was not equipped with any tools. Since that
time, the workshop has been equipped with a large complement of Chinese-made
heavy duty workshop machines. There is, however, still the problem of an insufficient
number of trained equipment operators but this situation should be eased as the
workshop staff gains more experience with the equipment.
MAINTENANCE PRACTICES
All of the units at Jamshoro have undergone at least one 90-day inspection outage
since commissioning. The recommended scheduled interval between major inspections
and overhauls is between 30,000 and 35,000 hours of operation. Tile next major
overhaul for any unit at the plant should not occur for at least three years unless some
unusual circumstance arises. The table below shows for each unit the number of
operating hours since the last major overhaul.
Routine maintenance is conducted by plant staff on a regular time frame if the
maintenance items can be accomplished without bringing the unit off line. A list of
maintenance items which do require a unit shut-down are accumulated until the shut
down can be scheduled wtdho,, adversely affecting WAPDA system reliability. When
the unit is available for maintenance, the list of items is prioritized so that the most
important items are accomplished during the relatively short outage time, typically 10
12 (lays. The station submits a proposed schedule for these short-term maintenance
iteflI in June of each year and expects to have them completed by November of that
year. Except for planned major overhauls and unexpected forced outages, the plant
is expected to be available throughout the remainder of the year.
Unit
Total running hours since last overhaul.
4076
3884
5370
4721
Through June 30, 1993
STAFFING
From discussions with the senior management at the plant it became clear that one
of the most serious problems faced at Jamshoro is the lack of a sufficient number of
trained staff. Those who are assigned to the plant are required to work excessively
long hours to keep the units available for operation. There is a major risk of employee
burnout unless this oroblem is alleviated.
AddiLirnally, in the areas of craft labor, there is a serious shortage of qualified welders
at the plant; there are only two assigned there at this time. The WAPDA pay scales
for these positions are insufficient to attract welders away from privately owned
establishments.
FOLLOW UP VISIT TO JAMSHORO POWER PLANT
On February 3, 1993 with the help of USAID Karachi, a follow up to the August
Technical Due Diligence assessment was done.
Met with Mr. M.M. Chandio, Resident Engineer Mechanical and Mr. Abdu Adil, Senior
Resident Engineer Cperations.
Prior to the visit a list of questions was sent to the station concerning outages and is
attached as part of this report.
Things have not changed, plant is still in a crisis management type of operation. Was
told that WAPDA will not authorize additional expenditures as this will be privatized.
There has recently been two criminal law suits filed by property owners and tile
highway department. Was rot able to obtain copies but have informed Hunton &
Williams so they can pu]rsue from their end.
To (late they are still running without adequate spare parts, colony is not staffed,
shortage of vehicles, no maintenance shop arid staff is not adequate to run in this
mode of operation.
The Senior Engineers arid Junior Engineers are required to live in the Colony and
during any emergencies have to report to the plant, most of them are averaging
twelve to fourteen hour days as they can't get in touch with the personnel who live
in Hyderabad.
In addition new areas of concern have been identified and will add to the
indemnification that WAPDA will have to make to the new Co.
A list of these items will be part of this report.
Dennis W. Evans
Advisor, WPPO
//
ITEMS NEEDING CORRECTIONS AT JAMSHORO POWER PLANT
Maintenance shop, no equipment, tools todate.
Air basket #11 unit 1 month outage to replace or clean.
Units 2, 3 and 4 hot spots need to replace insulation.
Unit # 2 main steam stop valve will not close very dangerous, drifts close after
machine has cooled down.
Units 1, 2, 3 and 4 experiencing, short circuiting during rainey seasons.
Waste water evaporation pond, original size too small, line to Indus river plugged
overflow's into farm fields.
Unit # 1 coagulator design not right as identified in original report, can't get parts
needed to make tie to units 2, 3 and 4.
Instrument air dryers on units 2, 3 and 4 need to be replaced.
Air pre heater motors modification needed to remove for maintenance without having
to shut unit down.
Units 2, 3 and 4 thrust bearings and pilot valves need replacing.
Units 2, 3 and 4 all pumps need to have grease fittings added.
Units 2, 3 and 4 main turbine lube oil system needs a complete filter redesign.
H2
compressor sealed units have to be replaced.
Units 2, 3 arid 4 24" supply line from Indus river made out of cast iron they are
experiencing lots of damage this could be

a big cost item if whole line has to be
replaced.
Direct road from colony to station for easier access.
Need to replace underground 6.6 KV line to river pumping station with overhead, lots
of failures.
To,
Mr. Dennis W. Evans
International Resources Group Ltd.
Private SecLor Power Project,
2nd floor, PIA Tower,
Egerton Road,Lahore
Phone: 6368790-93
From:-
M.M. Chandio R.E.
(M)
TPS, Jamshoro
Abu Adil
R.E.
(0)
TPS, Jamshoro
Reference:
Your fax of dated 10.09.199,.
Our
comments on
the
items
needing
correction
at
Jamshoro power plant are attached herewith.
Thank you.
( ABU ADIL )21/C

RESIDENT ENGINEER/ (0)
TPS, JAMSHORO
01
MAINT-NANCE
NO
SliOP.
TOOLS
EQUIPMENT.
TOOA TF
Comments:
Ma--i nt.enance
shop
equipments
required
02.
AIR
tools,
but
RAS. EI .
OR
i t.
is
equj ipped
nt
wi th
equipped
with
UNIT
washing
done
in
facilities
OUTAGE _TO
are avai ].bIe which car8n be
shutdown.
days
elements
can
However
Intermed ate
UNTTS-23_
MONIH
CLEAN
Water
be
i n
an d
more
4 _I(OT
.&
Cold
replaced
replacement. require
03.
fully
,t.Caff.
REPLACE
Comments:
and
now
is
AJj r
en
1 '5
Preheater
,.:iy'-,
hot.
time may he
SPOTS. NEE()
-h'j t.down.
(Id
el emets
of) e M 0
-.h
T0_R PPL.ACF
IN Su LA T I.ON
Commrient-s
Some
but
of
hot
the
would be
spots
done
are
in
still
without
insulation
the shutdowns w.e.f.20.11.1993
to 20.01.1993.
04.
UNIT
NOT
CLOSE
MACHINE
Comments:
No such
05.
UNITS-I
CIRCUITING
Comments:
DURING
Unit-I
have
MAIN
VERY
HAS
RAINY
has
the
STOP
DANGEROUS,.DRIFTS
COOLED
problem
.2.3
STEAM
VALVE
WILL
CLOSE
AFTER
DOWN-
now
&
EXPERIENCING,
SHORT
SEASONS-
no
such
problem
necessary works of
problem.
specially
However
on
Units-2,3
boiler
for
&
-1
which
providing shades and sealing
are
in progress.
06_
WASTE
WATER
EVAPORATION
PONDORIGINAL -SIZF
ro--- SMALl
LINE
TO
INDUS
RIVER
PLUGGED
OVERFIOW'S
INTO
Comments:
The waste
water
line
is
to overcome
this
open
channel
being
07.
UNIT
I-
IDENTIFIF
silt
IN
is
BE
Case
,:
AIR
water
be
and
of
pond
to
If
it
providing
river
is
is
found
startled.
DESIGN
NOT
RIG1T
AS
REPORT._
CANNOT
GET
TIE
10
UNITS-2.3
&
4_
int.ake we.te;
has been
made
accumulated
fully.
However
case
study
0RIGINnA_
TO
MAKE
Units- I ,,
1"
INSTRUMFENT
TO
Comments:
ill
Interconnection of
R ive;
among
08.
rk
w
plugged
consultLant..
COAGULATOR
PARTSNEEDED
Comments:
waste
the
t.he c
not'
problem a
from
done
by
workable,
FARM
FIELDS
s
is
DRYERS
regards
to be
ON
co-agulators,
removed
manually.
UNTS-2.3&4
NEED
REPLACED-
for
procurecrient
of
Refrigerant
type
drier
is
in process.
09.
AIR
PRE
TO
REOVE
I EATE R
FORI IAI
MOTORS
MODIFICATION
NTENIANCE
WITHIOUT
NEEDED
HAVING
TO
SHUT UN I-T
-DONN..
Comments:
Already modified.
(3)
10.
utS-?
_3
VnLVES
Coiner:.
,an
T-IRUST
puMPs
thrust
operation
of
about
mal function
of
gar)
between
lubrication
Chinese
are
carrying
done ,t
one
pilot
,orIle
After
bearings
governing
plate.
units.
BEAN
SAND.-sA
PILOT
NEED. REP LnCG__
the
I1 .
get
year
system
valve
successful
)hi ch
due
and
problem
out
damage
Lo
results
increase
governor
is
there
modification
result,
af ter
buffle
for
on
in
which
t-heir
own
the
same
will
TO
HAVE
GREASE
be
Janishoro-
UNIT-.S-?_A3
& 4
ALL
PUMPS
NEED
FITTINGS ADDED
Comments:
Which
pumps
provided
12.
Comments:
&
However
MAIN
COMPLETE
Addi tiona]
Units-?
clear.
properly on some of
UHITS-2_
NEEDS
not
FILTER
For
nipples
not
the pumps.
TURBINE
centrifuges
& 3.
-rease
LUBE
OIL
SYSTEM
REDESIGN
have
been
installed
on
Unit-4
it
is
under procurement.
Chinese purification plant
on
each unit is also in
service.
With
these
measures
reduced t.o satisfactory

13
H12
COMPRESSOR
TO BE
Comments:
the
problem
has
been
level.
SEALED
UNITS W4OLE
UNIT HAS
REPLACED
Yes
(4)
1.4-
Unit
s-2_. 3
&
MADE
RIVER
COST
REPLACED
Comments:
The
LOTS
ITEN
LINE
INDUS
FROM
CAST
IRON
THEY
DAMAGE
THIS
COULD
HlAS
-WHOLE-LIN-E
ARE
BE
A
BE-
TO
of
damage
of
interconnections
which
the
OF
IF
frequency
made
SUPPLY
OUT 1OF
EXPERIENCING
BI-G.
24-
all
may
Unit..The
damage
the
not
pipe
has
four
uniLs
affect
length
reduced
the
is
and
have
been
operation
being
of
replaced
with M.S.pipes.
DIR_1EC T
ROAD
EASIER
ACESS.
Comments:
Already
under
16.
NEED
15.
RIVER
Comments:
TO
FROM
PUMPING
FAILURES_
The
scheme
is
TO
STATION
FOR
construction
UNDERGROUND
R-PLACE
OF
COLONY
STATION
under
WITH
consideration,
6-6
KV
LINE
OVERHEAD-
but
TO
__LOTS
has
not been
BETWEEN
POWER
finalized.
17.
SUB-WAY
STATION
WHOLE
Comments:
Not
TO
&
POW ER
BE
PROVIDED
PRETREATMEN-T
PLANT
TO_ CONTROL
STATION
initiated
ABU ADIL
R.E.(O)
TPS, JAMSHORO
M.M. CHANDIO
R.E. (M)
TPS, JAMSHORO
L()1IN'I'IRNA'IIONAI, L)1E-V I :lOPMlN

U.S. AGENC(Y
R '(OW!v'I IROJIV ' I"
Ik
II.IVAI'F S("'
I "
JAMSHORO POWER SI"ATI()N
UNITS 1, 2, 3 ANT) 4
FINAL TECHNICAI, DUE, I)ILIGNCE
CONTROL WORK PLAN 1.38.0
FINAL REPORT
SUBMITTED BY
DENNIS \.\.. EVANS, .O-IN 'I'. BOYID CONMPANY
AND
FRED A. STONE, ESIS ENEIRGY/FPI GROUP
SEPTEM 13 ER, 1992
bEST AVAILABLE DOCUI-4ENT
S1XTIION I
'ale of C(IonIt{IlS
S'CT'I()N I
'I II
ON
.l*[I.f)N
III
Ml1(l(\
IV
"rfble of contenits
C\'I' 1.3S.(0
OVEALl. CONCLUSIONS
\I11()
OI
T()IASIk
SI-CTION
.'INDINGS, CWP 6(a)
SIECTION VI
FINDINGS , C\WIP 6(b)
II
SICIION \II
FINDINGS, C\VP 6(c)
I?
IKCTION \11I
F[NI)INGS, C\VP 6(d)
SICTION IX
FINDFNGS. CWP 6(6)
ATTACIIIENT I
PLANT COLONY .
ATTAC II IENT 2
PLANT STORES
ATTACI01 ENT 3
JPC STAFFING PROPOSAL
A ITI :NI) X A
CONSTIRUCTION COINTROL DOCUMENT
AIlIl'NI)IX B
PLANT IMPROVEMIENT POJECTS
17
........
2!
27
or
e t
W i.
(CorntroI Work: Pl-an
Shah !d
I'I .
apiJ Ii
le
I :,Ja
*,,
.
,,I ;
,V:ct
, ., ,
t,.:'lCc
fl.
&h'?
-m
-a I..nI
hose:
l.
;<
a)
'(<"')
,ai
,-"
%"
.T,: rt
,c I .r C!
a Ifl
(
','(
1
a a,
;h,:.
(l
,-i
,. .. ,
,:;eC I "
9l
Il-
eI
(! I
ISI ?:rV
o.(VO|
0!
e
L e".
conformance
'0'
S"
(f
0pc
&rl
ta~-l'_sbt:'
Name
x I-
Robert
of. Short
E.
-aA
.'.
i;,a
. .-- ]I
.lo55L.a
-o
'
Name of
VI:irm providing ser.-vices
Lnecy.
(Teal)
ESI
Evans
5,'yd Cro.,
"
'
I
r)in'
a.
,:'' .........
- ESI,
..
I,
.:;a
-,
I.
o.-!
Cneigy ,-h.CI
Joli)
T.
Co.
5.
commencinq a13eot.
Estimated period of performance
September 1, 1992.
1992 and compe-ting about
;.
Scope
(a)
.-.
.lohn ":'
Boy6
I.
a-
. C
Term Consult-ants
Dennis W.
If.-,
1.
ChieC of Prry I
Gri ils a.', -R.-si~derl P
sible Advisor
>?.
::
,1IS)
.d
a,..
Ion IiUmb.
c
n t.o i icat
.'.a
"
'
cI,
conditions, the Lea m a y.h

15
j.irt:ing
!1
r Corporation
(JP.C) rece)ive Pappr-onIf
3a,,
APDA or have the :l alL s
m V.
-:-.
c
(.
'.,(.
I
II-
u-aredu-s and progrram

C
n .aC
actiVit.vSI
ont-luction
the Team
nece sary,
i
A di
andard conditions.
4C.
a, i
.'; G
aa
,)c
.[,.il
in IaI
ushoro
:;i-
1 :".,]i.!
'"
I'* Ie)
i:03:,J
A
& (appro"
._
]. v ,;
Cd
CICier;a,
(c
Jam-'
I ir
o pe r a
ri
1
1 03
iei
i..
'*
.Jla~II ,ll
.LkC2
(-W
i II o
I
,
,I,
(imJ.
T.echrllce.i
l S,L mnj
1. 2.stud.,3,
c<e
n
Uo
01.'<.-t L~'I
)t u
r<~
a!a M.dakIr
(-Ina
the
1 :
I . 38; 0
C(WP
Piocj
fA.hirad,
za-tioi'
c:orra.a;
l e-c0
r or Z: I I L)ciI
(. [
,a
lo-r
pe
..L.['
!:
Poll-, I d
oat t
,h ,
Anqustl
of Work_:
obseJvdati.ons
study and copare j.t;
Examine the axist3Yg pr.esent plant condition-'-, codes
and conclusions
with
and conStrICt.orn documents.
-1
~r
nr
r)t
rl
Ib l ) i; I
rec or (;
i'dc l I (.i,
( m) -' rJ
)W-;t',"
L.:alii
[) 1(-V(! I I. i
'I I-ld
J)i
'r-
,id
ReviLeu
(d)
r'tie
heat
ro
w rit
( 1
' 2F L
l, (
opc-r'!l I
arld pl..,1
i I
u me n z
0
!i
'n..,
t.q
L/aror
00o.
opinion
Alo
in
the
in
a srecia.
or
the ;:
Teams
L-.n
... L.
"!.e
i-_ - contract
contained Ar-fin.c the
Contract
"
"s
..
P'!a-ra .:"WS iask
inl
i.oar
ad
:
sha r
i .lt a
it,:
c-el.av
a d
's
-. ::
.- L.."P",',
a;, d
,n
eaLe ,
Uha z,
i w2
I-t.in
nitioo
Lhou
- Lhe
,:
OlS
i:
I-. lity,
,1
nd
r;
her. -,I
L on
',
J t'05
fVcopCA
n
o
Lt
: -q
'w'1 1I
iU:
C'
fn'I
C Ot r e
:,z
I1i
IS
r
F, alIuate the
nezn t.
I .qi i r
:I .:
r
oc:cL
pn
1 !
10 1 S h i;', beL..e e r
;aLer
1:.
.
,: .;or
ZijOns,
!on,
..
IcI
r la
(,1Cel
I.
plant
ccnS,,
io1
I I ri
n )
evalua(e
c )
2 ' c O[
leve l or
expe lain
::
aCL
a
to
-Studies.
ADp r C.',: -
Stijl",ULed
Chinf
Private
Robert
by
PoveC
Sector
Z.
Mnagqo
(.,
Party
of
Grish
.-'
:wo)ycz
.PPO
Ml. i
--
.n :
osara:
Approved by
Progr am
orm-uI
pet
Val i Fy
t I)
n.,y;n .Il,
,Spec if Icat
iqnl
W'dr
conpi. ionce with
h,I
(
i ii )l~~I
.] '.'c % (2( I
'ot
EvJEIltua
( C)
:*c
ci
l; t
- r,.-'1)
I onc
Manager
USA_1I) 0/PE-N
Mian Shahid
BEST VAIUABLE DOCUMENT
SI1,:I'ION III
OVERAI1. CONCLUSIONS
h Fi-al technical due dilig'cnlce required for the

is to i)rlo i iic
The purpose ol tins (\'V
corporatization and )rivatization process of the Jainshoro Power Stalion A short term team
was
comprised of Mr Dennis W. Evans, John T Boyd Co. and Mr. Fred A. Sione, ESI Energy
assigned the task.
II summary, the Plant is a good selection for privatization. Unit I Is a 250 M\V oil fired unit
piovided by the Japanese, and Units 2, 3 and 4 are 210 M\V oil and gas Ifred units provided by
they
the Chiinese. Fu ndamentally, all uilts major compon nets and syStems are very sound, and
incorporate proven design concepts and technology. They were commissioned between
l)eceinbei, 1989 aid January, 1991 and arC therelore essentilly Ic,,, 111,
Unit I appears to be the best unit, based on construction appearance, plant operational records
aind testimonials of plant employees. Units 2,'3 and 4 are still going through sonic start-uip
The
problenms, all of which can be solved with the proper focus ina relatively short time frame
Ifew
a
although
IIar t SlI)port equipment and facilities are very adequate indesigni and nuuber,
problems remain to be resolved. Again, there appears to be no insurmountable situations.
The single largest area for improvement at the Plant is in the arena of site facilities, equil)ieii
and personnel mriaagement. This situation is most likely caused by the newness of the plant,
focus on commissioning deadlines, and the fact the plant is owned atid operated by \VAPDA.
Many plarnt employees are fresh, and are not yet properly trained or seasoned. Valid operational
go ai long way towards
docurients are scarce in some areas. Privatization and time wvIIl
resolution of these issues.
SECTION WV
A PI R()A Ci I T)
'I'ASI(
Ile ap)proach R) task tken by eamn was to meet with Mr. Gritshaw, k,A. WAIPI)A, M Ant,
A. 7Zaidi, G M., WPPO and Mr. Malik M. Ashraf, M.I)., WPPO hur an overview and
additional directon concerning the assignntCl
The team IOhn travelled to the Plant site wilh
MIr Griinshaw For a meeting with the Plant Management team and an e.xinsive two-day plan[
(liilpment lour wilh qluestiOns and answers from plant operating personnel
The leam then
ievcwcd he te)Oi I froi ibasco
SCrvices Inc., preparcd in response t ( I' I 23 0 ini Wl
to verify plant e(lilipinent and ,),teins
As the Hhasco feport was II ioiths ago, the taim used it as a gU(itde io! (lescription of plant
c'.(lii)liieiit aiid systeis lic (li.scepancies ioted at that time were c:),li,:n
reatl detail tw
deterine which had been corrected since that study. Also, a thorough rie ew of plant records,
observation ol operation a di imraililenance practices, personnel interviews and plant walkd ns
were imtade to dee'iine if 'ainy new conditions or problems had evil ed
The coitib intd
x l),rence of the
t
amie)eeit
mitore than 55 years in virtually all phrases of j)arating pow('
1)hiiit.
This hackground prou\ed helpful iii efforts to understald thAnt c;o s
conitIiOlS observed.
f indis\
l)uring the 12 day plant visit, Uidits I, 2 and 3 were operating, and Ui in' v.as on lof sCrviec.
for the First annual inspection oh coinponlents by CMEC i)ersoniol. While ;he team was oit site,
they obser,,ed a forded outage when Unit 2 tripped from 180 MW' due to low vacuumn caused
by a failed turbiine drain line. The team was able to observe the operator response, maintenancc
activities and rein to se.vice tirocess. These observations helped to crif,, findings froitt plant
record reviews
Ire taitt alo went beynnd he ,cope of equi pnent technical due dilieltce antd made 1t
Ii0timiis
it other )lant areas. A thOroulh review of the eml)loyee colony was ittade. Observattons on
)hant acilities, toolin, rollig stock, personnel issues and practices wer also ,atlliredI '[li
reirtindei of this repor will save to docuireent the Ltean's findings and tecoinlitelidatotts otil tre
technical due diligence iii response to CWP 1.38.0.
Included as attachments are gerreral
continents relating to tIre ancillary issues.
FINI)INGS, (Wij
6.a)
6(a)
and COnllonwils willhi present

lixamine the existing study and co npale 1is o)sCrvalions
(locumntsn
r
ostction
)lant conditions, co(Is and ci
areas were again revised and brought
Areas identified in the 11hasco report as problem
built to code established either in
to conFirm all units w,icIC
uip to date. We were Mhlc'
but prool apparently was taken
China or Japan All hiigh pressure welds were x-rayed,
about wclder qual fication agaiii coulI
by contractor when they IcIt ihe site. When asked
stani welders were rouglia n they do
not establish proof but werc told anyti e the lPak
Units 2. 3 and -1
have qualiFicat on A!ppea dix A is doctimctematlon typical for
which accoutslr the lov capacity
\VAPDA is using this plant to control frecqlency
outptl. Plant isbeing 1naintai1e(d
factor, and there is no incetlive to uin at iviaxiintnm
predictive maintenance being done.
by emergency mraii tellnailIce only, no preventive or
training is oi the ot) training only.
The staT is relatively inexperienced and most of the
1pivIn
and very little testing eqt
Presently there is io inainiance shop equilel)ld
testing
found no proof of acceptance
available to I&C or Alectrical personnel. We.also
3 illoperation. with all controls in
ol any or the tin ,s. Observed Units 1,2 and
autonatic.
discrepancies noted in the E-basco
The tables following present the findings of all areas of
uJNIT IN(.
I'RI.-FNT AS"-.MIKNT
()RIGINAL U.gASCO ASSFI-NENT

,oilefr
ipiobl,
;i have
All weals vlcCreCTlaCcd
Kid
aII
3ctlo
Yt
performeci
I-od IlUnl) Mcchinicral S al

,
(:ondnsci
Adlition of llydochrc acai
Scaling
has
corrected the probeim recent

inspclion indI cate no scaling
iol)lem due 1o
Still exJ)Ccrrry.'w
design. P~resentlv nc tming all units
together and indicart i i 2-3 and -4
Coagulation U:nits
Flat bottoms and Ilushing system not

designed propery
are suf icint 10 mal
up waler [or
entire plant____
Tube Lcak
No new ones silCcw
in Lcorronizer Section
.al
eInssei11rlI[
UJNlT NO. 2
ORIGINAL ASS EM ENT
___
A(ccpance lesting report1s ar not

A v labl)1Cer
Oil spills around No 2 lIBuriw

and on Wiidbox Casile
l)Ccks
Oil Burner Gulls do iot relract without

Solle Mantal Assist
i'____T________N
\Was told it was not done, unable to

y
Indications arc there but they have riot
)een btrLning oil, so couldn't verify.
Management indicated they have
worked on the problein
Interviews with operations indicate they

work and only hang up
now and tien.
Appears there is no preventive
i:nalItenalice oi 0is
B (
PleUl atlC Tit drive Io crn r I,.
and D out of Iservice
Three wa) \,i\cs Oii/OI/

burn Ip on Fuci Oil Giu
Actuators.
tle io:.,
H-ydIran I
Auto operation o1 Uit No. 2

Combustion Controls.
Exciter Carbon brushes have
overheating problem.
,\5,eIf
They aie operable but ioed help on
occasions.
Preventive inaintenance
shoulI correct this problem.
was told
application
iiotor
iew/dillerent
installed.
"llis has becl c Irc&;,',
\'Ciified Lin it will operate 'n auto mode.

Increased cleaning and precision
"giiilng of .slide ri has alleviated this
problein
UNIT NO. 2, 3 ANtD 4

PRESEINT ASSEI-MNT
ORIGINAI, ASSEMENT
AuI liilti will not operat
in Aulo
lntervicws wilh Operation departneiit
verified they still cant1 operate this unit

in auto.
It01(
I:l(
Watr
l t l'lukill
TIn!)
listiruinent Air Compressors do not have

illai HIIl tlic.
,id
hfvc cullidI Hlit
-I
No plans to correct problcmn.
As nea! as wc can tell this problem has
ben corrected. TI,: are still

experiencing some grounds on 4 KV
Electrical system that haven't been
identified to (late.
The managenmnt have identi Fied tis
Also
system as one needin- a upgrade
it has a single ailLire? criteria in ilt'
cooling water system lhat nee(
immediate attention.
Boiler Water Chlical Fecd S vstelll

won I oe)late ii aInuo
This
problem has been corrected, and
all systemlis are capable of auto
operation.
Sed ilmintatloil Control
Coaguilation1
(Manual Operation).
Still ruining in manial.
Water Treatient S\Stelms (Mallual
Control) on Dein-Cnralizier \iegCnerailoll

Cycle.
Was told they will operate in auto, but

no
preventive maintenance or control
tule-ups have been perlorned.
Diesel Generators '.

3 ;!md 4
WIII not perform in auto and they
indicated they have a hard lime gellln
them on the line in manual.
66 KV Switchgear l",ge.ig and
Trialili
Tagging is there but done in mairker pen

oily and is \Wearing otf. They are
taggaig with permaneili tags when thev
can. No training has been provided to
date.
Cooling Tower Fails and Intake Pu Ip
motors do notihave adequate overload
Still a problem area Original

recommendation to perform an
protection.
engineering study remains.
Uninterruptable Power Supplv

Docu entioll and Traiiinig.
Systems works, still no training,

however some )rints in Ellnglish.

"<0
UNIT NO. 2, 3 AND 4
OR I;INAI. ASS IM ENT
PIRF SENT ASS IM INT
secpac T2() KV Cables to 2, 3 and

(),I
(liMS
4 Ma[rin
Still a problem area no effort made to

correct to (late.
Grounding No. 2 Unit 6,6

KV feeder to Intake Water ,400Volt
Powr St pply
Haven't been able to isolate problem

Also they arc experincicng same
problem with .4 KV Flmiry, Section
.4 KV unit section on all the Chinese
Units.
Single li'ha;
I).C. batteries jiuts
I and 4.
Anto Operation does not work on

.OlihISloll (.:oiitil Feed-watel
Controls and S-tea
Temperature
Controls.
Positive side scalin, on all batteries

Observed auto operatien of Units 2 and
3, Unit No. 4 dOwIl o:Ist year
inspection Plant Mangenent assu red
that unit will run inAnto.
Aux Boilhi will iot Operate inAuto.
Still having same problem no effort to

correct to (late.
No. 2 Vibration Recorder out of

Service.
In Service now
In Service now.
No. 2 Generator Temp Scanner out ol
Service.
No. 3 Unit E-ccentricity Indication, IP
CI Metal Temp. Turbine Digital speed
and Condenser vac protection. O.O.S.
All in Service.
E-l1C and CCS .,,'Cii do not iuictioil

properly.
I'alIunction corrected and systems work

as designed.
Hydrogen Valves no atuto operation.
Not designed to opetate in automatic
rI'o',.er Cell da i,.ed by

U1it1 3 Cool il1
fail failure,
Repairs have been made to damaged

cell structure.
toses are
available at
All Fire Base Cabinets (to not have Fire Still the case.
the fire station.
Hoses.
Still the same. No apparent problems
Power Cable., instrument cables and
vet, but should he addressed long term.
ligliting cbles all in same
cable trays
and ducts.
9BESr AVAILABLE DOCUMENT
UNIT NO. 2, 3 AND 4
ORIGINAL ASSI-'
_INRESENT ASS IMI
ENI
may even be
Better hooisc' cpir,' rxlJuirCd in
400 V breaker S a EI cables at RO
Condition still exist,
tinloal ng facility alr kill (f oil, (lust,

dirt ard corroion.
w0I sc
jthi,
aire'a
I0(
SLC'ITION VI
IINI)INGS, CW'
6.1)
The ongoli , scldulc( d , aid preventive
6(b)
lellance
ininf
record s and pocedlures were
reviewcd, with the followilnlg Fn(lings,

02oi1n2 _ro
inI Ma iit ieiaice
As a laull or cquiml)ent defect isobserved by operations persoimil, tiley prepare a

Trouble Report Ti'hms report is reviewed and verified by the shift supervisor, who then
decides if lie work can be accolnl)li shied Wvi1th the Unit running, and whether or not a
Permit to Work clearance form is required. If the work is non-oinage type, the shift
supervisol th-n i,,sIi ."
permit to work clearance and the trouble report to tlw
appropriate maintenance discilpline department head. The maintenance dlepartment then
assigns a crew to worl, lhe job, and upon completion cancels the PT\V clearance
This syseit seems to be a logical one by design, but the execution was observed to he
\er'iousl] fla.. ed
I:
1,t , there was no system of priorities ini lace, only vemin
recommenldaioms of what should be done next. Second, there was no planning involved
to determine vhat piarts and materials would be required. Third, there were no writteln
maintenance i)roceduies available for the workers to use, fourth, the type and n1u.mber of
tools required were discovered while the job was in progress. And finally, there was no
the repair work was effective in correcting tile original lault.
attempt to determine itf
These condilions can only result in inefTective and inefficient maintenance over the long
MUl
l'eveli\t
e klaiilei' ice
There ts IttIle or ito prevenliVe maintetance on the equipment at this time. Although
many people appear to understand the requirement for a formalized program, tile mait
focus is still oin workini trouble maintenance jobs.
LnIi2 Teltill Relmir Pr..jLra mu
At )resenlt each of the units have undergone an inspection by the mann facturer after one
year in service. This was part of the contract to construIct the units. A request to make
a scheduled outage on Unit I for 30 days and Units 2 and 3 for 15 days each has been
made to WA PDA. The.time for hese outages, if approved, is October and November,
1992. A detailed plan of work to be done and verificalion of spare pArts availability has
not been madc. No plans were evident beyond 1992.
II
S<E"' 0N \'Il
SEC'I'()N
IN1) IN(;S, (VP
6.c)
6(c)
lvaluate Plant Systents to veril y pel forlMiilCe ISIi coltipllance wIth ksig1 specIficallons.
Evaluate tie potential adverse impact oI both financial ,cquirements and plant operation
of any non-standard conditions observed.

\Vitlh the exception ol: UnJi No 4 which was down for First year inspecihon, observed
units I, 2 and 3 in operation at varyinrg loads. Unit No I is Ihunted to 230 M\V due to
air lcater plugage. Units 2 and 3 were at loads from 70 MW to A(X) M\V Feed watr
two Oil the line one in standhy llls also appl ied to
)Ulnips were runln ing as (]esignledI
condensate pumps, air cormpressor, heater drain pumps and I) and FlD fans on the units
I
W!A\ Ice.
The calculated average heat rates for each Unit was Used as a IasiS for evaluation, as
perlormance tests are not run on tile trn its. From annual :orm E data, the heat rates itn
K('AIL/KWh for the period July 1991 to June 1992.

DIFFERENCE
(DIES - AVG)
UNIT NO.
DESIGN 1I- ,AT

RATE-
AVERAGE HEAT
RATE
2284
2363
.79
2584
2418
+,166
2584
2392
-192
2584
2414
--170
FillI datd 'ulo indicate Urtit is opetatirtg ,,ightly %ll Illll desi.ll, antd Untits 2, 3
and 4 are operating beiter Ihan design. However, the conditions for design are unknown
(such as load. fuel type, ambient conditions, etc.), therelore it is dilfficult to iraw any
ieaningful conclusiorns. Tie team would recommend each uudi undergo a periodic
performance test at design conditions. When this is completed, an estimate of finarncial
impact cart be better calculated.
Unit No. I has a six cell dourble flow cooling tower and Units 2, 3 and 4 have 12 cell
double lov, cooling towers, temperature was greater thanl 1001: when observation Was
made and circulating water ternl)erature were running 730TF inlet and 76F outlet.
The control systems on thte lits n.tuin rig were ObServe( to be operating in tie antonatic
mode, interviews with operation staff coni-rmed (EC) electrical hydraulic control and
the (CCS) coordinated control system are working properly. Units 2 and 3 were on gas
they hiv(:
c
lfl IndicateI
I 1i1ii load
woCouldn't oItP(l V oil I-liC ofp)Cai iolIi

for
otlctwo tillil
Only enot .li s alvaI l
nlerg dic.'l
in(hicaieC ti
'eraio
oiln
Jlirs
illirc;d 0il
%iccesSfully.
2, 1 and( 4 will no start and load in autO and staff
pil)It'lii ISil)cmlf', ,~ di( wt,(l by the manufactuir:i
Auix )oilcis l(o

not a priomri)'
IJiiii'% 2, , , ( I
t;i [ih s point.
Ij
l ijn
.ei e
iiie!,
i i li.i
"c
lI fcrvi1ewS indicate it'S

13
S ICTION VIII
FINDINGS, CWI' 6(d)
( (I) IPlan ol)eraltios, availalliliiy, p)erlormance, water chemistry and control and Instrumen
activities were reviewed with the following Findings:

Plant operations does. not appear to have any goals beyond making electricity. Unit
l-h(:iency is nor a major concern, and no performance testing is perform'ed on the units
or Oil the equipment Heat ate (gross) lumbers are calculated from summaries of daily
log sheets oil a monthly bast,. and reported on annual "E" formii An y discrepancies
from design are not exl)lored for root caused and subsequent corretilOi.
(il)l)a i to be of high concern to plant. l) rilg ou visit, unit
1liu; ,vailabilil) does utmi
the
iwipped ol low turbine vacuiln due to a ruptured drain line from the turbine to
condenser. The rupture was in a 6" carbon steel elbow. The elhow was replaced, and
the Ii lt reuLied to servie six days later. The actual time to cur out tile damaged pipe
was
elC
section and weld in a ilew piece was abotlt eight hours.
The reillailder of rite
S)eilt Oil perloring other ili lteilaiice as identilied by l)rev\ioLiS Tioublc Rep)orts. Had
availability been a concern,

the total outage time Should have been less than 24 hours,
resLthiilg in impl)roved availabilitv. Availability numbers are calculated and reported only,
WS ol atempts to iilpiove.
Fuel consumption is also an area that has concern only to the extent the storage tanks
don't run dry. There appears to be no effort to focus on reduction of fuel usage. This
area is one witlh a verq high potential for improveIlents, as wise usage of fuel translates
directly to improve hem ras. re sulting in a better financial picture overall
Water cheilistrv and control appears to be adequate. The pretreatment systems all
fuictioi per design, with some labor-intensive processes in place. The result is an
adequate supply of silt-free filtered water to meet tile needs of the demillleralizers, cooling
towers, plant service water, and colony constinlptioil.
leilineralizer, with IlurcI than adequate capacity to leet

\Vater samlpling is contiluous for make-up water, coldelsate,
o)erational needs.
feedwater, boiler water and steall. In addition, illalilal samples are taken every four
hours and analyzed in the laboratory. Tle boiler water chemistry is controlled to a
coordinated Ph-Phosplate scheme, wit automatic chemical injection systems with
Each ujniln has its OVll
iaiil
v.o-d
variable feed rates adjusted as required based on laboratory water analysis. In general,
tlie water chemistry and control appears to be il line with prudent practices, designed to
prevent boiler pressure parts from early failure, as well as protecting tile turbine from
early stage solid particle erosion or later stage efficiency-robbiig deposits.
1H
BEST AVAILABLE KCUMENT
The instrumentation pioblcnis all appear to be on Unis 2, 3 and 4 All of the problems
appear to be solvable and well within today's technology. It will take some time, money
and foctus to bring the inst ru mentation an(l controls systems o a desirablc level that
would he considercd acceptable for ciniInued reliallc opcration The problems can be
ilioken down into five main areas (I) Design, (2) [)ocuimnlatioii. (3) Construction,
(4) Pci sount. and (5) I'raining.
The overall control philosophy for combstion control, steam temperature

controls, dirnin level and feed water controls and turbine conlrols is sound, and
keeping, with current technology. The components appear to be a cheap imitation

of Baily contros equipment, and are very difficltl to calibrate, adjust and
operate. Calibration drift is a very common problem, and is not checked with
any frequency
1Docu mentalml
i
Documentation on components, as well on systems and control loops is very

poor. Drawings are hard to read, not properly translated and not made available.
Only some systemis have correct drawings, and these are hard to Find.
Consi ructioi
Instrument air lines are carbon steel and have rust and plugging probleis. Some
systems have been 'hanged to stainless steel tubing. Boiler instrumentation is

installed in the ield in enclosures that are not water proof. Very few instrument
wiring terminals are labeled properly and perianeintly. Instrumentation cables
are not shielded, and are run in the same cable trays as power cables.
IPersonnel
Adequate trained staffing appears to be a problem. Only a very few engineers
understand controls and how to troubleshoot and the, are spread very thin. It is
not unconmon for on engineer to work 24 hours at a time. The bulk of the
personnel in the instrument shop are fitters, and can only calibrate gages and do
other menial tasks. Due to the excessive hours worO:ed. 110 One is available for
call-outs.

I5
SVHC'rI )f\'
FINDINGS, C\VP (e)
6. e)
.ad ii:: ; that should be addressed during the

The tea ii has leintiflied a ilnlI l'
These items are listed in the following pages
corporatization stages of )rival
There are recommended actions i,.1 .. condition identified vith cost estimates totalling
$677,000. Many of Ihese issues are already being addressed by \VAPDA, as shown in
Appendix B
The teamin was n11O Iblcto i(lentily all), signillicant problen areas that should restIt in 1i
reductloll iii the i)urchasc price of the facility. There were a number of areas that should
receive all initial level oft illaimi enaince attention for one-titme resolution _.xain les (l
these tire:
Iim)rove Igiilli
il all boilei"s and equipment rooms Oil Inez.ianine 1n(I iawimwtn!
levels.
ketiril all
to ,ci vice, and keep ol a maieiai c jfl0_'Iii:
Contilue i)lOgi aii ofl marking wiring terminations behind BTG board and im
cabinets.
Repair sheet iieial lagging oil No. 2 boiler fhue gas duct work. Reinforce pop
rivels elsewhere
Replace bi u
,en ill windowS in turbine deck and in auxiliary bLildinlgs
Repair boiler t,.ilny cracks causing gas leaks and hot spots on No. ?. 3 and ,'1
boilers.
Investigate boiler slag build-up on Unit one superheater elements and formulate'
l)lans to desensitize the effect.
Perforit survey io ensure adequate spare parts are available to support
inai ntenance progra n.
Continue efforts to provide as-built drawings and documents oil all equilpiment
Theleamn also feels, ill tIei r opinion, there is no significant expected condition that woul(
require JPC to mainlain a level of' financial reserves greater' than normally expected.

17
IIT
CN
OMMINIATI(N OR
IIC)
RET
CORREICTION
Units 2, 3 and 4 have majol control
problems on coinhust lol control,
sieai letp controls ald
f-fwI c r/(IrIlr
Replace iron instrument an
lines with stainless steel

Purchase and install
I vel (0:o11it'1
*
6
weather-proof enclosure, Ior

all ou'side instrul rlentallon
Replace/upgrade (Iliclent
components with new dicsiin
Establish preventive
naintenalce and calbralon
(A I1ROX)
120,00(
65,000
, ,.000
0
program with proccilles
aid training
Provide shielded cable in
separate conduit for all
instrument signals
water.
Provide separate pumps for

instrument air compressor cool,,
water. PLumps with a back-u )
scheme and separate piping
arrangement interconnected with
sister units would be recomnmended
All niitits hta\c sialCuld-Jloite vital

,sleins of v alci . air. hydrogen
tic This reduces omcrational
Provide interconnection bet\keeu all

units for the followinrg plant
support systems:
Units 2, 3 and 4 have cooling

tower make-up )imnps to su)ply
cooling waler lmr instrument air
compressors Tli(ese pumlps are
outside, and occasionally uider
i6.000
48.000
f'lexibility, and adversely effects

*
hInstrument air
Pre-treated water
35,0X0
35,000
*
*
*

Demineralized water
Hydrogen gas
Emergency diesel bus
Service air
35,000
35,000
35,000
35,000
unit relabiliit
Units 2, 3 and 4 do not have

automatic generator hydrogen
Manual pressui re
coIt
pesre
controls dependeint oll operator
alert.
Provide automatic generator

hydrogen gas pressure controls.
with regulator valve. sensing
element and mianual bypass valves
15,000

18
I'")ONI'NI)ATION I"(OR
CO)NI)ITION
(O R R
N() loririal miaintCnance irograin
hwymid n~ouleh resonse
TI'IK) N
(A I1PR() X)
Install Compulcr ned Marnicnatlc

MaaltlcicnI .sysll (CNIM.S)
cquiiiJ) illtit) Inrltidc
S
*
*
PI scles(lls and work

orde s
PPlaniing/Sched iinrig
s
c
I IIII
elrIn niaintenanice
[Lo1or
plans
Spare parts Inventory
control
Cost accounting (per Unit)
Maintenance record kecpiig
leporting capability (iMulli
fornal)
80,000
for
it stall ati on
and trainillno
Only
Assumption
thai hardware
and software
have bece
procured and
are available.
Train plaliti)OpII latii on CNINIMS

No focus 0onwit or plant
availability. efliciency, or longterm reliability.
Establish positions of reliability

engineer and performance test
engineer. Positions should be
separate from line maintenance
rCS)Oinsibilitics, arid be authoriz,1 ed
to recommend courses of action.
linus 2, 3 and 4 turbine high

pressure c,,:2!r!;! 00l piping %%elds
have failed, and QC documents are
not available
Provide 100% NDE inspection ol

all H1igh Press,.nrc hydraulic oil
welds. Repair/replace dcefective
areas with certil ed welds.
TTotal Approx
No additional
cost, as
positions will
replace
existinrg
posts,
50,200
677,000

19
AVI'TACHMIENT I
I'A
0 NY
.i"'
The plant colony is adjaceit to Ole power slaltO, located north of the RO unloading facilities.
The purpose of the colony is to provide adequate housing and living requirements for the plant
employees. The concept includes all necessiies; however many facilities are under construction
or not yet saffed
The plant colony is about 25 30% occupied as of this date, largely [ie to the )oow facilities
available The majority of current residents are plant management and supervision, as these
employces are given stroiig urgTii to live there The rest of tie iiployees live in Hyderabad
City, or nearby villages.
San tation is ver) pooi with sewage dsclhiarged IIIo open trenchies, and no rubbish or garbag
disposal area. 'here is no l)Lblic transportatn i for [ainilies to travel for school, shopping o)i
other needs. There is a hospi:al, college, boys school, girls school, post office, bank and market
area for the employees. None ol these facilities are staffed, however, and are not available foi
use by residents. There are plans lot iecrcation facilities, but they have not been completed
There is a bus ava Ilable to transport workers to and froii the i)lait at shilt change times.
The potential for the colony is very great It should be completed and cleaned up soon. Priority
needs to be put on hiring tlie proper stall t open existing facilities.

2C
A'I I'ACI1\4ENT 2
PIANT STOR I-S
Not pari of Ihis (
I'
I [)I recqitc ld 1))y RCsident Advisor cvaluateci Ilie stores department.
The plant has four large warehouses on site, esimiated to be about 3600 square feet per unit
They are in tle process of seeing tIU) some control. Observe twenty large containers not opened
that coniained spare parts for Unit No. I. Was told by manager they have only received
appoxiIuately 20% of the spares for Units 2, 3 and 1
Appears tile), -ire handica)ped by lack of trained stores p'oinncl, no inivclllory control and lack
of cqipment iIeeed !ohandel large and heavy spares
(o;stiiinables
for everyday opcaioll u a large powei plail were not avalhibhl., they purclasc
on a as need basis in Hyderabad

Observed a laige quantity of chemicals that were stored outside and probably no Ionger use"lul
due to weather etc
There is no fire protection installed in any of the warehouses.

Management feels the), are well supplied Ifor Unit No. I but expressed strong concerns iII
regaids to Units 2, 3 and 4. They also indicated tile, are losing parts from theft.
\Ve also tried to obtain a list o available ecuiplmenl on site
Two
One
17
I-e
Two
Two
One
25T Mobile Cranes, nanil Iifact ured in Ja)an

Bedford Truck No. boy
Fire pumper units, one not 1tinil)
Pajeros for Management use
Small Fork Liits
Water Tanker
Stores is res)ollSible for fuel accountability including unloading, indication this is talking a lot
of manpower.
Conclusioni tiley have more than enough storage area, addition of an invenlory control, some fire
protection, equipment for Iraiisporti ng and training is needed to enstire plant is supplied as
required.
21
A'I'A(C[IMIKN'I' 3
%I'AI,N(;PRO' OS \ I.
,1l(
)ovcr ('ollilflny (JPC) with

Attached is a proposed organ /izilimnf l ,,tluttlc Io Jaillshoro
each functional area As you carl
preliminary estimates of numbers ol employees required l n
This estimate is based on
see, the entire comiplement of JIPC would be about 520 employees
comlpleted. Additional
been
efforts have
conditions expected to exist after imal corporatization
overhauls on a five year. per unit basis.
-ontract labor may be reqtmired to perloril large plant
adjusted peraiodcdllY as needs change.
Aso, tie standig compleient shumld be renewed and
Some features of is proposal include.
*
Pla
tllC olOn y a~ltI I
operations actvit
lm
c,:ratle Iroin
,ilnld iwtsl
" ,
\!if
lai lli
111ct1C11o,1
Procurement, in venltory
control and fuel sup)l)ly
normal plant operations and maintenance;
rmpIC:
FtMnancial ail cost

control functions are ali)
providing a check and balance system,
":llrdlC
ar
separate Irol
Ii ;i l)lant oelratron,
p rforlinrce in tle areas 0f

A greater emnphasis is placed on
improving the plant
availability, reliability and efficiency; and
,.
There is a signilicint inmcrease il the level o! traumvi
for al! eillplOyceS.
wi bc
som ie
complemi.
Since the proposed comp:leimlent is about one-third
of existing
I am
training.
is attrition through
required to achieve these levels. The key to this transition
proiposal to reduce the laboi force,
but
aware of the sensitivity that will necessarily accompaly a
it \ ill eventuall' be offset b imlprved employee net worth
JAMSHOR0 POWER CORPORATION
PROPOSED CORPORATE STRUCTURE
_liOn
)OF
.O
DIPECTOR5,1()
1O
Ic
EYEcuTIuE
SECRETARY?
PVmAgl
UP
PIOCUR1EM
l
EP[SURCES
A IllU[IITORY
SI
PLANI
VP
OPERAT10 6
FitNANCE
II
Un*tit
?tb
nairtn;Cs
'L
oi t;
0_..J
P:I t
LR :,r
* triat.d iplot~
Ech iv.
4
Acu;a
ln..(.-I.flow
PI..,ic.
lan
()
3tt Eous." .- .
'l;.lt
'" ,.
rh.k f-t
..
i
t
IU,
,
(,..
,t..yr,
23
UP PLANT
OPERAT ION
ARA~ i
I ~NS
'
8E
OPERATIONS
A I{ E AH E
SUJPERINTENDENT
SUPERVISOR
(IiII
itmi
*
I
SI
___ ___ ___ ___ __
i t (g
.t;i:ords
i i t .,
-1 *CC,.I
Sro..1r am
(~
,: . :.,,
,
.1
,,,.,,,,
Li
SKAINITFHCE
SUPI.
IASST. SUPt.
]
ASSI. SUPI.
PECKNiICAL
ASST. SUPT.
ELECTRICAL
ASST. SUPT.
IISTR/CONTROL
PLAIiI,,GI
FACILTIES
Kn
!.c.~~
'Intr

G,G ;
ItcIrt
OPERAT I OHS
SIIPERIMTEINDENI
Ii-,.
T&1
L
_1___
OPERATOR
IRA 1 IIMG
ASSI.
AIOOPIis.
OPHS.
ASSI.
3 A4
SUPERUISOR
...
.. ..
r
i:
(I
I~I
i~r
,:r
:,6
BEST AVAILABL EDOCUMENT
APPIENI)IX A
CONSTRUCTION CONTROL DOCUM I'NTS

27
aeater
Src;e
.
, ,."
of
'ilce:
j;/-1-;
No. 2
I
.stuct
1er
on
Co
~-
Group
3
Gp-ou: >-IcA..:O_,N
Ai
",j...
2 s%3-LF
- -
'-
,
.
C-N
__
..
..
.L
",.'
/
____.._-..
_'
"
i
r t
L_, .
& Technical
:ceptanlce
)des of glecr'ic Power"
n5tructiofl
.....
for
'
":'\
-.
.....
B3oiler
IL.."Ji
.....
....................._
.
.......................................
m
NG:Sb N
.-
H:- b :'.
..
"
~L~TR1
e r.Pc t ion
.
NJO
OAV. Ifk'-
XMU ESC!< IPT ON
lT
i;n,,I
o 'En
/-oq
rW
ACIGN-
POEA~CONSTIUC71Ne
of co l1 ' relda t
ste a - p fpin g
-
C~b 0
UA7~
Sep.i
AA
acc pt
mc
as
'2/
..
d c
P'
................................................................................................................................
d-rawin
3,,-
----
acceptanc
gi
kep
kg/m-I_
kg
Z717'
-.
--
Moealc
or5mn-te
olaocwifud
z-~tc=w3rnz
---
st
the~~ ~
requirent
a ~i~oCccz
~~~~~BS
aea
E rz
~~
cx
L u
A-ae
PLANT IM iPR() V IEM FNT PROJ ICT'S

hllcrina1l Plower Slation, ,Iainslloro
I&C lrol)1lis on Unit 2, 3 and 4
S No.
'rullltr
eficiency
,
Frqucnt iroblem%
iicuinjtlAC a;ltuJtir -- I
oIil.r &- Turliiic

Lmitillcrs. cajsn
rclutictiifl it load (it
tIrljp noil of thre U1t1%
Ircmpoal/Rltit'itif dalin
Ci
EC"- .,
too fIorimih a tIctailci
I liouaufaclulcl.
rklorl
lvctgwdtiiil\ .11(
rCuIt ti ndttiolis fi)r ,olitillooItii "

15 6 92 WAPDA
prrrlc ii
lll , would lic
rl.shl
Elltllcers arid t. l
uivol',d in c:rrying (tlilt necesry
.rk
or
rtit~ciI/tlei
III',
l'r sent Status
Action by
lhe problem was invcif:iIC'd in detail

, 11liellmlliofi
by Specialits from CI llC
mIianufacturer They ar, if the opii
CE (O &M)
that ic lugg
was due to the
Ol'Coratlin of actuator
qridili i1" theertall
used for InstrumiCltati I aid c i(ollr at

Jamnshoro CM:EC Informcd thalv
pI pinlre I:if the m:ntr i,
el lrii
11ild stel
to stil.
III
assOCiUtII
wilth CM E:.("
IFllst cirm, I
cill~coll Iil
bl to (fl d
;l i
I 0
od
sslc. 1,
"
cirryilig Out %Oln IOdll . iltllsm III

i
Ce 411rfr;i
filtration systeml the
actu.tors h.s, iImtrrvcd al'?;reciably
Since carry ng out thsCe i:,tIdIficat oti,
thre Coilbutiloli Ctulliol S,,cltnl (CCS)

has so far run 6S7 hmm, ,:i U it-2 it,
for 95% of the peri dl it ,orked
satisfactorily on Auto IIIo,&
The
problem is still under im chtialon &

CM EC confinnr:d th:t itc will rectify
tle defect completlyirI Sept 199? on
all 3 units.
In this re:gard tihe coiiiii. .o c al o
suggested that CM E( ,;d ItA1k the
control panels of act ni ih: doist ;ld
water proof.
29
.57
S No
Ir-r
e' ic n "r
InIP IC
I/)ei
Owi;rliy of l1151,icnrial
, o)l l', ito achltlat10 % i% no{it
lI
.,larrcps
cIla gles/ illOdIf C aI rs%(if

ppiir,gn ha,
.5irirlafreplac:irr-it Of tJi11n-4 will b

&'
in'dC during% its fist i'l".sYcCtiur
1de
iiiadl
ill
tllosec on Unit?? wi
qualily of
;Ill
Jalrslh
asociationi
already hcll Complete;d
Il)
for UJniit ? it co hlit
(if
COipleCtui due- to )il availability
.ith CM [1(
must risuirc
(NiI.LC arc (if

tie view ii;it %ileCe Unit -2 has ailrc-dy
bceet taken river by WAPI)A. the
mraterial requicd- [or this ,iodifi-atiOll
cOmictitoi
uill
',l ii th'
Shut(w(
itfirirni
oh
tie job by end

of Sept 1992
TIi,:
s pplirci by \byVAlII)A
e'irhliwued-i
wui'
hi
(:o1iri"ilittet
C ,41-( tih;it conier'r g' in d rt Lilirlis%
should tie
air oil
Ujiir' has :411-i 11ri14iy iiuthiO'(i

Tire are i"i dricsr Witi sirea cl.
Inmt
i l l
l1owever
ally convCnlient shit down oil it

tlade iil air
htilroveifcni Ilai al<ui b 'ri
filte-lr
additionial
drier I)y puttin
arralge'lwil lihe
lo l l
UnitIl
stipcl piin
(T". (O&M)
For Uit-31&4. the;
Nccs5sary instruirrerit air lines for tile

acl~tao ir a lice.. re lacedJ Wilth
A cti l n
rt Sr(
I
l
ll ( ;ltO
I I I Ii 1:
(I
il'!
\VAII)A &"CIM IC. th)Y

drier Is in crvic w11iile itOeolir is on1 OitwCeo
Itocorlipleti tihe
reconirl(
houltd
wor1s
drier
Tie
rcllcrrllill cycle
work in nlitr by
r
on trn at 8 ihrs dily cycle Tlicnoilflcatliloll
ll S plk of rlnalrrial
irchli
tllrcill"elves
tolin tte reellrlcllorlitit to CTine
h
i:Iiilliess
1pe s, i;rir
tei C I,tt
stec i
(t
enrsure coripletlo
I)'fcctrve cl.'cocillu'll
ire-;icrf
l li
The Co- -rti
htile l
ilstmet
I ill te
carltl
'lers
of Ite rrt
relac.iC ilt a1 tilei ]iwil
Tire cOtlillittee r-01tr1llttild6 trat tile

existing arra:irgcitrelrt of recoifllg
'ene-rator Iire.iril
Vil'r.lili:1 rcc
cl
ltI
brarin.- vibration ton 24 p1Otint re-corder

t%Uis:ilffiictory :iiid if il 11Tlerefore it sltlrid ie rclrl:iced wIll
lietier idue collKlcdriilg the %:It-tyai1d
reli:bility Ofi tile runt,

riorders sirrtill
Coniiltr
uuS l1 reicit
Ti1
liew
h:ise- less frc
rtr'gLItl
\VAP)A will pItrclr:iC ;i idr Istall.
(OlolM)
l
o litir
lurilih
Icailite t ill I
tei required
meters iy cnt
ii eflts alid recorder% o i
!
replaced in tire office of GM Thcri
l
remlnt
eic
iroi
Itheir
of
ent
for i rrantell
Of Oc't 9?
I
CE (O &M ) ilia), kindly bc advised ill
.tdy the inodificatOlnS%ploprscd b%
viihr
tie Cornlllillitee ini .stICs ritI 5 Witt
(E
CM EC S11r r:iiists & friir:l;'i1 tIre

olier t Icirinreat dc.;i!,
slr ileati,
if tire illsirull11 t & re,:,ers Io ic:
li1%rit ctioi Io
hi% staff
tor arrar-i
rci
t tt
ilz
if tiheir ;'m turter
.i*.
i,
.,
'd th.!i
a ll
suchlrititle tire V'rr rr l.eofd ,rsi"
replaced with licel qualir tire P-r,71
Station Matrere/p~ii~t--f
Ow.itcb
,; tir"
.,hiuld k ,.tll st ret
viliratrort rc hirr's in all tieix3 ililit
Porl.blte Vsiratrini lirte
lay tir
I
1
i ,wd
'i i t'. vi itiloil

for frcqu ritii che u', tie unit :tlld
tarrllng
liirg
d(
s.pecially
icadr,. s ibe
tile-e
al
ol
proprcr record
keplt.
. ...

30
(O&M)
Jarrtshoro to
recriaed ito lie ri.l,es' iI C\i Therr.is
"'Ir Colililrii,
r cr t\pe
reiC
oiif thre J-41______________
)
d to
midvibe
(O Mi ira)'
Pik"
CfutdiCE
Stui)dy tire indificalirs11 Irlnnps d ill)r
tire Cilllitute in . issi ,,iil wilh
t i ucin i~ i :
C tMI T.CS lj ec.ii sl
specification annd illicrr itinril detill,
tle l iht
I e ira c
rell.11Ie \VAPDA %iutlid reillwc ite-e

eters w ithi tih otse i ietle f i rl:ii e 3s
tm
or its
r
CM EC du tot :-rcc
Unreltable tirio
iLlI
ie ad' is d 1.r
iJlitlir lr rr1"1) iihlel
occessary
S No.
l'riiji(iSa/lRC-liikV
Overlhratiri/ulO~iiiiig i,
'
M/S CM F:C will
Col if Iihc
hcrcliroyldfa,iit
n
,'0. r{,
Iresent St ts
C0 iie" tilo
iii )
Pr iI I In/l) 'fric
Ili fact the

This probicli Ni1l ct,,,t.
tudy the Iroblem of
the Liver licatilig of coil offcklctrl
coil of FlICrCr(i hiydaluh
hiydraulic govrnnr clairl,', over value
Unit 2 wa% alo
to Mcliaiiiel goverll
ction by.
.....
taken
"
their
viLL! ver,a and will %utmini(
ardillg
irfliiosa , colloidiitiis i lo l ie2ls

i f Jlne, 1992
s
Ircitetdhes hy I5th
t l
of 1lic C( 1iiriirliik.
by
end of
Scpteinlrc
01/) aCtinri (iii icCoiiiifllnti'i
proposal
solve tli%
hi'roblei
inalt.lurin
S{ofart CM[C have
dIown, oIn" l 9
syseiri :iod
truwt
CMC
govcrnor of
1992
xcep
reassccllin, & nnrmal checking of

[-HG for Solving tis probliin CM FC
of Unit
lie cond
1r11111
Irforltil that
(iitlet%-llfal|) Ho.iwever the
i i%
tivericJrtiiig,/ hIwririii i l I :1 of Unit
and
ihiiii iiil11i.. .iii
lidilc
is mtill
that the.
ilos',.l
e
lla
Icy riv
by 31st
ss'uld suitIriIl a dtiill lk )ri1
',study
July 1992
1 i1;- 11,i lcI:,.t i l.

Iu
nstl lled sstlihittt
%
iroitectirng [tit e arid
,oni:
places flexible
tiCrocoules have liceen

us,d iitead of fixed
('N EC .
l,'S
Ciitillte
I
t:os(.i.I Ill IhI
r tlie,'d
tlicrlol
that tire tlerilocoulilcs tii
boliler and til rllt: s ile Should be
*
'
riistalled with thermocoulple well

,\/S CMEC will c-heck each poun on
4
, \VAPDA [- nmeers and
itL- wih
cx it is ll'le
(1s Cl 1.
I
, .lliCIC
e iw ll le :Likcii
ICIII'ri .1d SiniLlf SI
, _
00 Ul'2
r . I.I i
ii
IC
lup icr
anrd
d
1 g % lin
of:
C~rrf:l:
fin
tact:
till flw ilree.r
I% :mnd R.0 Ilov hma e no lault

h
"l.lc
I' e as flow meters require correctiri
tion
%nstro
IIg
Iris staff
keep strict
problem of thicmnrisll. les will not

tile
watch
.hIki' allc level
tu;sth.Ms~Ius
SrL.'
Ir
Z Cr
riire ardin
in
CMEC ilnfoflned 11a1 or'f.tlOii factor

for Ii oil and as flow meters havt
iitIceters require frequent
I li
Ill1iitrllart'e amid
CM EC will
dliitoiostrale tie correct proeilui r

ill
flow ieters have also bert
I.;ecialhsts to
deirolnstrated b) C\[C
id row%,
sta
tice
11ai11etia
\VAPDA
;iid epiur to WAPI)A
Th," CtiIIrlItt.e
Ic.-clihies.i.tslis
ietr urL~ik,
hI
rsitirCnerdC
d thl:il thre
Ir.rcilLced wstt
iit s
Hoevser M/S CMEC
ctrttitnettts/recoitnieitd:|tii\s
]titlc
rsfaclorli\
tlh:it
CM:ilC: infilillild
i,,1,dll
iii In
yI Sill
1912
CE (O&M )
!%fit)
ilh;,:
: 1 . ..
,:tls
coordinaitt
ChilF.C tllprovide
job with
gudance and Ira llng io WAPDA
CMEC &
1992. v.hci
ii:HIImtcnIIcc ltaft I Aui..;ir scat
site,C 1
rihl
t
tleli Speciali
irfori
J:anllhoro t.Ira' kindly be
adVICd i0 C 0rsllrdi.ti: !i, 'ork w%-ilth
(O&e.s)
CMIIFC
310
ah
Jiishoro
arid pro:ler
lt
requircLitii 1ous
ritarnlnrce
ha|ve irulfrmied that they will give
Job attended
by CM EC
!i% attendril
W\APDA irraintcnat isc' ..
tile
job
ituirelts
thce..'i!
redltiron (iflen.Ihi -ifIlc -n.1c ule

l nsured
thlt
i
,well,, CM [C hl: nwc
o :r
alsI b e:er iade
already ben provided Il, WAPDA
Procdures of scrvicm ., foil and gas
;I selilmii
:I
by CNI FEC
i." hil
factor dtoe to variation in tile gas

te.nsity Iroit tiledesign density Oil
____ll
Ioh
.rill
.N11-.C
Cil (Oto it,
ceaur
ii thiiit
iiiral n I h r
iiiaill
JailisOro to
on
2
3&4 (4 Nos nt Unit 4, af;d.cJ

11hllwatioiiissue
rave
Sorr"
1)
2
lit 3
reoccur aga
lChl.bilmt)
lI11
..
progress.
lI
lit
+No).
"'
Pr
Deic'
lieml(
I)
+I'IObiltvil
iiihit
.ql
.i
o
!wiI
" "U
II I e'lllII
iI
Ill
Pre
..
to irovide btitr
+tli.
i
thcIinicOIIIi:
.with wells
r rCvxtessjafy
ehve:ie
anid
fir Icli llCalic
iltndItior./+'a/"i.i
M1 1 ("Nil:(:
J'rilvidinig th:rinoi i,:1,
iiI.ililih
ti ic it-.II -,I Irtcr ;I
ss'IltI
,%iw il aciuil l, litllli\
ii*cd
rc
art,
ilic'riiiu-"ll
1
tu...on
"itlh
alshOl-o
"2ugCthlh
"
hirc
ill
CIF (O&M)
CMEC have chai;rtlj their st.id aid

fow tlcy dc riot a erfCtit pros.dr
thiCiteOCOtiuiplSttifilrlu f
%VAP[)A
II;I .
i iil
St
....
en
wells o n itlow pt. irc

piliC hlucs Ihi0.cvc r lil
iinfrmairlntloll
tltC
under Upcraifion in
cnillt-:
Thlc
.
\VAPI)A Systcn
air.nd the job

CM[C iliimt
clslor
l it I [loilll;c t)17
C~iiIIIIh;tM/ctl liht
l
CoIIIII 1mIi(-'llll
lialiity bot the ahic inodil3caiOll is

tIr:
(if
also iteces ry (for 1ic %:fi'+
this jii
On duty On pursuanl
operating taIf.l
of thie CoitiiteCe CMF.C dcsired that
LJii-it4 duiil.
Is fir
\VAPDA should inform the 1nC.ilion
irl
lrCCC.sary oi low
water/oil pipc Iies
therefore pleas
leclally till
timgrti
s m
C llahul
generator, F D
hai a:i
th' 11;1e
CMEC iave iforimed tlla!
already carried outl licc-,.
CE tOtsM)
Jailllorit IIliist
Ldjtisilh and rclair Of d1 1tal

%canners durine I slInspection of unit.
IfovideC it:eh
Sreh:ilihe aiid
,liild tic rellieCd \With

Siilim:1 lyllc of sctllier
etlier qu.tlht
iiot
i:ilillcd tilt Glddii Ulilt-4 ire ;iti(
4. However the Coitittz. still

. ihould
recoiiirrienid that \VAliDA
arrange reila iciil oh tIX c a.ii,-',
of the reqrtii
s..lillfs III
Irlable anidiiisl illit: 11mi1it :ire out

,'Ioil.';
swith tire better quality Ito.: ittso
1992
I MhiS C;\IEC ;ioreed tI Ik their

"
i
amid rectif) th
t cuel:
SlmCCi ll
''i
limlt
However lie conitnitce
ild
fCCct'tll
feed IputipiIS
ii
ciacier
scdill.
before tire end of I t iiisN.;t__
e
Ii'rrib,.ii
Iciilpe r
C l ll
CE lOkNi) ilia
tic idvs+ to pro'ide
such inforanation to CNiJC within oac

'eek so that ulcessary .lt;I regardin,
.*ouiiwe:"
ifIttiru , 1 ' *:augC
t
itirivitliili
t4
-.
tray be tAken bi) CMiEC o,
II
('M FC so that
thcy ailny
still fc:ls that such well% Inustbe

nainal pritclice
provided as it is nitcr
and similar arra gnicnt%cust i olhl
[lower plants
old providt
lite rcquisl'i
It
that
Iics
scli
'rsare riot
ll
f, r re
. C[ii (O~i&M) Lishoii'o I(&;S

therefore please tir atlismss to %tud)
iiodi riet' tol iii :1-1i.,1i0iii wilh
tills
s ait
aild fur iish 1i1'cL:'.atinnI
[C
C I
other technical
Cod Of OcL
i llit
I': uro
'tuuul
Seeiricatiii
Tire pitobl'in is lil

I C s
:U..s
electronic cotliiollCiitl
of proctui
lnt
and transislor'
CMI+C -! re Iito'sc:
rcqueietd loipro%!,
lit' .ry
Ptti(hai+ee tom\VAiD\ i/Ai[

also fijul h a lisI IiiIIIu
till the rcplaceimient iOf
eer alth
'
sp1N'
laiitare
';::e
qu.alYir
.,canners is madc liv \V._iDA.
Probleiti
indicators fr
Ilhevl
Dcrri
CMEC
(
%sillgive their c mmetri tr/
. 11)9
i.ilcldtiiiln%hir15th J rllr
CMIEC arc shill %'stJ-'' :
The
w iqtuir
\cill
providirt iclhlr:
tas.icnd
water tank. service: walej
iit
ct
iC
l
foil
olhilw,:. I tis
liiil.
'llr:,ll(
, \
19)?
required
32
hi
I'
irleiri
end Of ScpI
BEST AVAILABLE DOCUIENT
S. No
Pull im
II' 111hlq/De'icleWnt'y
if Isnisictaii
Iit.
ici . l
11I
II,
i11 yici llh fc
"( "
(+MI
M/.
(IM 10 1
iifll+ts
agcd Ihat llst
iiii ha 1 ics
1C i'111
I
dit Vs'iy tiill i
hdhii'
x
%1li(.'ji'l
1/ Ni/% (4MIz
i th
ark: cisidtic
rlig
tXl 11 i1
xiillriocoilfles
csleii'
p olcO._
li.iciltslloc
lulrin
('NIC si:icd th:
tht lroblei
is
tlue
ilt ere arei 1i) %s;:m1e

.[C ai c..: mI
mexin recorders
points kll [lit:
oeldr TmiJhciiii ,,qc ",,lllUitteC rd.W'itlt lt ile d to
m
l c
cirrhrs Ily
fcdl
onnictlmrlm
mmit.mll .
i'hck
,\ l ttho:I:ml tcil 1 ,efrtr~ic

i recording
c(tdtrs for
ii.Iti,.
(l
alcr ni
on HP exhast
,Ilc
WAI').\
id for curi|
m
h
IPelie
thcrtnocoulic
by cod of Oci
that
ull'u
iill .I
arr; I
ti:it
lllwiili
spccificattiii
of all
1992 so
.
(if -- hiii
)tler qualit
thferrrnoeir il,
kliih tic
could lie
in;ide
b clttlr
,loncoulpie, ;as chluiuu
qialite tli!rinocotillke% i% lc iindilhe

,
Cl
C
.
i, ,
;i,i c; III C kiE(
) m.+ay ilhcrelurc
take Icese
13
ni
afte-t
did nit.
;luld I',
tjiii
(Ok.
run
uils,,
ch
thinks that thesc riellactitl
['hie CotuinttCC tcrfri
w lthC MI (
slio)uld c'llhi1
i11ittC
,c r li" i it
req t td toi :inrau c finrIIt
cc
n c
r1%
-l.uc i nt if bttler iu.lri'
11drCIrly
thi1i
Iby,
lrhr.tl,i trduier ,turk
h, ::ll in if r ,asurfIir hii:ir
,i
.r
I ihi,. . . t~i uumiu,.l by their ". u;mh ,t
,i li Il il-: .
'
liC I11r i l lIic ell"I
lih -c
CMEC [3ijriug
with
rc~lacciiit oif 1lhr'uilcs
c+l.sl(jcfrd
li
u
ui1ut
tlI'c
icd
ni lsruh
1
.IIS
Unit
t.,itlh the rc%%l'ctinlcit
iide
thtie
C[=. ((C)EiiM) III

asocialil(ri
they IIc
11arlc+
ilill+rilniciwitlds with
thIiriimocoullCS will nlt :rIt loll: and

will stat giving troul)Ic a tai within
u ratlni o[ tho" plant
one yar of thir 1+
In tile
lic Inproveid
C4MEC Infolicd tIh,
on
thi1 iloIlcinI scniiisly and will Fod ou

[lIt
tile rcamir \ fori its occtjrrclrcc
C0liiilitetc rrcnmiiicridil that quality iif
ilelicrlooucoiple
Action ht)
ti e s im ila r tytic
.'c
if
ofi
I'r-eent StaLtut,
replaced c
" . 3 I,
1 11ttdc d (Iii Iii it
L,, Id 11,1 ti
I| iqtlit
. ,* .1 rlj
nm e n
+'
k eco
il
,J'
ary actriiii ,,nmmudu.dntehy
CE (O& lv ) nay hildly I'" .l,,'

(whlll C
coordinate work \i
lb. tiI'
of0h:n
ex pedite Iitallat litiiiin of
rccorders as prolosed I'I! 1:
ti
'nl
CI. (OKhMi
Jainshlno tI
s crisi,:,
that tit:
4
:.ulrd then tll
Cormrirttee first om UI111
Unill. svlhcnivcr is pio',ildlc
proposed
teinll
record,i
lieinst;illcd 1,.
CMEC
specially oil
Unit 4 btefor,
end of INt
111+.lic ."1111
r, , ii ;ir, 1 ,erl
for
l,,riit d
of
corp+ci.:itlmi"
stlch lilies till
.iMC %.crc shl
'","s
iprike tile %
I ,; oI tile
M4
Iw it 1
lrdilcin
dclc ,
l h:\ h
:e:u:I'rr ul'-to sturdy tire
ii
arid recily ireces:rv
k'lciml
The .lltodirica lhol work i\ itI 1 fi re'sS,

aid \viil be cot 1 rleCtEd lict,tr tire cod
howe\cr
of 1st ilisIecIoii ol Unit-"
tle \rorkl of simrilair
Job Is .lhrrw,
coltlitlect i I
CM EC
0";,
rrs oitdi'i
U ,.t; _ ard 3 \ill Ir' c.n id oMilI\

CM [C in as:i,,momr %I!! ,.AI'l)-.
stall s and when shul dwwn o illhe'
Ct'." (Okl ) ,'ia.
ilittss av:il-ablc
lehas\ be oVdist'd to Lorh.luirt this
sor,
I 'I
l)iil'crc',iC
rcjedii,
ir
Icvcl tdc:itrl
ii
unit.2
ii
tlh:
.:C
MI1S Cm
lt:r,
iodcr drumu
slic'ally
Ito
tii.h prolem
CMEC have Infurireil 1h::' l1,:
Unit.
tol h:itll
lhrec'r
Unit.,. %I/SCNIEC expet are

uil I o tile problem antd
t ly lur
tiley \ , mAinrt ai r-,-nloit to \iAPDi
ru;|gau
L
I
+tiler'Ilcm
coniditiorn havc
Aund tlIre
iiIrI-'ivccd "11srdcr\ilV
Job Ii,
ii':llltld
iplo
h111 C that it wvill oIt
h';ms;uge ii
furtlier with tieC
and their
ieiidi iii I|i'ieasitcs-,
33
No
N
idrltufi~lIIIII
No, plIIIP(
101
lll
on ontol'
aind dfI(crcmi
I, l
iiII:IlfsI
cxIlin
oi'
It
f11
I'epl~Ico
Ivm(rl
i'-ben
M/S CMFC
polt
w~~ll~
sIlIoi
-'
5l c 11thIIc1Clfiny
Icloil
1IilMIS
COI" 1%
of
IfrawtIng"
CMFC wcre
t of as
fi
suiicrfito
a)
b)
bilt
wvork O( 111
I-be
Regatrlin'
buth dfawo; Ili
i,hil;1
arc aga,.in atfvised toix

actin
n till-
no1
lool.i,~ 1i.1
agerncy fcC
(If L
Si~
l01051
CIIIIfiAce 111'
el'
nimediitr
adill
CMiFC if) do%1
rqga rd
(.MLJJC ;Ii'1CLf Ill U.Irry 0111

(('(iglIlamillw-l11 (if
0L:1.11t
Tile ltoil
Illn
~'
CMi& 11111
opti
I
)od lbyfend
1992
W ji
20
i-ell.I
Ins"ItI
c~llf'il~ll
Stamie
.111
MYIS CNILL w~iiistdtigll
IS (INifC wiii shd

N,-
of
IIC
(iiIa
~ctiulc
(MiC
foil by
c(t14C
%U1,11)
I;4c
iI
iit:lfd
beCo advised to rx1
fl p(WIcV'
IniJW.lg CMfC
;15 I'll[(11
lIfIIIImcd 1111 tlcly ColdWI

llic
ofcI1IC:1lon
001
in Chla In pIIovlfel
ClosvsICZ
III)'
theylI~
110miRc
requesied Io Contiact 111c,design jo,11101C
~llho:
li~
1
dw drawoing InI wh'ichi
oil Um114
and
11, J( lo darkin,',
mnodiFied
%YAI'D)A
I
nill
alt dircaIdy saryin
imiil
el
1
that \VAi'iA
rcqocfIicdl
slil'iAti11
Ill11c [I Ia 6ol III'resent
.
giv
proper
samet
.iI'tI
IldIotl
BEST AVAILABLE DOCIUMENT
34
til
NMle.iaiicnt 1
.sNo
jRipid
Pr ili
Prfi i
(t'i i tilm'
ii ul C
cll':M
and li ci cioiig
1.1'
icipcrlitirc
t1011linc I', lt onnrv,(h
c~v,:rv %lilt(down
il
CMI
to stdy
St;tis
Illilt'
l
regard1i
it ii\ ....
i t.t.nillillli.
ititilc f.mlild i
II.Icc
laipid Ilkic~ iII
hot reasnuifte
tvillpcrllur diffcrntiatl (if LI, iasm, i,
not c-n+rinflllit y howeve
iit
il
ils
.3 aniid 4
tliito2,
'(iltl
iliplc
it
ii the iCtcii i
11'.titoi.C Mealliilc NIls CMIIC wT

C
1i
IL
l
t
i
liICCKtk
h
lihtrtoui
(lilt
carry
oi f tJliiit4
iulalliOll
If reqiuired
i1iiil.ivciiitiit w ill i-. 1i1;Itl: iil

liclc:usiii will hc ,h,civcil
Action by
No
Ni (CSO/1 2791
Iclc
,
C head
(M (jicd I 6 9? [oin (from
which it
ofticc ia 1icr-i re'vcd ili
[iriimcd that tile
pIrolihemii of diffc4cnci
iifteipci
ill
t
hiric
attire hIwcn NIl' and HiP

t'
luc i" i"ICfililf faull
Ilic iiiiittc
nlillcili pcI,,Iq
di
iil
f[romt vci\ luclli

:r
111dtLimld not licc WiiIlll'h c il by

Cioic,c \iccia'lllt t ic ik'
IirlliMlciii0 ic u111g
Moiureovi r ,imni
.itUiiilcylsiicuuc.cih
.
itolcm and
Ihcy Ioul
a
stmtlil
(dctaiild rit+jmm
ii tils
lci
l2
(; lu di:
tihe
fctlerli
"
or
(i'fuitlicr
itire
iriti lii
ltudy of lilt.
" 1hc\
iowever Ciii utI.l
Of tile
have checked the Iitsttiliot!
Tlhe)
ocation0 0i
t3sigll.
Itrtine
OK
tlerincotiples and follud tlillill
era're betcei
TIic dfferctice of Itlie
upper and loier flng.ie ort iP and 1I'
+
llctr
c i
turtiile isnot du t cilhcl
.div.It l' tLCOtillic
or
iilof
i1 tatlil
To investigate firthuer CIEC informited

forin [lie
thant Ire T]'tine Specalut'
h l
'
j:tuiist i'
uifacturer will ic vii ,
.tIc iii stuidy thi pribiteiii
Is
till 11it1:11uhilll oi the i Wen:tliii
acllhived. CE (0&M) Jaimhoro Ina\
ticadvised to , take qociiit
, .l
ipret.+illuyilr
ci~;'liltc
of tile11
miid "ttltlliili
tIli,:
i olfh
inding of thiir
tcrcloic iilllorint-d
that ire) fti uire
an
,l
I1% uIhitloll In
.',ti.
'I17 iili
wvhlichI% ,iko,
[ic
CM[L1C site oi-
tilil
,olvc (him
his
,.-i ,,
.i 1'
CNIMF(
slon+l-'.l
1id
t,',:4Vu "il.
SN.
l'rohlirldcitI1CY
Drain iliCs
" ihan
Ir(iftoslll((itiiiiet('ndttiis
.* htlthr
thi:it such
,t.,+d
1'..4. CMIS :
.'
hey
(I occur
of (draii piteleshoul
ol rIIIIriItltei: arid
"w. (1
a,;rct-d ,wllh Ill,
Htt.,1'
iii,,,l~ ftdi'-s-i,
strain lipinglii
IllP hiitunc hrv:
tirrjirciiily iuis, I
tljl.,hthy (if
11
, ,r1icriall
svr1IIcivcigaletd
I roper claiolnigp vill litP
Siifll i'clt
,-,r.litio'i
Proper arraigeitrirl "I

att steam1 drains\ ti
atin
cptere1,
I-,l0in
Ih,. c.XitrIII
hL
li
Is/S CmI[C -Ill
ten grd will i. rit.ru.t tlc cq:l
dc..
I santhill
ilr., \,
They
willl
must ,olvc Ih,.,

by
probicl
alsi hecr checked and necessary

acl on/repair vork, was carvicd out
end of SqIt
1992
CE (O&M) tray Ki,ndly ih

advised to take acti,,) a ordingly
,s.
It
CMEC Informred thIt pipe matcrral i

l'rnpcr clamps of thc pipeS have
OK
ato
2socatolln
with CMI:C
init
i will tic
to give
ll'illaitll
irsisirtm
illhiltlt lhcil si!i11iii' i'
Jaroshoro it
tire supcrvistoit of CMI-C during

Of 11"N
.iihuhng
annual impccthonlovt
stxlIr;iiii. dir 1,1

li
,ulti.igatlu will IrC lr,'iVdCd
it:id l Iliic
various pips arranged by \VAPDA

forlli outside acncrs w;rsl provirl(o
CMI:(" for clheekinglcoiPiis(rr
+.rie-iisc
ll,'gcinIit, or
iirt
.rlliirt
A__________
C[- (O&M
.I
vhcrc cvcr reured oii lJnt
I[wcer for Unit 2 and 3 sinilar work
C;II tie carried (ut by WAIDA under
pr vdd
iu
Prset
I'rNo.S.(nt Slrtrirs
"Thi Miallurgical tc,,St rcl)rtls of
lune.
!99?
d
llripose thalt tre drain
The coIiittec
of Unt2 should also Irc diverted to
otsid turbiine tail triwards
CMEC mti
stiItit thi1
transforer as i done on Unit No 3

m1ormtrine
W rtiic
E will
:rd
of Atig
reolriri Ir) c:J

19)
In study thi, prolenm They will

sirhiort their reporl brefore end of July
199?
[carIll
colyII
wrt.r
altcriate arratnge1nt Irr

Riser Intake -,,,ter
irut rr,
Arl wterti.
C E Projects In.,). kindly tie advised to

request PES for iroviding propcr
sclienc for altcrtratc arrangement for
lfearirng Cooling satcr for river intake
arirfl.eirll is irccss!.rI
,
ur+r.rtiit oil' tie rurnl,1 eVe
to contitin
is%
itle
in casc co(llig/e.t1tig s.alr
,slaiit,_ed M/S CMEC ,h\,osd theti
inralily Io IlI W APDA in uriidirg
water 111itrl1
tid Tech
altr;lrttrwl\th .1 ltibc wCll tic
r,..rt.ei siiliii.s " III c.'Ir IIr ii
tixi.tirli.-"
det. ar+I:I
prolpr s.lreii
1992
Lir, od collai iitt
t and nosture
prt
Cntrantree prubler
toay exl'.rliti
PES to furitrli
their iro!mts.
detjils by cn
rf .\ugi 199'
;IrrIriIaciltlr
s'clletli I, I .l t,tr,'ine,
t,h t
.Iuiw'erlIr c t'U ttllitite r
ca.vaica it
oic.'t
l:nk ,I0 trl'
a sim
s
CE Project
I'1'
liii t!'i
sjii krul .sr,,r,
latCll by I Str June.
t,"
.iitritrcio,
T're C.i.,rntitti.w.
pr,-tirc nw ,, .'tr :I'll h.
3 ard 4
its 21,
CE. fOM) irtar kuidl. lie adsised to

irure oil celnrifugc e r+uh for
Unit "2. 3 ailnd 4 ott iiort V basis
CE tO&N' I
Ja-10h1(u
enlsure
install; io
cttrtfurgc
I
un
Unit 2 and 3
bry end of
Aug. 1991 71,'
on Unit 4 Qr
end of Nu'
1992
,(5/
No.
Lcak;igc prohlciii Ini scil
oil coolcrs Iciii(oizCd foriii

uinder lItling bly M/S
,,ical
two
Ili
Unitanilt
oil cooler
CMI:(
Finai
by tIteirI Iy
Action by
Stt-is
I
- nrC((.isent
iiieIIItd
Prol Iil,%;, I/
I'rihlemildeicienry
rl,:polt will bie sgltleid
IIh liirc. 199,
,ici
CMEC inowi,'rd that sCal 4I
crc
chocks
was disirianltd and
CME[C Int
carried out by Ilici. hul ilv could not

find any problrirl .lIch Iii'. Ca's,
[lir%,
rhly
frcqujcnt leakage of til t
arc nlow carrying out ftirilici iest,%and
reporl by cond
of Autj, l
will subofit their rt

Spcl control Probleim if
ctiergeicy dice l
,cncraltr set of Unit-,
Ni/S CME( ,re w:iting for thei

slci:hlit lle.i d tie fitrlt 1Te
td to rc;r h 1lhk:-sIt
tist Is%,,l
I)CEt
Iv
0th Jrtite
I99?
CMEC
:ltcndinii
peciali ts ar
submit till%
199?
lIll. end of July

at
Itt and are
[he jot
CMEC taunt
conriri that
the jolt i"
attended by
themn
satisfactorily
[fictring cooling water
1ii11 rave
lt ;-cell
1.keii in service %inc.1

C. it11tlsi%10nIii
Isi/S CM[C stited tht [tea ring cooh'.li

ii ill l ie
I.Jld I putmii1i
*II t lie
i-l
. Lrmt'li
n. illlts ,
til
litlcr
111in%
.,tilcr
ii
t.d
loihloi
Probllm (if acciinulattoit

of ltul tjuanity of sand
on the coagulator
Arr:tngemnitert for their
R.1ilov.iI S.iid aind it%dtispii:l frti

tie co:iltio:thir rcquirte detailed
delpth tudy. At 1 icset21 it is bti i
removed ttri li mnitual lahotr which
dispolm
N1M/S
is costly arid little cotliinli.i

CMEC h.ve licen requested to ftrnislh
their 'iitI:IIInlotsa.d recnttincndattntio
10
c. ;
li0ittcc I't
tcL
t1
tlt t thicse
Tle
titaKc law watlcr pittle,
ties Ile iiletcIt,'iecd lCilor

\/S CMIEC hic
reCeiVIti:: I',,ldIt
thicir riopo.hI which
tiiticd
,
th'rc.id)
Moreover
,ho0tlt Ie followed til
itite tieces with
illicint ll C Io S lN
,... ,
the
II
the
Frequent h:ik:e' if tl;.
Flesifility ii tlhe %ikply

of (lariled
'
,1 ,
I.,;,
-i '1 ..
I'll
Tle inodification/rcpair % irk has been

dte t t ellnergeilic hlcari!.- cooler
wa';Itf ruIiips installed ilir t:t 4 Tire%
t
:I: h: tlc 41;
will lie LakelII 11 strvl
CtI [C ilit
Clliorc takitli:
In servi c it,
restitlli of Unit*I
bearing
cooling wand
C rlnj 1, lic h.
of Oct 199'
For lite solution ol prolt:' ol

accutnulation of hl;ge quantitV of s311d
fit tihe water pretreatment area, the
cotlillittee recolitincnds that CMEC
proposal given by them vide their letter
CE (OKM )
Janllshort to
takc nce,,,,1r,
No
eItf1cocy
action
CSOII3031GM dated 15 692 may
tic acccpted
order Itl
MI/S CM EC for imttercon :tIloll oh
illtake water pipe tines I:' kinidly Ie
expedited case is iii the o:;ice of GN;
W D)&OCE Projects Jamitort rma
l
c
foll"oi up
IillidIS t c advis td
The cac of i%%uill sali ;ll
_-
Approval o!
dlie variatlol:
ordec has lc'ii
granted by
IGM (D&D)
Thermal
C'J
,I
'I:auc lit
ctIIplclt til
1111c,
lhe c,,oiiittlCe rccinittitetids titt UnitI . 2. 3 inl 4 It, ctnrniected it) cistirc
addittiontal elahhiluty The wuirk cat lie
rti :citt IIy
i. truci tit ld plr:t
work by cod
of October
1992
CE (O&M) inay l:indly le advised tl

iv
dejurtrt:::.ll
:tlttetd this
C F (O&'l
Jam ,h ro
un':
ellmire
comitpleitii I1
the job by coid
of Dec. 199
12
IitiercuInetioiII
water talnks
lf Den.III
lre eLlitili|ct c recoiitllirs that :ll lite

liitrt i cctedl
t:IIk
ll
D Ir wierl
The work cii IC cirricd iit
S:ilast
bove
- dtlto-
SEST AVAILABLE DOCUMENT
S No
ProlIl(.iii/d(r'i
tic5
S IIte ,._.. 010tt

%oda anrid
calitc
Vroj(lm l";I/ elic '
]Tih ey Irly
l it(I t
lie ilr,:I
ducparlinrinta'ly
Aclitti hy
Irt's'rescil St -ltu
iI nI
atinvi:
avCd
Sute as
crllS
I yditirihl"ic ,Ior t
.111. ,S
14
ol
on:etinii
iit,,ercn
ijistrurCnti air ",tlldI) .1
unlit
a nd 4
CM EC aIrcd lhl (tt L:ItC

rellablily the nstirlu ncot air "uipjly ni
siS
unit 2. 3 and 4 m:y ie ouitcrcrniected

M/1S CM:C rave ;tgrccd It striitl tri
i Nt cstulri;rte
,tlth
'u hrerr"w
inomd ih it lhey havy

uto i Chiri
'. :i
rtcJuCstcl their
for Technical detail% 'l1h arc %till
A rcrlrirr r iS I,wng sCft
a alited
M/S CM -C
rl-
c(li1iilIVItr
I~ t
I~ I{ ,tl
ll
ag(ainlt
trrhr,
(rttlif
cxtI.
rInI
Iistrtnllrtliia
J snI,*i
tatri
Ii
Ujitt ?, 3 and( 4 ali indqxr),wnrt stURC

l
I r ividcd
,i 2,
n,
of Sulply ol lllslrfts
[Of
]| tlll
tutuI
for caCII
Ihlt
NoiIlii
confnccICl, I
iay kindly '

problem
i ass
PIBS and take
:11"i.
('F
i
iii., '
..
ga t;an' ud
tlit 2. 3 :rir 4
II ydcOugCt
xi/S CM EC did nlol urece nit
itrallnt.,oiCi(i (f HydrogCe Inks of
Unit- 2. 3 and 4 because it ma al'fct

;tie
s.cl'
1991
I
(()& M )
ulthe -iUri
Iv.)rrK
rut Ir.
demtails
oif tihe 2nd
c I
,Icttruo.
rtl
(OI.iI
tilk
nvthI'iS tuid
( W, C III !
... '
hi,
Samei: as albn e
of tile oth,er utits, if lproblemn
ti' purity or leakage occurred in any of
tre unitshe However they agrecd that in

,'se of ClnCrgette-sV rC.tUirCeuCit. titey
.i.
_;
.* I.
,Aik
s ItIitt
itiuinCtiiatei)
litcrcoiteltiklll dt
of at,
(W(J
(Mi (
,,
by cud
rel~ior
(,
'IN.
iiiML
OW,
twil
s.,iibmil their
(-
ItII)llti
lX,,;
('M [C ,nutt
tic temp rarily itulercoiullC ctI[
, :
i,
', (, nh
"I II FtC)) hri
Itivw r St.tion, j.aislii,o
'Iliuril
oitil Unit-2, 3 ;111l 4
-l.txIric'a lVroil
rcm.st
il)
No
fI: VI'CIID
II thkeoi.i',,i "f Ow cimoioricc Instcad

(f mriaLn s i.iar, tc 6 6 K's' ovCrhiead
liiics as ar alternrate lIo cl -11t 1)'
'Ai
.iPply
Ahircmiil",,-'
iill River 1I0it:,k: il'ii '.
SNIIII
Action by)
nay
Jnshoro
1
O
propoal
Ilic
tudv
tf)
advici
be
k:0il]y
"
anid take action .oc'odnl
Chief l!,C-r
'cx
1i Ctisiri
'1 k[ty
iil aetI
the hine :I'ain,,t 1bib',
n tl e .tnOw ahtcrii:1tc t l
Io'pi
of the l h e i
lhncie
400 V brealers i:'C

fie,.iicii ; i,,In i, '.
iih
the result th.t .1ld .l
otetkcrs hIavecl:c
uutch/d durmir the
io moilllee lprl1.
.1l,
end of SCpt
199-1
uCt
,(' t lnl l1i1in

1Ie nhn'rt'u
liwii .ik: iuin , fn-i cclli
Lm K .1,11In m nl
1.C l. 5-
I.
I IhiitI00 K\V
14
riI, k Ir1.ll111%
IUIm
'
M/S CM C ll1"mrtid |hu11 lhe

.-: '
w;I
r 1n.i, ci .i, ,if us:Io,
r llcd by thucin . ll l l
subit theif re.urt l h' 15h June 1992
the proulcm of burilIitg/tusrlicatillg ul

it:,,ac covers of the blreaker coils
mtl I lhe: L'tuIIIIttcc s"Ilte

Ill tile ioun
1
,
ill.dilialt'Ill k.iii he tidc tit .ivo d
overh.uiti,;'~':itg oh plastic covers
required
. ,.'iet
spare breakers hc
Ni/S
CMEC have also
kept in mt, i,.
CMEC
r
further
tIwi
CiEC
the)' "'"oluld
M/S CMEC s1ttl:t11
s101ly ilte iu,,l'ci: in dclii ilnn'rith
rncc n d - IIl
\V A PD A EDc c'.i
i [au
MNorcouve
Ilic dcLails to
THE(O) for
a p proval by
by list:lig I I KV/0 4 K.V

ll
lit, i
r;iisl rlicriies it 1"Cr
lio
inust submit
the o/o GM
ourcc I, river Intake pr ,,i tile

I I KV upply heinrg ieCCelltl)
exisli
td
h iill/
(I bc
I
Lid Ij street hi'hht1
holusc
CE (O&M)
' c
silbilutl their
rcl,)r
[)' cod
of Augist.
1992
InVesti.gati0on by
CM [.C %e.l sulnit their

tile end or july 1992.
Iortliy
agreed ti supply tire %l rc b-raikers,
AI"ic.l tley
:,ve tutIhcd duritig
giarantee periud :Is replaceneit Ill
nIle,
kl licd
di:
plte.
NNU rjui n
iuu
nt
te i ti.h
Niit~m
ic ik,
lihcre is ;
lit t
1i drawtl
l
tg
termin
niumibers and ac'tull Y

exis'ite
tcrinltu:i
niulmer
NiS CNIiEC
;I
ie
.,
u lc iiI
iou
i.m,,,-
Amit
-.!'uu Stp
','.,. -
., ,
Tie job rttt :
.::,..,
i cCco lOpleted
l r
1 9,
1992
1cii
i1
It
will b I. i,
loe
li
Ulllt-2 .,nd
3 :IN allh v'hulei these utll%
NI/S CN4[_C remquested
are slhiddo,'u
uiuui
iIlll
that \VAPD.A [Ic.tricMal [iglliecr Iny
Ill rhim.hilslch
ulitllll ii tie L IIwIIdisereptilcies eXIst
Namuiic plate tIf Cquilmlentt

relays etc i,; in Chi
cse
lgua.'1e
otlV
M/S CNI[C iltmrcduizithut the work

h:ns alrac.ky h cen t t1rtci : dis il
CMI[C Inforted ll thel, 113itc

au... icd special stlf fot ptroviding
NI/S
Te ct.i' nnliicml
I:i11e p
reonmiitudcd t11:11\VA\DA Elct.rical

u si'.c.t cml
with
sti:il shou!di uicuim
Ill [ti'hii
rc,
proge
%tif cqu
ciiim. relays. et"
The workt I, I profress%

:i1tl w l I,,- to i ciitcl sIonirly,
lhe job nimiUs
te' co llipit tcd

h. end or
ctnhe'
199?
14/S CNIEC prc._,.

39
__Ni P r ;lic
ili/Dcm
~inci~:
ACtiofi by
I--.--
I/____-k II olnd
(It
II.N~
lv/S CM EC iInrimied 111:iiIt
in'
ii
Sp~rI
chtic IIIiiprc
1: tnciAcsiriaiily
tcrii~hic\
carii
.1lo iutjiis
cisc:
i
ccl1101c CMNl:(
atiucii
prnl, Wcl1~i'il
ittiichcc
lc.i
lircvidil:j aditioirial fiiaiii
III carry
Iiiuiii of itic probicn

ch(;
it11
is beynd their Coiil) itic Icy. as Stichi It
NL icsi,,u
may lie ffrchttoii
vssii
smijhcic *iji
fo i 11
itile ininer
its,
hii
advised by
GM 1TH(O) (inl
27 7 92 to
slighitly mlodily
tilie CXistllnc'
fitting
arrangemnt.
Jainshorci mush
cnsurc thai hlic
comleted
:IcCnrdui1iNj
1St31
Ialinro
personally
iots
Iflb
%,-illCMiF(? D ljc III".ii
\VAI'lA fii
I
( I 1&M) Ina),
picitsc tic adisiscit i'
WAPDIA will icscscctc dis:

iii cisrill .1iid
MIS CMEEC will pccp.irc cilclc.-iicIol
Il,
ic
Iciic
c-'Imc: Ai1 cannot bc
fm h
prividCd as hhicic Is no spcc availablc
hY
11(
hciici
by ic Commniottee [iir
ploipncc C.Iriwr
;iran~i~l
(>igsd
FC
fii
shigirilys Lilii
-as
(IN
1o1iriicied that Ilthe frctqusiicy (di

claiil:caihiii hirtishic [it wicicaiscd
Mwiccover MIS (:
IE
niorlicd 111;c1 Ile nodification

lC
lwN.
abi 1131hi
.iiil
hissp~ikii~
tcciceisd collIidh-(;ihily
%i11dY ccf tic P"tcinlcii
Afic er tii
.'i
by)
end of Oct
992 fi Uii1is
ciiiaccoringly
2. 3 and 4
t ie
tli:it tutuCxgc.
lie battery iinnu[.ictuiirt511.
Iwo
visihd tilie %lh lie dllies

M/lS CNsIEC fiiiorliicc
Prubhl,~of Scalilit Ill
tile
itive pilate ilhi
suiion D C. batcry cell
.1ii
iiiminlainice fill lilIcric%
1o 6
KV IfreaiK-
llicrc
lc csI
Ficta
actzio zuitd
r:cckcccci protilcitl id1t
wAPDA
11.1
suich
prolemlti
icina know how
Mechlaical criahleul
hiiiiii
NcthcIiic
iit
1. i,
hoii
cii,
kiilv
lhcl
theit jclr (it
NV.,iivided and
Ncs.3ry Iraillit'
oicw
11it0t 1%Ito prittlew
iaff Hlowver M/S CMIEC
grecd III Iunhari moreC practical
1Iill,_'iliiliii lIl
and1. demn
titllh
ItWAD
Operathlion avid Nia inicinocc "I.111
Propel. IdjlIstilitilI of bilade :III.J:
Fircklocti lii~5I
i5 t
1C i0Ilil I0ittii
iItiIll'_
If
lc
Clii111,111
01 rc :, !I,
h.'s
ic y CM EC
11117sIlI
S til
prlchilcic
'fle lt~ildihnIii 1.%iigi'
aui.A Ilic
lilIistcrilly
5
.,inico
iThrepir
\'I propet nt.- oin

s-cnniisl ccrc
itwork is in p rog res ft Uitl4

TIe
The %:tiilekill U1IIt-, and 3 'Ihllic
N4etd ii
0;
1i iii
ivltir u1%~l3~~t
1hci
lit
coosllwi, ics.cr I'an blade
dilleI
carriedt itil :I' cI r"i l I it
BEST AVAILABLE DOCUMET

40
PrOici rimy -J
pay siccial
:Iiiiils/IIss-Cct 'Ac
call
Ws~i\AIDA %taff
p~iidtiili
toi
allcltn
M/S (MIC .iiic'tt It) L;iIlryoutl
with CMEC
It must bc
coinltI)C(d ISV
cold of Oct 92_
onl all tilec
i.f (. 1 Kv
Iliiiiii.c
iailcls at 10 iicter floor

ftiii
iiit~h*tc~iiItile.
giigtc
rccosiinciidcii that ade(hIlaI.1
No j't..-rc% 11:1% (mt1CCII Ilaic ill
till
Icireitiiylj
... lc ciits lie ma~de oh

lmllels v. 1.rotct themi (rilii
pcritjlrcIjjIt r
_______________________
work,
WAI'DA will c.,rrvotit 1lit

Forf techiiiical I liitaiicc CMEC
will heclp \VAPD,\
hi rc.:Igd CMi hi wcic aai

rcqiic't,:(l it) mr.imsc.ili oifal
CI. (01" MIn.
il
pli
cistonv'id
ttO'
.___.....___
BEST AVAILABLE DOCUMENTJ
(;(*i~rat l'roileiur. (im
No
I-ec itIII
lrupoa I/
I eli()
iiihii.r/
I'
' Kii p ,iurt.
.i
dl, ir
('
N/.IS;
3 and 4
fiii(-2,
irfit
CM [-IC
.IC list (1
ireI :
_ +,,grer I
caliett. iosevt:r ilic commiiutttee
ve
c1i:,lt;ri/ed 4/S CM[L-C to
(if ilrrchinic lull

lto ,.
cioinpreslior
ticsalcd
i,0
i''(uiC-
[i
rhc i'(,,iniitc lSr
""
'
i's
by cnd of
Sept
Cl_(O&M ) nay kildly 111.advisd it,

lake tuplthe Inailer de alm nt,'ly
l uirIiig
urklh hul l :rld ittlir ar:la, should
wire
irgeidC..l with IrC .ddltioni:l
hc
fuinrslr the
comiinplete ist
1992
llrctl
r(
lo.eillly
'llr,i y oin ie
, -old .;it , ,I,r
by
" ol,
CM H lU
,. rk Is in
ied llatth1,.
progrs.s and comipltc IN (ifslare

paits for Unlt ?, 3 and 4 -i'll bIe
shortly
Io WAPDA vc
%jiItIcd
%,par i ri Miuch r3- required by
WAI'DA and ,,rbiit quotations -1 tire
D,
ActlIoI
|'tnen't Statli.
' hl(ill"
'hi
gl/C: door% tl p .'vv lo li,. elrlraicte til
is very
presently 11c
i1npoill it i
e haz3
condition is quilt
(l (O :M
Iisi
J;'lri
cinsurt
n :-
,,
ill Nov. 199J.
aiii
i'iCi
;'e
,i,,3
in
irrixid . lto
le
CE (OkIM)
ltec ir(,pOsc t1:1l Chief'
fak.
fire
(O&:M ) should i
r-n i',er
ii
[lie
,'~J
rl ilir?
Fire
ge
.a
;rrrai
lnghit 'i
take aciollt
kiiitll
itla'
' ,.
ti
(l'rr re I )
(CdvrserI
irrit ensure
:ccordit.eI v
i l
ent ifro e ly
et lii
it(
sri O,. I I 0')
'
-,
Ioi neirrc ;isi
'
itce rCCiiiili
.iiiImmiiiiit[
n" ii
, 'si:.rl
t
:i
iI.rcrnl~l~ .rct.;
\\I
ndths lh:il III
is
Jilishoro.
freqetll
, ;\ivoiid lilt%
rtler~llll ilt it is irllosel that
orderr
h 1andwith C: F Pi'0 cs
le 11:ts I:Idl\ be ildvis'd
(A: 'rojeti
iIlIS1 cxpc.ltl
g, ihi rib
iro, oil
-i'e|liriii
lo ehxledite co
work
sCli:irh rcliurir wler pitiloio'gv'ith
rmpinarran.ement be constructed at
Prelreaitllttare 50 that tire rettim of
water lit river l IdIsiitay lie
rt-,i ,+'[iiiriC r'i gil

Ini~
dc
lie keniiiiillle. r.cotnnends that thre

leallroln oil aid
lhe klt
hliird
.;r .
il
g'c'k
Acli
from C IS tOM
ix
rLqtt e,d
CE (OISl
Jainshoro [trril;
ensure rr
lire' hi:iimd i:ilerial such as oil

ia _'%.rubiber hoses etc
ll
-i
6
l.r
'learnorri tIre
nugrlitirrm lit
hr:r.rdois
it
,r:cclL
signri+atr;| "nn s.ie ail
t
Crrsi,ierti
techll e~il c:. l
e i'lh.plsr, kill
,licr:tioii
ol
trt:linirt
ille.i
lmpr octill'r
fi, liies
eggIIIIrjtec gItg irir rids 01:1i
At:&T p
tcdit Jarlshrii. ltie
ci I Io;
p glily l,.sr, Tii6
g'i
l;
.I
i1:iy kidly le ..\ iedted
Case Is
v.it
Cl. (IsNim S).

needful is
11CIOt(10Ml
;rrr:iie:erir llo Iir h:,td:1tiol gif :I

slitnilairr .-it J;rinihorti iho ldi r gu
The case of rourcl lli .ni1d

irrstaliation rf sliuiiirltu .,.i:lrr.ig,
s l: lpeiuc :dll
',I
oftiltire
existl'
Arr.!
corld int
' tr itrr~
tEarc
42
LitiirrC
BiST AVAILA LEDUti
BEST AVAILABL EDOCUMENT
Rcphiccmiitl (if fliig
1I1gilf'u
,'% 1ipuil
aid lan~ i1iiiipuvcI'

i
pi ' i and
v a ndsc (iif
all Ir~iuIliiu" aund CmIil
lili.
flu ll:c 1'i.I

hliuit
ii
Ii
112
i
.ii
uI
111 Mdli I
1%pripi.'%ci
~uiuu
.,, kindly be
moM
jdvIwd to (c1stiule am~ jid.mel
oif
ilicsc
J.111,lioro Ilrtll
cnsurc ta t
i w l
jiiip
CEi (0& M
itrhuh
.111d
lend4i
on
th
its Ist
ins pcct torn
BUST MVAILABLE UOCTUMIENT
U. S. A(,IK'N( Y I()
I RIVATI
IN'IIRNATIONIAL I)1 NII 0II'MIF, NT
,E('I'()R IOWEIR PR),IC'I'
COINIRA CT NUMBER
391-0494- C-00- 0540-00
DRAFT IREPORT
JAMSHO1 O POWER] , STA' IO N
UNITS 1,.2, 3, & 4
EQU[IPMENiT CON) ITION ASSESSMNIPNT REI'1IORT
CONTROL WORK PLAN 1.23.0

EBASCO SERVICES IN("
ONE VOLUME ONLY
Submitted by:
InternationalResources Group, Ltd.
*A TS Center, 1st Floor
.30 West, Blue Area
Islamabad, Pakistan
In Association
iflt:
John 7.Boyd Company
Ebasco Overeas Corporation
1-furiton & 11illianms
International Training and Education Company
ESfFlorida Power and Light Company

November 1991
.JAMSI IOIt)
I'{)WIIZ STATION
tiNI'I'S 1, 2, 3 & 4
IJI I'MINT (:()N I)}ITION ASSESSM1ENT REI'()1Z
CON'ITNTS
Pagu No.
I(
1.I
12
2{)
Overall Assessment
Projecid Repairs and Replacements
Introduction
2.1
2.2
2.3
2.4
30
Sumrya
Purpose
Scope
Plant Background
Data Sources
Overall Assessment and General Concerns

3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
Unit Performance Capacity

Unit Performance -Heat Rates
Availability
Unit Performance
Unit Operation
Maintenance
Quality of Installation
General Housekeeping
Detailed Condition Assessments
Unit I Steam Generator Components & Systems
12
Unit I Turbine-Generator Components & Systems
24
Unit I 3alance of Plant Components & Systems
37
Units 2, 3 & 4 Steam Generator Components & Systet
69
Units 2, 3 & 4 Turbine-Generator Components & Syst
86
Units 2, 3 & 4 Balance of Plant Components (KSystenu,
104
BLST AVAILABLE DOCUMENT
139
.JAMSIIORO I'()\VEI-I
STATION
UNITS I, 2, 3 & 4
.Q III'M I'NT CONI)IIIION ASSIESSME--N-t
R I'ORIT
SECTI')N 1.0 - SUMMARY
Powec
This report documcnts oUr equlpmlent condition assessmnent rcvlew of tli Jamlishoro
of Ilhe
Station Thc purpose of this revicw is to provide an overall condilion :lssessrleni
major systems, components and structures necessary for the safe andicliable gcneration
normally
of electricity. Also identified are repairs or replacemcnts of major components
are anlticipated
desigled io last 20 plus years but due to the current condition or operalionl
to faill within the neit 20 years
ic repoi
Secton 2 0 "Introduction" outlines the purpose and scope of work pieslnied in il
data used
together with background information on the generating station. ThC sources of
Concerns"
in our analysis are also identified. Section 3.0 "Overall Assessment and Gencral
provides performance data and lists concerns in the areas of opei3lion, maintenance,
quality of installation and housekeeping that should be addressed io provide safe and
rcliablh operation of the units. Following this section, details of our assessment for the
power plant major system and components are provided. Separate sections are provided
for the Unit I 3olier, Turbine-Generator and Balance of Plant -Systems and Components.
A similar breakdown is provided for Units 2, 3 & 4, (treated
as one) since the units are
duplicates. An additional section for the Common Facilities, is also piovided.
1.1
Overall Assessment
'he systems and components reviewed at the four units of the Jamshoro Power Station
should be suitable for conLinued operation for tile, next 20 years. li ojected repairs and
replacement of major components and sub-components of equipmeni that can reasonably
be expected to provide relatively trouble free service, by American standards, for 20 plus
years service are provided in Section 1.2. The assessments are based upon the newness
of the unils, the effects of the operation to date (September, 1991), projected operating
regimen, adherence to manufacturer's recommended operating and maintenance procedures
and resolution of curretIt deficiencies. The assessment assume all equilpmcnt currently in
place was designed, inanufactured and installed in accordance with applicable code and
standards and are of powei house quality. Verification that the above criteria have been
met was not part of the scope of this equipment condition assessment report.
In genelal, Unit 1 facility appears to be of superior quality arid exhibits better overall
.lAMSIMII()
I'O-'LI( S'TTION
iNI'TS I, 2, 3 & 4
I-QUlI'MFN'T" CONDITION AS.SI:'SSMNI
lI:'Okl
than Unit 2, 3 & 4 Unit I is Cxpr-ced to

workmanship ivth fevr currentandproblems
less maintcnance than anicipated for .Units 2, 3 &
operate with fcwer difficultics
and control systems, will cause
4,The current deficiencies, epecially in the instruernnt(,ion
levels tlat Unit 1
more hequenl unit trips and require higher maintenance
1.2
I iojecled RCpairs and Replacements
ani ipated
lhe following tepairs and replacements of major components arc
two Unit I ant
Orl elit
Estimated cost is S275,000 per replacement.
Replacement of the cold end baskets due to

heaters at 10 years intervals.
corosion
Replacement of the cold end baskets due to corrosion of the two Units 2,
S275,000 per
3, & 4 air heaters at 5 year intervals. Estimated cost is
replacement per unit.
,ea.s
Major repairs, due to corrosion, of the Unit I outlet flue between the
2001-2011. Estimated cost of the repair is S250,000.
Major repairs, due to corrosion, of the Units 2, 3 & 4 outlet flues between
unit.
the years 1996-2011. Estimated cost of the repair is $250,000 per
Replacement of the DC batteries for Units 2, 3 & :!witlfin 5 years.
unit not including
Estimated cost [or new batteries is S100,000 pi
installation.
Note:
for
All costs are given in current (1991) US dollars and are based on costs
States of
similar repairs or replacements at plants operating in the United
Anerica.
In addition to the above anticipated repair and replacenvents, there

outstanding dcficiencics and areas requiring further study idr ntified in
pcisonnil or
of these )roblems are currently being addressed by plant
items will
under the watrantics for Units 3 and 4. It is anticipated these
to PlrivatiZ7tiont.
are a number of
the report. Most
are items covered
be corrected prior
(JNI1'.S 1, 2, 3 & 4
EQUIPMI.NT CONI)IIION A.SSlSSMlI-NT RlI'-I'.[
-C.ION
2.1
.-
INTRODUC-I'ON
lPurpose
Units I. 2.3 &

[hc purpose of this equipment condition assessment report for Jamslinto
.1 is to provide the following:
A gencral oveiCw of the power plant systems and cquipmelli
majol
Identification of anticipated future repairs and rcplacements of
the
of
revie,,v
cormponents based on the current condition of the equipment,
projected
current plant operating and maintenance records and prac:rces and
operating duty.
Estimated costs for repairs or replacements identified above.
Identification of general concerns noted during the revie. process.
2.2 Scope
systems and
The equipment condition assessment applies to the bulk of the power plant
components necessary for safe and reliable operation of the units.
The current condition
of plant records.
of the equipment is based on the information provided by our review

made during
intervies with plant operating and n-mintenance personnel and observations

the site visit.
and installed
It is assumed all equipment currently ;n place was designed, manufactured
power house quality.
in accordance with applicable codes and standards and are of
part of the scope of this
\'-'rification tlii the above criteria have been
met were not
report.
and sub
The projections for ft.urc repairs or replacements is limited to major components
components of equipment that can reasonably be expected to provide relatively trouble
Components and
free service, by Amc ican standards, for 20 plus
years service.
component parts subject to normal wearing mechanisms are usually handled as part of
JAMSIIOIR()
t()VS'I.R
STAION
tJNIIA'N- 1, 2, 3 & 4
EQUII'MEN
CONDITION ASSESSMINI RII'OII
SECIION 2.0 - INTRODUCTION
2.1
Purpose
Jaim,,htto Units 1, 2. 3 ,
The purpose of this equipment condition assessment report for
4 is to provide thc following:
A general overview of the power plant systems and cquipment
of major
Identification of anticipated future repairs and rclflaceMients
review of the
components based on tile current condition of the equipment,
and projected
current plant operating and maintenance records and prac:iccs
operating duty.
Estimated costs for repairs or replacements identified above.
Identification of general concerns noted during the review process.
2.2 Scope
plant systems and
The equipment condition assessment applies to the bulk of the power
condition
components necessary for safe and reliable operation of the units. The current
records.
plant
of
of the equipment is based on the information provided by our review
made duling
Hnterviews
with plant operating and maintenance personnel and observations
the site visit.
and installed
It is assumed all equipment currently in place was designed, manufactured
of power house quality.
in accordance with applicable codes and standards and are
part of the scope of this
Verification that the above criteria have been
met were not
report.
components and sub

The projections for future repairs or replacements is limited to major
trouble
components of equipment that can reasonably be expected to provide! relatively

Components and
free service, by American standards, for 20 plus years service.

of
component parts subject to normal wearing mechanistms are usuaily handled as part
.JAMSIHORO tOFI
STATION
UNIIS I, ?, 3 & 4
EQUII'MENT CON)IION ASSESSME:NT R.IPI*
o tihe Wate and

maintenance and are excluded.
Futurc operation of the unmils, according
for the nexi 20
Powef Development Authority (WAPDA) personnel, will be base loading
pet year. The

years with a minimum capacity factor of 60% and approximately 10 starts
assumes the
irojected repairs and replacements are based on this operating recgin and
systems and
manufacturer's operating and maintenance procedures are followed and the
probems
equipnlent arc kept in good operational condition II is anticipated tile current
identified will be resolved in the near future.
2.3 Plant Background
Indus River The nearest ci1y

The site is located at the Jamshoro area on the bank of the
[out
is Hyderabad City which is approximately 18 km fron fhe sire Currently there are
and
units installed and in operation at the Jamshoro Power Station. Unit I was designed
by
built by Tokyo Electric Power Service Co., Ltd.. Units 2, 3, 4 were designed and built
North lEast Electric Power Design Institute Ministrv of Water Resources and Electric
Power Changchun - Peoples Republic of China (CMEC). All the units arc built on the
solid limestone formation at the plant site.
The units were commissioned as follows:
Unit
Unit
Unit
Unit
No.
No.
No.
No.
1
2
3
4
January 27, 1990
December 3, 1989
June 27, 1990
January 21, 1991
Units 1 and 2 have been turned over to WAPDA and are currently being operated and
maintained by WVAPDA personnel; Units 3 and 4 are under warranty and are currently
being operated and maintained by CMEC and \VAPDA personnel.
2>;
.lAMS1SIOl,() I'O\.:I, SI'A'TION
UNITS 1,2, 3 &' 4

EQU PM E:NT CON[DI[TION ASS.SSMEINT REPOIRT
2.4
J)ata Sourccs
obtained by a team
The data required to perform the current condition asscssmel was
during a ten (10) day visit to the Jamshoro Station in September
of five Ebasco engineers
1991 The following sources of information were utilized
Plant records including contract conformance documents, manufacturer's

dravings, first
operating instructions and maintenance manuals, dcsign
log
inspection reports for Units I & 2, unit trip reports, daily operating
records were
sheets, and maintenance records. It is noted the maintenance
and until
4,
minimal as the units arc new and maintenance for Units i&
recently, Units I & 2 -/ere responsibility of the supplier
Visual inspection of the power facility. As the units were in operation,
that visual
internal inspection of components was not feasible. It is noted
control
xc-ternal inspection of mechanical, electrical and instrumentation and
the case
equipment provide limited data to perform condition assessment. In
current
of the civil structures, a visual inspection is essential in assessing tie
condition.
i3ESl AVAILABLE DOCUMENT
'21
.JAN
I I()Z()
t
E-Q
SEC-ION 3 0
3.1
Unit
(OWI( STAI)N
S I, 2, 3 &, 4
IPM[: N[ (()N I) IIION ASSESSMIENT REPORT
OVIERAILL A.Si"
[-MNIT AND GENEIAJ. CONCERNS
I'crfor n rce - CapIcity
Data from
Based upon review of selected Unit Daily Log Sheets and review of Summary
Commissioning to August 31, 1991, tie units arc capable of the following output
Continuous
Operation
Unit 1I
Unit /. 2
Unit # 3
Unit # 4
Demonstrated
Maximum
262 M\V
210 MW
250 MW
200 MW
200 N4\V
200 MW
210 MW
210 N{W
3.2 Unit Performance - Heat Rates
Unit #
1
2
3
4
Heat Rate (K. CalWI-I
Average
Design
2284
2584
2,584
2584
2441
2547
2594
2725
lie average heat rates above are plant operating personnel estimates based on fuel
consumed and power generated from Date of Commissioning to August 31, 1991. These
encompass all operating loads and start-ups and thus are exp ected to be above the Design
(guaranteed) Heat Rate at the best operating point - Economic Continuous Rating.
Performance acceptance tests for Units I & 2 have been completed and the units accepted
b,, WAPDA. As recorded in the Unit I Report on Performance Test, the actual
performance met the guarantee. The Unit 2 performance Test Report was unavailable
at the time of our site visit.
I3EST AVAILABLE DOCUMENT
JAMS!IOR() PIOWINER STATION

UNITS 1, 2, 3 & 4
CONI)ITION ASSESSME-NI
3.3
(Jnil Performance
Ihe information provi," '
operating personnel on Summay Data Shects "As of
3108 1991 Since Commissionig" indicates the following Unit Availahiltis

Unit I
Unit 2
Unit 3
Unit 4
83.02% Available
61.06% Available
Available
38% Available
.j/O
Unit I & 2 availability percentages include the 45 day and 57 day shljioowns respectively
for First Inspections. In addition, the Unit 2 availability suffered duc to a bowed high
pressure turbine rotor keeping the plant off line for 55 days. It is noied however, these
availability factors should not be considered indicative of future plant availability. The
start-ups of the units'are recent and low availabilities during the first year of operation are
normal until all equipment has been completely checked out.
3.4
Unit Operation
Per the plant personnel provided Summary Data, the hours of operation, capacity factor,
and total KI,-1 for each unit from commissioning through August 31, V)91 are as follows:
Unit Number
I
2
3
4
tHours of Operation
9,329
7,376
4,505
Capacity Factor
.63
.73
.76
.78
Total .M\Vi Generated

1,S37,126
1.355,655
1.115,441
707,604
Operation of Unit I is satisfactory. The unit is capable of and normally operates in the
automatic mode on unit master load control. The operating instructions prepared by
Mitsui, the constructor, are comprehensive. In addition, plant personnel indicated an
extensive operator training program was conducted by Mitsui.
r/g
.JAM,1I()I,()1
I'()WI:
,' [ATION
S
IJN'I'." I, 2, 3 & 4
fEQ,
,,'i'r
(()N)ITION
ASSFV.SSMINT RE-I'O)I,
All of the above have contribumed to the relatively good opcration of

ration
ihs of
availability of 839/ .
Jnat .1 and a unit
I The units are

OpciatiOn of Units 2, 3 & 4 have been more troublesome than Unit
tihe uneliability
automated mode at this tine duci
incapable of operating in a cc",,,tely
of instrumentation. The units require a high degree of operarot atemInt on to adjust the
process variables manually. K addition, calibration of the insltnintati~no has iot beell
completed resulting in inconsistent measurements relayed back to the coriiol room It was
hoted that the thermnocouples on Units 2, 3 Q 4, unlike Unit I, ai, iiot installcd if)
rplacC a iaully
to rCpair M W
ihlermowells. This necessitates a shutdown of the un
thermocouple and thus will tend to lower overall unit avallability lh OpcrailiN Mainiuals
provided by CINIIC are not as comprehensive as those furnished Nin I.nit I by Mitsui
Add iornally, operator training suffered niiore from the difficulties III COmUlnicatiILI
berveen plant operating persoinel and Chinese engineers. resultnm, Ill less skilled
operators
3.5 Maintenance
A long term maintenance program for all four units has not yet been established. Due to
the current shortage of power throughout Pakistan, plant maintenance personnel stated
these units will not be shut down for overhaul outages for at least 5 years. Maintenance
activities for all four units were directed by the suppliers for the first year of operation.
Maintenance fot Units I and 2 was only iecently turned over to WAIIA, wile Units 3
al intenance checks
andd mainte nance is currently .c ig coordinated by CMI C. Routi i
This
arc performed daily by WAPDA personnel and repairs made as required.
term
a
long
maintenance mode is acceptable based on the newness of the units; howver,
maintenance program should be established.
The Maintenance Manuals provided with Unit I are comprenlicnsive and Supply tile
necessary information for proper care. The manuals for Units 2, 3 & 4 however, are
sketchy at best. More complete manuals should be prepared for these units to aid the
maintenance staff in performance of their duties. In addition, maintenance and trouble
shooting activities will bc hindered on Units 2, 3 & 4 due to lack of "as built" rawigs.
These "as-bilt" drawings have been provided for Unit 1.
REST AVAILABLE DOCUMENT
ILI
.JAM0IU
() I'()Wl.R STIA'TION
IJNIIS 1, ., 3 & 4
EQUIPMEI*NI (C()NI)ITIONAREI. ,S,,I1NT RI '()1 1
3.6 Qualiy of Inslillation

of maijor COmpOnCnlts and systems that conpris tile powel
.)inspcttiO
The walk-1thi otigh
genriating eqtuipnment for Jamsh)ro _1nit I through 4 ievealed that ltHir is a tllajor
contrasI in the workmanship on Unit I (Mitsui) as compared with Unit 2, j A, 4 (CM EC)
Although, cctrain of these (liferinces may he strictly appeatanc iclated, such as Ihc
quality of boilci lagging installation, there are areas where the worknanship of installation
Seveal
will irsult in increased maintenance during the operalig ihf" of he units
exampI)lcs of coi)itOns obser-ved on Units 2, 3, &'1 that will piobaly afccl fulrUie
opianidi atidainltelaice ar. cited below:
Cable trays that have no covers and arc exposed to tihe cl lontctil
have accumulated consirclable debris on and around the cables
Severlal ares
Incomplete lagging at each hackstay elevation at the corners of the boiler. The
blanket insulation is exposed to the weather, and in several at as the boiler tubes
are istible where Whe insulation is missing.
Much of
The we!lig oti iany suppo is is ver)i poo. The iller welds have cxcc.ss crown, are,
rlregular, and appear to have poor pienration.
The local control boxes located throughout the p. .lave no gaskets oil the access
door assembly to prevent moisture and dust from accumulating inside the control
boxes
6.
The wiring of various instru,ments is poorly termnlinated antd exposed to the clemenlts.
7.
Control board wiring is not marked with imCt
ilie but-ncr deck (41 unit 12 was assembled using pop

rivers. In many areas the pol1 rivets have i::d, probably because of inadequate
ishanging loose
expansion provision. Illthese areas the
lile lagging
aroulnd
annt identification ta!s.
Aside from tile external appea rance, a major concerti is these conditions may or limay 1iit
reflect the quality of workmanship that was used in the fabrication of equipment and
components not visually accessible during the walk-through inspectiotl
9
,JA
.III() k() 1'()\'I':R S AI(ON

J
IEQtIJI l'
3.7
SII1, 1, 3 & 4
NNT C)NI1)I I ON ASSISS,'IhNI" RI'T()TI
;cnetr l Ilouiscl,ccping
debris was
The General Housekeeping of the staton was relatively poor Construction
The residual ol
observed throughout the facility even though all units are operational
was
unloading area was especially lackin, in ,ood housekeeping placticc Oil spillagc
m
[his
c
in trenches anid on .!rade level
IIotd
commnonplacc wiih oil and wal'e iixtlc%
(:ICatus a SeIiOLS [ilc hiazard and should tn aigindcd tn rmIniCdia'lv ( :ood Ihot1sckccp III,,
in the uIIIS
p)iactices promote case of opeiationI mnd niaiiienaiCe and wIll hc HItllcte(d
availability and reliability
.3. Detailed Coudit
(iI
Assessments
during the
Ile general concerns discussed above were based upon the obseivations made
s tevisit and discussions with plant operating and maintenance pcisorniel These concerns,
as well as the items identified in the condition assessments for ile (.,ndividual system and
more
components, may nor reflect all curreni de ficiencies o piol)lcis, hut only the
a1)paret and serious ones uncovered duimn o on ireview. Ma ny o( these deficiencies have
ain adverse impact on o[peration and mainrenance, but may iot necessarily result in repairs
lead
oi replacements of the major components However, if false insti umentation readings
to maloperation of the equipment or result InI exceeding ille design margins of the
equipment, pteflruluic ailures may occui In is rCconed that the units have prily recently
Ite outstaiidiing_ pioblicis are commirlionily encountered d-iuig the
tarlted arnd aInIU, ,: [of
start-up phase o all units. Plant personnel are currently addressing most of the probleris
on Units I & 2. Since Units 3 and 4 are still under warranty, it is expected that problems
supplier.
for these units will be addressed by tilie

t0
.IAMSII(O)
I'()WI.R STATION
UNITS 1, 2, 3 & 11
[Q UI PM IKNT CONDITION ASSI'SSM ENT REI'ORlT
Ihli
(.ondition Assessmens, listed below, follow this section:

Jit I Steam
c'icrator Components & Systems
Unit I Turbinc-Gencralor Components & Systems

Hnit I Balance of Plant Components & Systems
Inits 2, 3 & 4 Steam 'kecrator Compoiicnts & Systems
Units 2, 3 & 4 Turbine-Generator Components & Systems
Units 2, 3 & 4 Balance of Plant Components & Systems
Units 1, 2, 3 & 4 Common Facilities
BES[ AVAIL ULE DUCUI:Li"
.lAMSII()I() IJNII I
STEIAM
;NIG'IN-RATOI
()M
ICONIN']I
&, S\'i;M
1he Ulin I steam gencratol is a Milisui kilcy i)'IC 151k hoih1

col)l)OtIWIlS aid
[fiing residual oil only. The StCam1 gelncrati
1 is equipped for
1h
,,1l
sys l'ls cvaluated
consist
(if tII. following:
Steam Generator
Superheater/Rehearcr - 'ub ng
Superheater/Reheater -Headeis
Supcrheater/Reheater Pipin!
PrnnnmTi,,,r Tnlrp
T4iPdrr
Economizer Inlet TcLbinQ
Steam Drum
Boiler Enclosure
Boiler Air and Flue Gas Systems
Forced Draft Fans
Steam Coil Air Heaters
Air Prehcatcs
Gas Recirculation Fans
Ducts, Dampers & Expansion Joints
Boiler Combustion System

Automatic Burner System
Automatic Boiler Control System, High Pressure/Low Pressure Turbine Bypass
System
Awliary Steam Systems - Boiler Side
House Boiler
Soot Blower System
Boiler Structure
BEST AVAILABLE UOCUMWIt

t2
.IAMSIIORO
UNIT I
SI IAM (;1N IEIAT'OIi
l)cscrip ion
ilhy type ISP, boiler equipped with a threc.

j
4!Ciii-l;
lre!r!o s ;I N,
JClt /1 stc.
I he boiler is pressure fired with gas recirculation for
stage supchcalwi and split iclheatc
Maximul raed stean output is 795.633 tonS per
TIhe
reheater steail tellperature conlrol

2
psi) and 538- C (100HF) at ihe
hour (1,750,000 lb per hour) at 169 k-cm (2400
arc 5380C (100001:) and 40.91

supCrheatl oull(t. SCain conditions leaving the reheatcr
kg/cn' (581 psi)
designed io be completely
All Su)pCrhteatI, reicalCr and economizer elements are
located on the front and
drainable. The boiler is fired by eitphteefn (18) circular burners
is equipped for firing residual oil
rcar furnace walls at ihrce (3) elevations. Tihe unit
installed oil this boile
exclusively. Thecre are no inarural gias [illn provisions currently
The
feet deep, contains the final
front, upflow convection pass, which is approximately 14.75
The rear, downflow
superheater, final reheater, and secondary superhcatem elements.
pirnary superheater,
convection pass is approxirnately 14.75 feet deep and encloses the
pirinary reheater, aid tie economizer elements.
(29'-6") deep.
Tile primary furnace is 13.38 meters (44 ft.) wide by 9.003 meters
Comments and Current Condition

15 and June 1, 1991
File first year inspection of the boiler was conducted between April
or water side of tile boiler.
No major abnormalities were found on eilther the gas side
burners during tile oulage
Minor repairs were made to the refractoiy throats on several
report, and
Based on the walkdown of the unit, the review of the first year inspection
boiler is in good condition
interviews with plant personnel, it was determined that the
on January
after accumulating approxiratcly 12,000 operating hours since commissioning
27, 1990.
Assessment
test of Unit #1 was conducted
Prior to the first year inspection, a complete performance
April, 1990. The results
by Mitsui, Fuji Electric and the Riley-MitsuIi Consortium during
or exceed contract
of the testing detcrm iuieCd that boiler pierformance and efficiency meet
requirements.
L J AVAI LA' LE D,.C" ,:
.1AI'1SIIO)4()
)JNIi I
, I'i'A i (; 'LN IEATO lR
Pfriiod o liic by
hs IIIolr caP he CxpectCd to immu,,(ldc Iiklhlc SCFVICC ovCr aui CXiClldC(
the manufacturer and by
operatung the kinit within
the paianjmtcer established by
pe-form ng routine iIain!tenaince anrd periodic inspections.
consideration to avoid hot spots

hc pressure firing feature of this boiler Cquirs special
rates of tempera ture change during start-ups and
Very consel-vative
arid gs leaks
problems associated with a pressure
shutdowns are reeomnmended to prevent long range
hiied I)ollCr
14
BEST AVAILABLE DOCUM""
JAMSI I()I() tiNI
BOl1ILER AIR ANDIILUL (;AS SYSTVIS
rU
IF PC
,RLB
4 AVAI f,
rXIT
MesaI
) iion
I
wttdboxand provide
The ait and gas systems supply heated conibustion air to the boiler
stack. The major
:iconduit for conveyig flue gas (roti the boiler outlet 10 the
componetts of the ai
heaters, air
and gas systems consist of the forced draft fais, ait
[he staCk
to
flue, and the flue froml the ail hicater as oMtCl
ducts, windbox, hoilr outlet

that extracts a I)Orton
li addition, the boilc is equipped with a gas recarculation system
of the fuc gas from
boilet furiace as
the econolnizer outlet and reintroduces it into the
the supeiwlaic
a icanis of extending tie tCm perature control range of both
ll-
and recaie
mnajor cormponents of the air ard gas syste.11m, include.
(2)
inlet
Forced draft fans by Nakashirna Mfg Co Ail foil rotor dc.,ign, double
(2)
Steam coil air heaters by Seo Koa tin Kolgyo Co., Ltd
(2)
Ljungstrom 26-VIX-2550 Air Preheaters by Gadelius K.K
(2)
Turbo Vane, double inlet gas iecirculation fans by Nakashima Manrufactutring

Co., Limited.
Coinmenls and Cu rrent Condition
the first year

Al! componerns of the air and flue gas systems were inspected dunng
and inspected, and

inspection Pei tie Inspection Report, fan hearin-rs were disassembled
and all womnponcnts,
tile fanl rotors wetc eexamined. The air heater was water washed,
Operation has been
including the cold end baskets, were found to be highly satisfactory.
of the first
normal since returning the unit to service June 1,1991 following completion
year inspection.
Assessencrut
the boiler to the

With the exce)tion of the air heater baskets and the flue connecting
The
stack, the air and gas systems
were judged to be suitable for extended operation.
to the stack are
heating surface
of the air heater and the ilte connecting the air heater
residual oil containing
subject to corrosion resulting from tie exclusive firing of

end baskets ,ill
approximately 3 percent sulfur. It is anticipated that air heater cold
peri ielacernt.
require replacernet at 10 year intervals at an estinlatei cost of S275,000
years
The outlet fiue is projected to require major repairs at a
point between 10 and 20
JAMSIHORO UNIT I
IBOIL[I
COMBUSTION SYSTEM
tics crip lion
steam atomized oil burners

]he boiler is cqu-ppcd with eighteen (18) circular Venturi-type
at three elevations on
manufactured by Volcano Co., Limited. The burners arc located
configuration Eighteen
the front and rear walls of. the furnace in an opposed-firing
been proided for ignition of the
electric spark. light oil ignitors by the Volcano Co. have
Main burners
The burners are designed for residual oil firing only.
burni:nq nitMural gas.
This
boiler is not equipped for
wi1h burners placed in scrce or

Burner operation was observed to bc fully automatic
intervention No significant
removed from operation, depending on load, without operator
systems equipment on this

operating problems have been experienced with the combustion
u~nit.
inspection in carl' 1991 and

The burners and lighters were inspected during the first year
were found to be completely satisfactory.
Assessment
for anuexteuded period

The oil burncs and ignitors arc l)rojected to o)eratc sat isactorily
cleanine and adjustment.

of time. Normal maintenance is expected involving routine
of the exit orifice.
Periodic sprayer plate replacement can be expected due to erosion
proper operftion
Replacement of the sprayer plates is nonnal, and is required to maintain
of flic burners.
BEST AVAIAELF DoC U

16
JAMSIlOW-) UNII
AUTOMATIC ItJIRNLR SYSTM (AIWS)
I)cscripion
The automatic burner system is an electronic digital control system manufactured by

is Model AFS
Forney International Incorporated of United States of America.
The system
except the
100 and controls nine (9) burner pairs. The system is microprocessor based
Master Fuel Trip (MFT) circuit which consists of DC electromagnetic relays.
All top and middle level burners cal be manually staited and stopped in pairs
BTG board in the central control room and corresponding local control panels
as
front burners. -owever, six (6) burners at the lowest lcvcl, which also serve
burners, can be manually started and stopped either in pairs or individually from
board and individually only at local control p. hel
from the
near the
warm-up
the BTG
in pairs
The six (6) burners, at the lowest level arL automnancally started and stopped
depending on burner header pressure
The twelve (12) burners except those at the lowest level, are automatically stopped in
pairs in case of emergency condition, such a5. Fast Cut Back (FCB).
A master fuel trip pushbutton is available on BTG board to quick])' shutdown the boiler
in case of emergency.
This system provides of the following control functions:
Furnace purge sequence
Master fuel trip
Ignition fuel trip
Warm-up fuel trip
Oil fuel trip
Ignition burner start/stop
Oil burner start/stop
Gun purge
Fast cut back
Air resister open/close
Oil selection
Ignition burner header leak check
EST AVAILABLE
17
JAMSII()I() UNIT I
AUTOMATIC IIIRNIR SYSTEM (A HS)
Warm-up burne
header leak check
Oil burner header leak check
Comments and Curren
Condition
Interviews with plant O&M personnel and rcvie.v of unit trip record indicated that the
unit tripped two tines, on lune 30, 1990 and March 7, 1991: due to the automatic burner
system. Both trips were due to human error while working on the system.
The automatic burner system appears to be in satisfactorily condition based upon the data
reviewed and unit walk-through inspection No unusual conditions were notcd.
,,-)scssnrtnt
Assuming proper selection of component, availability of spare parts and adherence to tle
manufacturer's O&M procedures, the automatic burner system should be suitable. for 20
years.
BEST AVAILABLE DOCUIAENT

18
'
JAMSIORO
UNIT I
AUtTOMATIC BOILER CONTROI. SYSTEM (ABC)

I I I II I
SS1.R IOW P.ESSURE TUR BINtE BYI'ASS SYS'IEM
[)escri pt
ion
boiler control syvstem is microprocessor based and MallinllactUired by

Yokogawa Microprocessor Electric Corporation (System CENTUM-DI')
"11C
ail nl1c11C
'[he' systemi hardware consists of (2) field conti Dl stations, (1) terminal
board cubicle, (2)
naishalling c;abinct, (4)I/P converters, (7) 1/0 positioners,
(39) hand/auto stations, (I) unit
master %.il)ervisor panel, flow/lcvcl/pressure/differential pressure
iransitniers, flow
elemcnts, T/Cs, 0, analyzers, repulators, and 1IP turbine bypass control
valves
"lihe Automlatic Boiler Control System (ABC) is designed to control
hl.: :olr wllh
coordination between turbine, generator, and boiler. The AB3C pro\dcs
the following
functions
Unitn master control (including turbinc master and boiler master)
Automatic Combustion Control provides fuel oil flow control, flue gas 0.
control, air
flow control, a'nd residual oil pump discharge pressure control.
lFeedwater Control is designed to maintain the drum level at normal

level
within
limits Single element (drum level) is used at

lov load, and three elements
(level,
feedvater flow, and steam flow) are used at normal loads. Feedwater regulators
and
BFIP speed control are utilized to maintain drum level within the various triodes
of
operation.
A startup feedwater control valve and Imain feedwater control valve

are
pl(rov(Ide
The Supeibeat (SH) steam temperature is controlled by regulation of

spray watet
flow of the secondary SI-I inlet to maintain a final SH outlet temperature
of 541 oC.
Reheat steam temperature control. It is designed to malillaill rchcat

steal
temperature at 5,11 OC for loads greater than 50% by positioning the datnpes
of the
gas recirculation fans A&B.
Air Preheater (Ali) Cold-End Temperature Control is designed to maintail

average
tetperature of air inlet and flue gas outlet at 115oC based upon residual
oil sulfur
content of 3 to 5%. This is accomplished by regulating the heating steam
flo,, to
the steam coil air preleater.
19
Y'
JAMSI(ORO UNIT i
AUTOMATIC [BOILER CONTROL SYSTE-1,M
(AIIC)
HIGH PIRESSURE/jLjOW pIRE SSU
T.-'URBINIEj If '('ASs SY)-'SITM
Iligh PressurC Turbine Bypass Control is designed

to opcraic during startup to
increase the boiler load quickly and shortcut the
unit starup timre to reduce
misnatching between main stcam and turbine metal temperature

It
"also operates
when a large load rejection occurs in the power system.
The excess steam is
dumped into the condenser by LP and 1-111 turbine bypass
valves
The automatic boiler control (ABC) system also has the
following neccssary and effectivc
interlocks:
"
Protection interlocks in ca.,se of ABC failure.
Interlock for unit operation mode selection (coordinate

mode, turbine follow mode,
boiler follow mode, unit manual mode).
Master fuel trip interlock.
Cross limit interlock which restricts unbalance between

fuel Ao,, and air flow to
avoid unstable-firing and steam temperature excursion.
Fast Cut Back (FCB) interlock, which reduces the load

quickly to 20% of rated
M W.
lnteivcwv
,platit pesonnel, walk-downs, and review of Unit I records,
indicated high
reliability and excellent performance.
Assessment
Based upon newness of the plant, assuming proper design

and selection of components,
adherence to the manufacturer recommended O&M procedures
and availability of spare
parts, the system should be suitable for 20 years continued
operation without major repairs
or replacements.
IHST AVAiLAL,. L
20
AUM t.
JAMS IIOR() UNIT I
AUXILIARY STEAM SYSTEIMS - ItOtLEl, SI[)"
[)kscriplion
The major components of the boiler-side auxiliary steam systems consist of the house
boiler and the soot blowers serving the main boiler and the air prchca:ers.
lhe house boiler is a prcssurized furnace, shop.assembled, mcnbran" wall construction.
oil fired unit manufactured by I-1ydndai Heavy Industries Co., Ltd. Th:: boiler is rated at
20000 kg (44,100 lbs.) per hour of saturatcd stcam at 7 kgt, per cmn (10 0- psi) The boiler
iS equipped with one burner.
lhe soot blower system consists of twenty-eight(28) STR-8E long rctii, :..le and eight (8)
STR-SE half retractable soot blowers by Mitsubishi Heavy Industric, Lid., and two (2)
swng type cleaning devices for the air prehcaters supplied by Gadelii, 'K.K.
(omments and Current Condition
Complete inspection. of the auxiliary boiler and the soot blowers system %ereincorporated
in the first year inspection. All equipment checked out to be satisfac-ory.
Assessment
The auxiliary house boiler and the soot system are cxpected to operatc satisfactorily for
an extended period of time. Normal maintenance is anticipated to maintain the
equipment in good running order
replacement.
and
to prevent thc need for :-jlor. repairs or
G(-.ST AVAILABLE DO'CUM i'

21
,JAMSII)RO UNIT I
IIOILE R
'R ,RJCIt[JI.,
tcsc riplll(in
The boiler SirUCILJIC
23 2 mcteis widc in the North/South diremlioll, 40.0 incters long

in
Easi/Vesi direction and 47 2 nicvirs high at its highest roof
points. There ac iwelve floor
.-
levels most of which a:c spaced 3 meters from each othcr.

The weighi of the enirc boiler
is suspended by hangers from lh(- girders ai tihe roof elevation.
lhe hoilei wall is laicrally
Supportcd at platform clevaions for wind and earthfluakc
loads but is allowed io expand
and con11icti due io tempera tre changcs wiilhout being restrained.
lic girder loads aie
tiansferied to columns and caricd down to thc reinforced
concrete mai foundation at El
1.00 micters [he columns and beais at several platform
elevations are biaced by a
vrical and horizonial bracin syscmtio
resist the hoizontal loads due 10 wind and
earthquakes The boiler building is not enclosdd by walls.
The stairwells provide access to the platforms. There is also
al elevaior shaft, separate
fron the boiler building sriuctUre, with horizontal ties at the
platform levels. The elevator
operales bteICCn ground level El. 0.0 meters and boiler drum
level ai El. 39.00 meters
The platforms are covered by galvanized steel gratings and
protected by hand rails and toe
plates.
Air heaters and gas ducts, fans, burners and steam pipes to
and from ihe turbine building
are supported by the boiler building structure. The ground
floor in the boiler area has a
1/200 slope and a trench for floor drains with a checker plate
cover.
Comments and Currcnt Condition

I-lie Unit I h)ilci structuC appears ad,quately designed
and detailed. It is in good
condition. There are no pockets to accumulate water and
other loose debris which could
initiate corrosion and dctcioiari)n.
Because the boiler building is a tall structure, tIferc was a
high wind constantly blowing
dust and fine sand at the higher platform elcvatins. This
may accelerate weathering of
the paint on the steel surfaces.
No deterioration, cracks oi settlement were observed at the
ground floor level. The top
of the mat foundation is I meter below the ground elevanon
and was not accessible fi
inspection. The mat foundation is supported by a solid limestone
formation.
22vilih
2.,JI
2.2/6)
. -, S.,C,
.JASIIORO UNIT I
01LER
I
STR UCTU RE'
A sscs~ Imef)t
Assumng pfOpf)E design and erection, the boiler building structure should be suitable for
the next 20 years of operation. -hc structural steel should be protected aga'inst corrosion
hy piopi mainit:nance at the req uired intervals.
BEST AVAILABLE DOCUM1tT.!'__N"
23
(/
.AAf,'1qS1()l4()
TURIENI
-GI'NEATOI
IN I I
C()MvPON'4NTS & ,SYSH:IMS
II I1 562/68-2 type
pw. 25p0
IIc U nIt I IIuirn-gcnrcator is a [ UJ I1:.c tIc (Japan)
n1do(01 nn111.The Itifbinc is a ,andem co[I pounnd, 3 casing, doubIlc-low cha us1, reaction,
wheat, condensing typc. I-he gencrator is a synchronous, 2 pole unit type which is
hydrfocn cooled. Thc urit has a static excitation system.
Iic turbin -genira tor components and systeins that weme
evalualed consist of ihe
Ifollowing.
High Pressure Stalionaly Components:
High Pressure (HP)Outer Casing
I-lB Inner (7asing
Inter mediateIBessue (I1') Outer Casing
IP Inner Casing
fiP Stationary Blades
IP Stationary Blades
Combined Main Stop and Main Steam Control Valvc.,
Combined Rshuat Stop and Interccpt Valves
HP Turbine Lead Piping and IIl Turbine Lead Piping
Turbine Rotating Components:
1-11B Rotor
1l Rotol
low Pressure (11)
Rotor
fIll Rotating Blades
1I1Rotating, I31ades
Low Pressure Stationary Components:
L) Outer Casing
lB) Inner CaIsing_, I
LB Inner Casing 2
LP Stationamu Blades
CrossarouLnd liping
Gencratm and l:ixcitatoii - ueictricai 6, Isolated Plhase Bus DUCI
24FT
"24
AVAILABLE DOCUM'Egr
TURIBINIE - (;FNI-AT()IR (()M
(3enC
alofI
otirtrnp
(o(11(o)po
111
Nle.i:
IONI-NIS & SY. I'FiS
llical
GeclCrator Rotor I )ginrp,

(iCulcratol
"''l>iil
Reulting Riligs
Supl"',,i.sol y Ir1%tilluricliti()u & Monitoil,p
StIeICa I1
UrbilM! CMtols, lc-ht I.olhydI aulIc Gover rIot ('or()I
o
ol
teItI
Tu rbine-Genrator Atuxi ialy (omnponent.,/Sysc ills

Lubricating and lydi aulic Oil System
Turning I"(pripmen
Gland Sw(amiSeal
Sysi till
lI'li
brnc l t ingS
"lrbine Aes(:5 tals
Generator Seal Oil System

G(er:ratol Hydrogen System
Performarnce
The Jamshomo Unit I performance test was conducted in April

1990
Itbic-gen;ator results of that testing were:
'he icrtinnt
Pic corrected gross turbine-generator heat rate (ECR) was

me-asued to be 1912.1
Kcal/Kwh wuch is 0.10% I)ctter than the guaranteed turbinc-genciator
hiat late (IURC)
(
1914 0 lKc;l/lKv.'h with an allvable tolcanc of 1 1.5%
lhe (m1c ctie

tilblnc-i
mtol rraxill-our OUtl)ut (MR,C) was mcasuned to bc 254.0 Mw

than guarantced turbinc-gencrator maximumt output (MCR)
of 250
Mw with ai allowablh tolerance of - 0.2%.
which is 1.6% btte
BEST AVAIL,".~
25
.U
O()RINI
.JANIS
IIGI;H ITiHii.SSUlII. STAIt()NAI~Y (OMI'ONISNTS
I )(scri pliorn
tills l
c a
afe Composed of tile followIing: Il1 ()iising,
four
with
arid
circumf~erential f]ariige at the exhaust
casing with a split biltd vetrca -l-ongittudinalJ(oint ,
lhC high prCssurC sttit)lry coIIpoIIents
oI
562/68-2 turbine
lIl.:cctric -HRI<
(of the. b rltel typc kv,,fh a vertical
lain stCill CoIrirCctloliS, 1IBI inrte

,it
h a convent tonal
B oflti (:s wi")II
II
Strill Connections, [J) Inner casing vith a
villi Iwo hot cheat

convenitronal hoiled hoJ iznIi~d ji)n, I iBStatlllnaly hlades includiig the inlet impulse nozzle
and 20 stages of tea:timi iiozles, II' siatinaly bladcs of 17 lows of ieaction sages, 4
co
untrol val.,s, and 2 combined reheat stop and
comhined maul stop ;n]d min s:aii
boltcd
horizontal joint aItl
int I: )tvalve%, IIt
11hii
u * lead Iipl
',and I ' tu1tmn
Ilead
pinig
Vic -Pl' (JutCI casin, Ill' ni11(1; casIn, ani IP irni casing are Chrornium-Miolybdenumstationary hlades ate 129/ Chronmum-nolybdunumVanadiun alloy steel IlP and I1'
Vanadiun stainless steel lhe cornhin d maittn stop and main steam control valves and the
comb1)ined reheat stop and inter(:cept valves ar e inade from Chroniun-M4olybde tILniVanadium alloy steel. ]hc IP and lB Iurbi: lead pipIng is from the steani valves to the
casings
Cnditiol
(Ioni nts arnd Cmrit GC
No 1)1oblenms were uncovered based on ilter'iews with Ja mshoro plant llairnteiance and
operaving personnel and the irvicw of tle first year inspection report on this unit. Duning
that First inspection th: 117 and lB sections of the tWirline were not operied; only the IB
I. rlSl)euctCd lat the nllt scheduled
section vis dismantled. 'l'v IIP ari IP sccti o <
,,,'ill
outage in about 5 yeas. (:uiititly tilrt I ;i,(C (1 ktuil ,itt)obleiiis with these lighlprCssure
stationary compotienits.
ol)tiCrits (described above) all aflpe;wt to be in good
'[he hlighI pressu re,C at totta y c
ancec problem
:ondition based ol tile pla lit personnel itetviews and t hle absete:" of intt
records.
26
.*AMII0O1()
111III
lased ot iic evaliarroi
i1
I'l?1'.SStJRlzl: STATIONARY CO(MIPONIEN'.S
i)r for nld using design data, informalion O)[aindC
1fiOr1
ile
ilh similar d-sr'illunits, and the early ae!C of*r.hrs unit, no

nrlrcrx ws, industry expel icncc
urIe
major problems arc anticipaied in tile neaI
i1) val', arc 1 1 I
mr for ihc IttP caing and the main %
oru
p rois
lhc luhibir ,Tieral Iith' eor
-xr apoharng thi,
% and 0 4% rIsl :ercyl'. y lriun thIre c mmvli. .,sror (1alr to Jun: 23, 1991
20 )(yeals and assuming base
data and assuLmlng thre Saie everlity, of start tips [mo the IeXt
pl, r ycar (2 cold,
i , apacity factoir (d 60% and 10 start u
n
loai operatlom ,, th a i 111111
liilll) l n v..,:1 bc
(imS
life
l
l
ll l tll. 111' (asm;ri, rii[hinc r u
rli i
i
4 vllir, 4 hot), it
el Icss tha o
rrlitrron
less than 25 /c,and rh I rlalll ,I )I) valve" rill h i " r ta I hrfe c
uAbll e ibr
Iu h
r)CClC
I arC eX
l , (d ilt
10%. The: hgh pirs i !:I ar Y (', rrPOrr
Malnte naIC(
leplaceilirl
20 yCar, of. COutrtiLd O)lnatllorll willrol llajor Ipalls or
riiariierialCC ou a;g:
sdllri
shrould h. i oullilc-y p'r In men 1r(i regmenularlye
13[,1 AVAIL, i F
27
.JAM'SI( )RO t
"I'JRIIINEROTATIN(; (0MIONIN'.
I) esc ript in,
flow". tntb)lIC
lhc turtbine rotatintg conponeriltS on this 250 MW tanLdCm coHI)OUnd doubl
blades.
ototnf
assembled
P fotol, l1'rotor and L rotor and the
e oniprsed of ihc I1
awi
?(l I Ulcto1t stages.
;a single fhnov type with one impulse stage, followed by
The III' ltol
lotor is
,,on lhI ITeH
I eam
The 1 blot) IS also ; singlel flow ty)e with 17 ows of
en
a double fl.w type ,.tt / low of (ectioll Stages ()It c l(dh
y
.la 1(dthe
len u In - Va iadmur ilhmv 1,sc
The liP ctimm and the IB icutot ae (Qhromtiti i-N-Mll
Vanadumn stalc, ,tcl The
l-it) and ll) fotating Wlades ate 12 (.homtn-Nlolybdcntll

ilmt
uIn t-N4()ilyit f('ln 1 -Van tul lhl(),, lN 1,, and
, Nickel. ('h
"00
donlbIc flow,% ITP o
the IT i t;tn! blades at I ., t ,ttrile; steel
(omuICnl,,
;trd Current Condition
the first yeat

wth
wi plant mantrtic( cc and op'e.rating crisonncl and recew of
the [irst yea[
.1()oll did not le,.eal a y ltol)Ierfs with these: Cotpow-efts. During
ins1)cix-o
opctled and ,isasseirblcd lot InspecttOn
5was
tSIlp'clioti In1991 only the lBT tutlhblte se.ction
) r
otot ate ilatnted fol illSpcell lt;t the next
Oe
Ilotol
adl
Th eh1-11'
of tw I ' It)t
1)1ol itim with
c,dltaC, In a o01t ) yC;ea , At lie piresent ltlcwe are no kto%..'
h-i
scII,
litt,~e
lhcs
ii
itj nt: irt
B (rtor,L.' rotor and all mtott tr blades all

Thc ttltnh Itolalting CollulJtt , Iilrotor, Il)
)t the iecotds IteVieWd ;lld the plant
contItioni based
sfaetoti)
it
allpCal t w
As I ll (I i rv'
the oit rimsston date

The ttrbtitc metal life coisuilptin for the 11' rotot is 0.07% bor
that the turbine metal lile coriin ption for the iP rotor
to Junc ', 1991. It as asuintit
tc commission
isn0 ,te thgu that of tlte I IP casing which had ; value of 1.3% from
date t( JuIic 2), 1991. E:xtralolatitng this dat;a and assttiing sinilar sewtty of future Malrrt
tas load Op ation with a 60% capci t)factor 3n(
ups in the nxcl 20 years an tassun
i
28
l7,+].".
( ,
.JANI SII()I() IJNI I I
TURIINI.: IOTATIN(; ((OMPI()NI-NTS
10 start-ups pcj
,
i,1 c
ycaif (2 cold, 4 W tlI i,
t aitil life COIISUml
evaluation, the
ricw~ncss of the
sl
ow
iIll
olbtail
the twil;
qIa
we(:I)i (
Iwi' 1d1( 11) I{l(f

11H
ht lt the
i;l:( I
p1 iOli , .. ill hr Ic,> thaln li1t) 8 o
infOrmllatiOl
tillit,
4 hot), it
'51%
")rC
i(vi'd,.,5,
ICiS, 1ncl
l IPI )
(8l[()lnpone(II
it T e Ii 20li
oCntahl
asscnble:d f011 ing, hlidts shoui)ld h() s,
tern l
iliii
ll i0
maijOl r( txil', ind Icplc c niv
I I'
Ifio
' ith,,l+
ild
;nd tile
,(civiC.WS
IT
1 1I
tlit
IC
(i
ICt
(outa cs
a
shchduled II;t ilInc(
BEST AVAILABLE COPY

29
m i onl thi
vy
ro)l)
an( the
tl(i
rtmlm
wilioul
folliic
'i
(Uring
.JAMSI [OI.() tNI I I
LOW PRESSURE STATIONAIRY COMPONI'N[ S4
I) Ccri[liion
lhe low pi:ssure stationary components oil this FUJI L-ectricIlanidCto CoOunrld double
LP outer casing, LB inner casiHg 1, I nne{ casing 2, lB
[low tnrh ine are made up of '
Is a double [low
I at 0naly blades and the ciossaround piping. The low precssu[C S ctl()I
and downwaid exhatis (}th iclndenser. The
sVtCHOl With crosSarOund admlis.There ,are 2
(n Ii NI,{C
,lai{natiy blades arc syn~rnetil.i, aid opposite hand
(:r (S-aori H d [ipt(s; one on each SidC of ihie turbiriC
C{nu pienis and C rrcnl Condition
Ihere, w.ec no probl ms found with the low pressuie si-t l) /ary COIlonentS based oil the
inteiviews conducted with Jamshoro plant maintenance and opelations 1nersonnel and the
review of the first year inspection report of this unit During rltat ist 'cai inspection the
IL section was completely disassembled and inspected. No pitoblclt ,,Cre reported.
The low pressure stationary components
noted above all appear to be in satisfactory
condition based on the plant personnel interviews and the review of tirrnetenance records.
Assessment
No major problems on the low pressure stationary components weic (ound nor are they
anticipated in the future. This assessment is based on the information obtained from the
plant personnel interviews, maintenance records revie\ a industly crience with othe
similar low pressure stationary components. 'lhe low pi)CSSUIC siately cOi1}t)onCHnIS OfI
Unit I are expected to be suitable for 20 years of continued operation without major
repairs or replacements. Normal maintenance arid inspections should be regularly
performed at scheduled major maintenance outages.
BEST AVAILABLE COPY

30
JAMvSII(I() UNII I
GENI:RATOI ANDI-XCITATION - IC-II-CTRICAI.
I)cscription
The generator isa synchronous type manufactured by Fuji Electric The.generator is

hydrogen cooled, 294.2 MVA at 30 KqJcrnm 1-1,
085 p.. lag, 165 kV, 10.294 kA, 50.lz,
3-phase, 3000 rpm, 370V field voltage, insulation class F
The siatic excitation and main exciter field b caket are provided by F:ujji Electric
Thc isolated phase bus duct is
manufactured by the Fl-ur.kawa Co., Ltd , with an aluminum
conductor and rated 16.5 kV, 150 kV BIL, enclosure temperature rise 40 C, conductor
teniperature rise 65 C, aluminum enclosure The main bus circuit is rated at 12,000 Anl)
with symmetrical current of 80 kA. The su'b bus circuits are raicd 100 Amp with
syienictrical current of 160 kA.
Interview with plant personnel, walk-downs, and review of plant records, indicated that all
the above systems ar6 functioning satisfactorily.
Assessment
Assuiaing proper selection of components and adherence to the manufacturer O&M

procedures the generator excitation system and isolated phase bus duct should be suitable
ior 20 ,ears of continued operation without major repairs or replacem-nt.
BEST AVAILABLE COPY

31
(V7
JAM. ISI(O)
[NIT //I
GI NEI'AT()IR I(IOAIIN(; (OMI'ONIENTS
- MEC(ANICAIL
Description
[Tie generator rotating counponents-mcchanical on this FUJI Electric horizontal cylindrical
rotating field hydrogen cooled gencrator arc composed of the following; the generator rotor
forging and the generatorr e.ai(tlring rings The generator rotor forging is a singlc piece
forging with integral turbine-generator coupling and fail hubs. Thc generator retaining
rings are high strength high alloy non magncic steel shrunk on to the rotor body to contain
the rotor coil ends at operating speed,
No problems were discovered based on the interviews with Jamshoro plant maintenance
and operating personnel. Currently there are no known problems with tile generator
rotating conponents- mechanical
The generator rotating components- mechanical, the generator forging and the generator
retaining rings, appear to be in good condition based on the plant personnel interviews and
the absence of maintenance problcrn records.
Assessment
Based on the information obtained from personnel interviews, the generator rotating
componenrts-mechanical: the generator rotor forging and the retaining rings, should be
suitable for 20 years of continued operation without major repairs or replacements. The
condition of the generator retaining rings should be carefully monitored by nondestructive
examinations during regularly scheduled maintenance outages. Routine maintenance and
inspections should be performed on the generator rotor forging during scheduled
maintenance outages.
BEST AVAILABLE COPY
32
.JAMSI IOI() UNIT I
"URtt
NE SUI'IRVISORY INSTRUME-NTATION & MONIT()RIN(;
Descriptio n
The Turbine Supcvisory Instrumentation (TFSI) consists of cabinets, scnsos, indicators,

records and alarms. The "'SI provides monitoring of the following paaneteI's
o
o
o
o
o
o
o
o
Eccentricity
Control valves positioji
Speed
Shaft vibration and position
Expansion
Differential expansion for HP, IP, and L) turbines
Bearing (metal, drain) temperature
Shell metal temperature
Comnents and Current Condition

Interviews with plant personnel, review of records, and walk-through inspections, indicated
that the system is operating trouble -free.
Assessment
Assuming proper selection of component, spare parts availability and adherence to
manufacturer's O&M procedures, the turbine supervisory system should be suitable for 20
years of service.
BEST AVAILABLE COPY
33
SI!IAM TJRBINEI.
C()NTIOI"
CONTR()
(,OVII.N()I
FLE(I'iR(IIYI)IRAtIJIC
1'.fI
I)escriplion
The steam turbine by Fuji EIcct ic, type iclicat condensing tandcr1 conpbund double
flow, is equipped with sol-state aid ana log ClcCI rohydral Ic control sysicin (EHC). T-he
The EPIC is
load control and protcction inicrlocL
El1-IC takes charge of speed(,
manufactuted hy [uji -lectric
Interviews vth plant personnel,
icview of recoi ds, and walk-through inspcions. indicated
that the system is operating trouble-frec.
Assessment
Assuming proper selection of components, spare parts availability and adherence to

manufacturer's O&M-manufacturcr procedures, the steam turbine contirol system should
be suitable for 20 years of service.
BEST AVAILABLE COPY

34
/'0~
UNIT I
JAMSI[OR1
I
BALANCE OF PLANT COMP'ON[ENTS & SYST EMS
220 KV Underground Cables

6 6 KV Cables
D( Station Batteries
Ducts
Local Control Boxes, BTG Boardwiring Control Cables, Cable Frays and
Plant Computer System
lurbine and Central Control Buildings
BEST AVAILABLE COPY

38
l
]
rtJ'UI IN[--(;,IE.NIRIAT() I( AtU XIIIA It' (:()MIP()NI :NV 'S
'
1tITMS
I)c",cr I[) l lI
l
1 562/68
.l7,
Helcii i 1"-l
"Thetnt h ic eierator auxiliary componcints/sys t ns oll this f:tJJl
2 unit consis ofltile following: lubricating and hydraulic oil Syticll, ininig .equpflMenI,
tlcnl-iitm %cfloil systemi and

fhnd S twainl eal systi, tiribine 1)ealiiip's, tirill e P dciil,
h\'vd iugrl SyStell.
iiCliie ; i lan
I hw I h i ailmil an(1 hydiraulic oil systCi incluc-id s

Main oil tanks
Main oil pump
,clay dump valve
Oil cooler
Auxiliary oil tI)UMp
'urning gear oil pump
Emergency oil pump

Jacking oil PUilip
Oil conditionet
Oil filter pump
Vapoi extractor flor main oil tank
Vapor extractor for oil conditioner
Turbine oil storage tank
Oil transfer pumlp.
turning speed
The turning equipment is an oil hydraulic type turning gear which has a
raipe of 80-120 rpm.
The gland stean seal system includes:

Gland seal regulator
Gland steam exhaust blower
Gland steam condenser
Tlis tandem component three (3) casing turbine has fou
(4) journal turbine bearings. The
of the
niumber two bearing is a combined thrust and journal bearing. The thrust bearing is
Kingsbuiy type with straddle construction. The getnerCMtr has two journal bearings located
1-HP
in the end shields. There arC sliding turbine pedestals at the govetiot end of tile
the
section and belween the HP and IP sections. The turbine beating pedestal between
I1 and 1-1 section is of the fixed type.
BEST AVAILABLE COPY

35
.IAMSII)I () IINIT 1
TU ItIN-(;:NERATO I AjXIIIARY COMIPON-NTS/SYSI
IIMS
Ihc gcnerator %eal oil s1ysteill include's

Seal oil (:oolcl
Main scal oil ptuml
1lnnCrgcnCy SCal oil pump
I)
Radial shaft sal,
Seal oil 1it
The ge ncratOl hydioCgel systel consists of tile:

Hydrogen coolcrs
IHydlogeC gas contiol cubicle
I-lydrogc i g;s d ic
Hydrogen cylinders
Pressure gagcs
Purity measuring devices
Valves
:aoirlon dioxide cylinders
(onnents
and Curreil Condition
auxiliary compleonelts/systeills
There were no report(d problems with the turbine-generator
maintenance and operating

noted above based on tile inte-views with Jamshoro plant
the urn
personnel and tie review of the first year inspection report for
to be in good operating
The turbine-generator auxiliary components/systems all appear
condition.
Assessment
turbine-cenerator auxiliary'
No major problems were found nor are they anticipated on the
interviews, the
components/systemns. This assessment is based on the plant personnel
with other similar turbine
results of the first year inspection and industry experience
auxiliary
turbine-generator
The
components/systems.
auxihary
generator
for 20 years ot continued
components/systems for Unit I are expected to be suitable
maintenance and Inspections
operation without major repairs or replacements. Normal
should be regularly performed at scheduled maintenance outages.
BEST AVAILABLE COPY

36
JAMNISIOI()
11AIANC-
UNIT I
01: I'LANT COMI'ONINTS & SYST-MS
The balance of plant mcchani al, electrical,

structurcs evaluiatedl consists of
instruelentation
a1)1
rn ro1l
and civil
l1e following:
l-eedvia-tesiei
puimlps
Coridensa tL'e
[cedwater lcateis
Dea ltor
Boiler fecdater punmpS
Cooling Watcl Systeni
Cooling towe
Circulating water pump
Condenser
Cooling Tower Structure

Instrument Air. System
Fire Protection
Chemical Feed System and Sampling Rack
Water Pretreatment System
Coagulation Sedimentation Tanks
Water and Wastewater Treatment Systems
Water Treatment Building
Emergency Diesel-Generator
Power T'ransforrncrs
6.6 KV Metalclad Switchgear, 400V Power Centers, 400V Motor Control Centers (MCCI
EST AVAILABLE COPY
Uninterruptible Power Supply (UPS)

37
le,. r
JAMSHIIOI,() tJNII
'II1.
l.l--D
SYS'II]
I)cscriptiou
'lic [cedwatet system conveys water fron the condenser outlet to the boiler econollize
otl seven srloes of.' hcating as
oul'h
Inct. It prheats the boiler inct water tem pera ttirc
ejec(clor Coolers and tnrhiie, gland steam
Well as condensing the stcarop in the steain jet allliis rtco rtarc Ole condensatt- pumps,
imlajor colm porelnts addressed in
lThe
condeinser
lps
fctedwatc hic, s, dcarator and boilcr feedwatcr ptju
lh tee 50% capacity [lotoI driven c.Clodenlsatc pumps aw provded Under normal
bc operating with the third pump in

OPcrati ng, conditions at full load, tv.o punips wouid
tl ,,rre wth bronze impellers and
stalid-by Inode The pullps are vcrrcal cerlrlfifgal
stainless stcel shafts.
closed feCdvwater healers. All heaters
lhcre arc [our low pressure and two hnigl pressure
#I has aluminum brass tubes and the
are hotizontal "U-tube type. Low pressure heater
hrart have carbon steel tubes
reilaining low pressure heaters and both high pressure
stora -e tank. -he dearator and
The dearator is a cylindrical tray type with a horizontal
trays are stainless steel.
storage tank shell are carbon steel and the dearator
driven boiler feedwater pumps

Three norinal 60% capacity four stage barrel type rnotor
coupling and a feedwater
are provided.
Each pump includes a variable speed hydraulic
would normally be operating wth
booster pump. Under full load conditions, two pumps

the third pump in stand-by.
Comments and Current Conditions
no unit trips attributed to the

A review of the Unit #1 trip records indicate there were
as
The condition of the major feedv.,ater system components,
feedwater systems.
as follows
documentated in the First Inspection Report, are summarized
and conditions were

Visual inspection of Heaters # 1 & 7 waterboxes was performned
noted as satisfactory.
of abnormalities during
Condensate pumps were not inspect"d due to absence
operation.
BEST AVAILABLE COPY
39
.JAM.S II()() UJNIT I

11*"I)
'AII'T
,
SYSTEIM
the storage tank

eCvealed ;I dent ol tile surface of
Inspection of Ohe dearato[
were fou il(
defects
other
No
welding.
y
I
paIICed
ic
was
dl(t
manhole tlange Tlhe
13oile
r
FeedwatCI
rep laced with ncw
and collars. Ilicst parts " ee

A had dalaged thrust padsA&C
'euinp
had erosion of the reheat
pumps
(S.
1Boilei feedwatet
resolved .,, FUJI Electric Co. lid

spray pot I lhis problem Was addressed and
all three pumps will be supplied by Ih(:
report dated July 25, 1991.
New parts for
manufactures.
were inspected. A \lrc ring and sand

Boiler feedwater punip hydraulic couplings
No damage, was found
and removed
were found in pump A coupling casing.
Couplings for pumps B&C were satisfactoty.
personnel indicated a current problem
Discussions with plant operating and maintenatnce
It Was stated this item \,ould be corrected
with the boiler feed punp mechanical seals.
indicated no other maJor problems with
later this year by the supplier. Plant personnel
this system.
based on the data reVewed and
The feedwater system appears in satisfactory condition
were noted.
unit walk-through inspection. No unusual conditions
Assessment
design and selection of equipment and

Based upon the age of the unit, assuming proper
and operating prccedures. the
adherence to the manufacturer's recommended maintenance
be suitable for 20 years continueO
major components of the feedwater system
should
operation without major repairs or replacement.
BEST AVAILABLE COPY

40
,IAMISI 10R()
(O()IN(;
I JNI[ I
I
AIWAr
SYSTIEM
Descriptiol
for'the condenser and the bearing

The cooling water system provides tile cooling water are (he coolinte lowc', circulating
the rcport
[lie major components addressed in
is covered in detail in a separate
A
structurc
cooling tow
water pumps and condenser. The
coolers.
SeCtiOnl
The cooling
cross
u ilharical induced diafti multi-cell
is aIower
ow lype
T]hc structure
is polypropylene (splash type)

is reinforced concrete and the fill rnaterial
Fhree 50% capacity cii
no; eal conditions, i\,

i u;i1 w 1t( I un1 % Me provided. Under
are
In :talnd-by. The circulatirw water pumps
pumps are operating and one pump is
and cast
lhe
pumps have stainless steel impellers
vertical, single suction mixed flow type.
iron casings.
box horizontal surface typc
ihe tube material
The condenser is a Iwo pass, divided water
and titanium in the air removal and exhaust
is aluminum brass in the condensing section

impingement zone.
Coninients and Current Condition
personnel and a revie, of the Unit No.
InterViews with plant maintenance and operating
in
on the condenser tubes. The unit was tripped
1 trip record indicated a scale build-up
unit was acid cleaned in 1991 to remove the
October 1990 for condenser inspection. 'The
in the Minutes of \r4eting dated
scale. Subsequent testing of the tubes, as documented
August 12, 1991, revealed no damage to the tubes as a result of this cleaning. The cause
poor quality of the make-up water to the
of the scale build up was attributed to the
water treatment modifications to prevent
cooling tower. Recommendations for make-up
on Condenser Scale dated 12/25/90.
future scaling are contained in tile Mitsui Study
as documented in the First
The condition of the major cooling water system conponents,
Inspection Report, are summarized as follows:
cathodic protection system
Visual inspection results of the condenser and condenser
were satisfactory.
BEST AVAILABLE COPY

41
JANVSItI( ) IJNII I
CO(,IN(; WATIER SYSTE".M
All parts w'.f( checked and found

(ii culaling Water Pump No. B was dismantled.
and tested by placing back into
in good condition. lhe pump was reassembled
Circulating water pumniS A and C were
operatiwr. Performlance was satisfactory.
performed. Restilhs we re satisfactory.
visually inspectcd aned in operating test
problems with thlis system

lirt wivsoancl indicated no other
majoi
WerC assoClalted with this system.
condition based on the data

Tir systen appears in satisfactory
were noted
thiough inspection. No unusual conditions
No othe[ unit trips
ev ,ewedand unit walk
Assess mcic
proper design and selection of components,

Based upon the newness of the plant, assurning
maintenance and operating procedures,
and adherence to the manufacturer's recommended
or
continued operation without major repairs
the system should be suitable for 20 years
system should be modified to prevent future
replacement.
The make up water treatment
scale build-up in the condenser.
BEST ,VA1 LABLE COPY

42
S'tt,
(:O( l+I rN{(; "I(} I
[) c {i Ip
IR<tj..u ,
ion
tnIc "hic ;tIae somic

place co nCrCtC Stl[tJC1
lhe cooling tower is a ITu ti-cCl1 basically cast inI
along the ouitside of thc cooling
)re[abticated Sections, such as concrete draft b~afflhs visible
la z;hcell has a fan tttstdc ;I sholt frbcrglass
toels and the covel slabs. at tile to)
of Ithc cell
1
ctd on a colum n at the, Cttct
hyp rbolic shaped stack. Ihe kIII iss upp
nediate I\c,.l III [out dirCctllonS
an ilti
Ihe (:oitinn is framed with beans at the top aIod at
thte eKt 111al columns or} cell scja(ating walls.
at r llr'.t
Co<n-+tmetntS :111d C11-t
{itionl's
o d
n +,{
the site was visited Thce sLrucltuJil

Ihe cooling tower of Unit I was in op)eration when
Most components are conctfetc,
parts Of cooling tover appear to be in good condition.
water splashing plastic boards and
therefore no near-tcrnm deterioration is cxpccted. The
is unavoidable.
,heir hangcs wiIl dcterioratc as aging and corrosion
are welded steel and painted. Steel
The stairs and handrails in the cooling tower
structure
properly.
parts will corrode in a wet environment if not maintained

limestone formation which was
File cooling tower structure is supported on a solid
settlement, cracks, or detcrioration
recognizable
even at the ground surface. There was no
pumphouse.
observed in the cooling tower structure nor in the adjacent
,\ ss es srin cii
structure is suitable for the next

Assuming proper design and erection, the cooling tower
and replacement. Miscellaneous
20 years of continued operation without major repair
attachments will require normal
components, such as stairs, handrails, hangers and other
maintenance and repairs as necessary.
BEST AVAILARLF COPY
43
INS'I'ZtJM INI AlI Z SYSTEI M
I)cscript
of
operating and one in standby,

Two instrument air compressors arc provided, one normally
fice, nominal capacity 7 mnimin,
-ach compressor is reciprocating type, water-cooled, oil
vollll1C 3and ic air dr-yer unit of nominal
(u)330C fiee air with one air reccivei of 2 5 i'
c(apacity 14 n/Tmin @) 33C rice air
comnpressor ai(Cconne:cted together to the
Tlhie discharge pipcs of each instru n t ali
system is
:nt alt back-up line from the sctice air
list i nflcit ait recciver. At' 'nstrumn
connected to Common header.
regulator and all filter soi and vertical selfFlecyst.m includes i, self-operated pressure
sta:nding control parnel.
(omments
and Current Condition
and walk-downs, indicated that the

Inter-views with plant O&M, review, of plant records,
instrument air systeri operates in satisfactory condition.
Assessment
to the manufacturer's O&M
Assuming proper selection of components and adherence
without major repairs or replacement.
procedures, the system should have 20 years life
BEST AVAILABLE COPY

44
JAM.SIIR()
UNIT I
FIR 1, PROTECTION
)cscripion
components with aCceSsofriCS:

The fire protection system consists of the following
Freshlwater Extinguishing Equipment
fire puinip
a)
Motor driven aid diesel driven emergency freshwater
capacity of 760 mVhr @ 9 Kg/cmlg discharge pressure.
Lach has a
each with
a capacity of 30
b) Two (2) fire water pumps manufactured by EBARA,
rn3/hr discharge pressure.
c) Sixty-six (66) fire hydrants and 145 hose connections

o
concenir.v.e iank. injection

Air foam extinguishing equipment, which includes air foam
pump, hydrants, and fire fighting truck.
Dry chemical extinguishing equipment.
detectors and manual

Fire alarm system which includes a fire protection panel, fire
pushbuttons.
(54)
hand carried and
Portable fire extinguishing equipment, which includes fifty-four
tVo (2) wheel carried dry chemical extinguishers.
Comments and Current
Condition
records indicate that the

Walk-down of the system, visual inspection, and review of plant
unloading and receiving area is
system is in satisfactory condition. However, tile fuel oil
areas. It was also noted that
considered hazardous due to the oil spillage throughout the
due to security reasons.
fire hoses for jse througlhout the plant were stored in a warehouse
45
BEST AVAILABLE COPY
/13
JAMSI I()HRO UNIT I

FIRE PROTECIION
Asscssment
and adhcicnce to
Assuming proper sclection of components, periodic f-unctIonal tcsts,
for 20 yCars continued
manufacturers rccommendation, the system should be suitable
facility is ncedcd to
operation. Howcvcr, immediate clean-up of the fuCl oil unloading
the hosc racks providcd
avoid potcntial fire.
In addition, fire hoscs should bc reinstalled in
in order to ininimizc rcsponsc time and extensive fire damage
BEST AVAILABLE COPY

46
.JAMSI10I() UNIT I
CIIEMICAL FEE) SYSTEM AND SAMPLING RACK
Description
Condensate and fcedwaier arc chemically adjusted to prevent scale fo0n1ation, corrosion,
caustic embrittlcment, and contamination of steam, such as silica carryover which would
deposit oi the thurbinc blades. This chemical feed system, combined with boiler blowdown,
demincralized make-up water quality, and boiler manufacturer's recommendations provides
the basis for each Unit water cycle quality.
The system feeds chemicals to the boiler fcedwater to control the ph and to inhibit release
of oxygen in the boiler tubes, drum, supeheater, and economizer
Diluted hydrazine is added to remove dissolved oxygen contained in the feedwater and to
control the ph value.
However, during plant startup and shutdown, aiimonium solution0
is added to control the ph of the feedwater, and is injected in the condensate pump
discharge. During long terrn shutdown, concentrated hydrazine is used to protect the boiler
from rust.
The sodium phosphate solution is used [or inhibiting caustic ernbrittlenic-t, and to remove
hardness of the boiler water.
The sampling rack supervises the quality of make-up water, condensate. feedwater, boiler
water and steam.
Tie c hemical feed system consists of the following equipment manufactured by Nikkso
Company Ltd.:
(2) Hydrazine solution plunger pumps (0.286 literk.In)

(1) Diluted hydrazine solution tank (1000 liter)
(1) Concentrated hydrazine solution tank (400 liter)
(2) Phosphate solution positive displacement type pumps (0.58 litcr/mini)
(1) Phosphate solution tank (780 liter)
(1) Ammonium solution tank (400 liter)

(1) Ammonium agitator
(2) Ammonium solution positive displacement pumps (0.286 liter/min)
(1) Stand-alone control panel
(1) Stand-alone sampling rack, open type, single side mounted with pH analyzers,
conductivity meters, dissolved oxygen meters, hydrazine meters, pH indicators,
and conductivity indicators by L&N/Yokagawa
47
BEST AVAILABLE COPY
JIAMSII()1O UNIT I
CIEMICAL FE-E'!) SYST'EM AN)
SAMI'[[N(; RAC(K
indicated that
Intcrviews with O&M personnel, walk-downs, and reviev of plant records
as
the chemical feed and sampling rack are functioning on automatc/iifanual:operatiol
designed.
No major troubles were reported by tle O&M personnel
Assessment
Assuming proper selection of components and adherence to manufacturer's

procedures, the chemical feed and sampling rack should provide 20 ,cars service.
O&M
BEST AVAILABLE COPY

48
.JAMNSIOR(
UNIT I
Description
pond for removiing large size

File river water is pumped to the intake water receiving
tank, coagulants and
particles. Before the water flows Into the coagulatiron-scdimtation
into the river watcr

other required chemicals for coa!;,nlai(on-scdirmentation are injected
is not obta ined, the suitable agent is injected to

lh( pi I of tile river watc is adjusted by caustic soda
make the floc stabler and heavi'
often by the addition of the
injection to maintain tie optimum pIl I value W1hich flItra!es
unit is in standby.
coagulant. In normal operation, two units operate and one
feeding pipeline
When good coagIjlatio
oag;ulat o r-sedimentation tank is collect 2d in the

Tlhe clarified water flowi ng out )1 Ih cir
cooling lower and the
clarified water storage tank. Some of the water is punpcd into the
rest is pu mpcd to filtei equipment for final treatment.
tank is
The sludge concentrated from the intake v.atcr ecceiving pond and sedimentation
remove
to thoroughly
discharged to the evaporation pond.
The filter equipment is installed
tank.
fine suspended solids and organic matter carried from the coagulation-sedimentation
set is in rinse or
Normally, two sets are in service operating semi-automatically and one

tank and the water
standby. The filtered water is collected in the treated water storage

is used for plant water and domestic water for the colony.
imldicated the
Interview with plant personnel, walk-downs, and
review of plant records
is functioning
system, with the exception of the coagulation sedimentation tank,

of the
satisfactorily and on auto and semi-automatic as
designed. Refer to the assessment
Coagulation Sedimentation Tanks for details.
The system components were included in the First Inspection Report. All components
B agitator
Were in good condition with exception of the coagulation sedimentation tank

surface
gear box and filter scrubber air blower A. The gear box was replaced and blower
finish was repaired.
BEST AVAILABLE COPY

49
//
JAMSIIOI(O
WATER
JNI[
ATMENT SYSTEM
II'AREFR
[he systern appears to be in satisfactory condition based upon the dala reviewed and uni
walk-through inspection. -owevcr, we have observed that when the coagulation tanks are
cleaned-up, the mud is dumped on top of the discharge pumps and pipcs which Will cause
increased maintenance for thcsc components.
Assessment
Assuming proper selection of components and adherence to the manufacturer's O&M

procedures, the system should be suitable for 20 years of continued operation without
major re)airs o cplaccmcnt. Care should be exercised when cleaning the[ tanks to
)rCclude dumping inud on equipment.
BEST AVAILABLE COPY
50
h1
IAMIHORO UNIT I
COAGULATION SI[MENTATION TANKS
I)escription
for the unit. L-ach Is shaped like a

Thece are three coagulation sedimentation tanks
diamete a Ihe 101) a'rd the
truncated cone in the upside down position with the larger
narrower diameter at the bottom.
out of steel with tile Siialier
Iriside the tank there is another truncated cone made
tile tank bottom l he water from
diarnctcr on the top and the larger diameter towards
and is distributed at the top center
tie r(:ceIving tank is mixed with coagulant chemicals
the cone letting the particles
rotates the fluid inside
agitator motor settling
An bottom
inside cone.
at the lower side of the
of the afrd
openings
ghe
tank.
the
of
scttlc at the
Now
space betv'een the insdc and outside
IetalI cone let the incoming water pass towards the
top su rface then Bows rhrough sn tall holes
Cones moving upwards. The water reaching the
to the clarified water storage tanks. The
Into iadially placed steel iIoughs for transfer
by the sludge drains provided at the
sludgc foimed in the inside cone bottom is removed
bottom of sedimentation tanK.
aI
To facilitate the emptying process, a pressurized
pipc
is also installed at the inside bottom tank periphery.
Comments and Current
Condition
cracks at the lower 1/3

T"lhe coagulation sedimentation tanks showed white calcified
seen. This does not assure that
elevation of their sloped walls. No major leakage was
In the long run, deterioration of
possible corrosion of reinforcing bars is not occurring.
tie tanks did not indicate to any
reinforcing bars may be expected. Soil conditions around

any reporcd damage to the
settlemeint. The coagulation settlermnt tanks did
not have
internal steel cone structures, troughs or agitating system.
compared to U -.Its 2, 3 and

Plant personnel reported clean-up of the tanks are excessive
Clean-up is performed
4. The sludge removed pipes are not performing their function.
miarutally on a continuous basis by local contractors.
BEST AVAILABLE COPY
51
.JAI'vSI[OIO UNIT I
COAGULATION SE)IMENTATION TANKS
A -s c s imcii I
lhese
frequent changing vet and dry conditions.
The internal metal cone is subjected to
and normal repairs of the internal eonc can be
conditions accelerate the corrosion process
high O&M costs arc also being incurred.
cxpected inI apprOximately 10 years. Abnormally
are
to determine if modification to the tanks
Itis recommended a study be performed
[casible to reduce these costs.
BEST AVAILABLE COPY
52
Description
Water Treatment System

and stored in the demineral
Some of the filtered
water is treated by demincralizer
consists of cation exchanger, degasifier,
izer water storage tank. The demineralizer

anion exchanger and polisher.
while the othcf train performs

Normally, one train carnres out service run,
regenrertion.
hydrogen ions from essentially all

The cation exchanger is furnished to substitute
resin, and the anion exchanger is
cations using strong and weak
cation exchange
all anions in the degasified water,
furnished to substitute hydroxyl ions for essentially

using strong and weak anion exchantie resin
with packing to accelerate air-liquid

The degasifier, which is vacuum tower filled
dioxide in decationized water.
contact, is furnished to release oxygen and carbon
acid is used for cation resin, and caustic
For the regeneration of resin, hydrochloric
diluted chernical is downflowed
soda is used for the anion resin. In each exchanger,
resin.
for weak resin and upflowed for the strong
completely irace ions in the
The mixed bed polisher is furnished to remove
time of approximiately seven
demineralized water and designed to provide service
(7) days between successive regeneration.
resin, the diluted caustic flows
In regeneration of cation and anion exchange
The
acid from bottom upward.
downward simultaneously with the diluted
pit and the final rinse water much
regeneration wastes are discharged to wastewater
to the service water storage tank.
purified than demineralized water is recovered
system is received in
Wastewater of acid and alkali discharged from demineralizer
air blower. The mixed
the wastewater pit mixed automatically by agitating
wastewater is pumped to wastewater system.
BEST AVAJLALr COF-y;

53
/Y1
,JAMSIIt1k() tJNI' I
SYSTEMS
WATER AND \VA 'EWAI'R "TRj [AIM[NT
Wastewater Treatmcnt SystCm

in the wastewatCr storage pond
The chemical wastewater from plant is collected
the waste is stored and agitated
through cach surnp and pit. In this pond,
equipment which is processed in
temporarily and pumped up to the neutralization
This pH adjustmelt is carried oui
injection.
alkali
or
acid
diluted
by
steps
two
water is returned to sitoage pond.
autonatically and, if not suitable, treated
Comments and Current Condilion
and were
included in the First Inspection Report
The water treatment components were
of plant
plant personnel, walk-downs, and review
with
Interview
condition.
in satisfactory
are functioning satisfactorily on auto and
records, indicated that all the above systems
semi-automatic modes as designed
Assessment
and adherence to the manufacturer's O&M

Assuming proper selection of components
for 20 years of continued operation without
procedures,
the systems should be suitable
major repairs or replacement.
BEST AVAILABLE COPY

54
.JAMSII()4O UNIT I
WAT'I'1
'ItRLATMENT
BIllLDING
)Cscription
grounds ol
thc main power plant
of Unit I is located inside
tanks
metal
ar
1he water treatniert buildingmain
there
building
this
In
post.
entry guard
the left sid just passed thce
water. Thc
are used to demineralized tile pretreated
with acids, anions, and cations, which
The corcle
as a concrete frame structure
vatet treatment budding is constructed
placed arc
are
paint. The floor where tile tanks
surfaces arc finished with mortar and
Outside
surroundings are raised in case of spills.
covered with acid resistant tiles and their
trenches
has a terrazzo finish. There are covered
of tile protected tank areas the floor
below the walkable floor level.
frame
exiernally or internally. The structural
No defects or deterioration were visible
the outside perimeter there were no signs
elements have mortar finish on them. Around
of settlement observed.
Assessment
the water treatment building should provide

Assuming proper design and erection,
satisfactory service for the next 20 years.
BEST AVAILABLE COPY
55
,JAMSI Ot,()
JNI'I' I
'M -RGENCY 1)1 E.SE[G ENERATO IR
D)csc rip )fl
400V, 1083A, 50 Hz, 3-phase, 1500 rpm,

The generator is rated 750 kVA, 0.85 p.f.,
hc generator was
excitation system
insulation class "B", and with a brushlcss
ifact
Imall
Ued by uJl -lectric.
5 compression
650 kW, 150 rpm, 12 cylinders. iL,
ilic diesel engine is type S12 NPTA,
b%
lithe diescl engines -,is .,nanufactured
systems.
combustion
Injection
direci
ratio with
Mitsubishi.
air compressol
control panel, air circuit breakci...,.
The diesel-gencrator isequipped with
equipment which include:
(I)
(1)
(2)
70 0 rpmn
mm stroke/
Vertical 2-stage air compressor of 70
3.7 .\W 380\1 electric motor, and
air ieccivers of 300x2 m" capacity
start to reach full speed within 40 seconds

The diesel generator is capable of autotnatic
lost to the 400V critical bus .nd automatically
It automatically starts
when power is
StO)ped when normal power is restored.
Comments ,and Current Condition

indicated
of records and walk-through inspection,
lInterxviews with plant personnel, review
that the system is operating trouble-free.
Assessment
and adherence to
Assuming proper
selection of components
20 years service.
procedures, this system should be suitable for
nianufactturer's O&N4
BEST AVAILABLE COPY

56
.JAMSI IMO() UNI'l
POWIR TRANS1ORMLI ,S
outidoiti
on
I)r
oil
The: main power transformer is manufactured by Fuji Electric Company, outdoor,
294.2
220 kV/15.7 kV, 7.

immersed, OFAF rating is 294.2 MVA, 50 l-z,
Kosan Ltd
MVA base, mineral insulating oil by Idemtsui
ird
[he auxiliary transformer is ian ufacti
-1
4.91% at
oil
l)y Fuji i ecilic Company, outd,: or,
Delta/Star, with ianisformcr ground,

immersed, 25 MVA, 16.5 kV/6.9 kV, 50 Hz,
insulating oil by Idemrsui Kosan Ltd.
Z
o)
10% at rated MVA, mineral
The startup tralisforllc
ufactur(d
Is is a na
by Fuji l.lcciic ( orpany
Ltd., oil
(ONAF). ??0 kV.,'6 9 kV, Z

immersed, outdoor, 15 MVA (ONAN/25'M\'A
at 25 MVA base.
10%
Current Condition
visual inspection of the transformers and

Interviews with plant personnel, walk-downs,
operation of the transformers is satisfactory.
review of the plant records, indicated that the
Assessmient
and adherence to manufacturer's

Assuming proper selection of the transformers
for 20 years continued
should be suitable
recommended O&M procedures, the transformers
operation.
tests are recomnrrnded on a

-lowever, oil sampling and insulation interity
periodic basis to detect transformer deterioration.
5FS! AVAI!,APLF POCUM.q!,g

57
.JAMSII(I0 () UNII
T
6.6 KV N I-IAI.CL
AI) ,<, IT(I I(,I' ,
ZIS
400\V I'O\yt , CI N
S (MC(C)
CINIFI
400%, MOTOI, ('()NTN ()I.
flescription
arc provided. Both have copper

Two (2) 6.6 kV tnctalclad swrtchgear assemblies
circuit breakers.
capacity and draw-out vacuum
buses with 2200A current cairying
at 7.2 kV, 2000/\, and 31.5 kA.

The incoming and bus tie breakers are rated
are
rated at 7.2 kV, 600A, and 31.5 kA
interrupting capability. The feeder breakers
interrupting capability.
are provided: (1) unit power center, (1)

Five (5) 400V metal enclosed power centers,
power center, and (2) pre wastewater
cooling tower power center, (1) common
Fuji Electric dry type, rated 1300 kVA or
treatment centers. The transformers are
700 kVA.
" :,;
in breakers rated 2000A or

with t!c
The air circuit breakers are draw-out type
The feeder breakers are 1000A
1600A
frame, and 50 kA interrupting capability.
frame, with 50 kA interrupting capability.
control centers are provided with main

Fourteen (14) 400V, 3-phase 3 wire
motor
400A.
copper buses rated 600A and branch buses rated

anu jctew of plant records indicated
Interviews with O&M personnel, visual observation
motor control centers are in satisfactory
that all the switchgear, power centers, and
condition. No unusual conditions were noted.
Assessment
and adherence to manufacturer's recomAssuming proper selection of the components

centers, and motor control centers should
mended O&M procedures, the switchgear, power
be suitable for 20 years continued operation.
BEST AVAI LARLE. DOCUMIEN'T

58
.IAMSiI C)I()
UNINTER|UITItILM
UNIT I
I'OWEIR SUPPLY (UPS)
Description
400
UPS. The input voltages are 220 VDC and
Unit I has two sets of 30 kVA static type
One set is used for all the computer
VAC, and the output voltage is 110 VAC.
to supply 120 VAC for tc following, control
equipment, and the second set is used
ap plications:
o
o
o
o
o
o
o
o
Turbine bypass system

cabinet
Auto burner control system cabinet
Auto boiler control system cabinet
BTG board
BTG auxiliary board
Auto volt regulator 'ibinet
Electrohydraulic system cabinet
Turbine Supervisory System Cabinet

ruaintenance records indicated the UPS is
[nterviews with plant personnel and review of
operating satisfactorily.
Assessment
adherence
Assuming proper selection of components and
service.
procedures, the UPS should be suitable for 20 years
B~S AVAI_Ld3LE DOCUMEN
59
JAMSII[OI (
tJNIT I
2201(V UNDERGIOUNI) CABLES
!) C,; ci ipt on
underground cables run in the underground

Iwo (2) circuits of forced oil cooled 220 kV
conc:ictc tunnel:
o
C)
From Unit
1 main transformer to the 220 kV switchyard
kV switchyard
From Unit I1 startup transformer to the 220
I 220' kV cables. The electiical-maintenance

No problems were reported on the Unit
and log the follownii
personnel run daily checks of the cable system
o
o
o
o
o
o
o
Oil tank pressure

Oil leakage
Sheath grounding
Lighting systems
Drain pump motors
Tunnel fans
Other abnormal conditions
of the cables and review of maintenance

Interview with plant personnel, visual inspection
satisfactorily.
rLcords, indicated that the cables are operating
Assessment
and adherence to the manufacturer's O&M

Assuming
proper selection of components
for 20 years service.
procdurcs, the 220 kV cables should be suitable
")iiV A I*\[LdDC) G ,AICN

60
/.)
.IAMSIIORO
UNIT 1
6.6 I(V CABLES
Description
of the auxiliary transfdrmer, startThe 6.6 KV cables are used on the low voltage side
power centers, and as fccdcrs to tile 6.6 KV
up transformer, subfceders to tile 6.6 KV/400
motors The cables arc non-cornbustiblC type.
personnel and Visual inspection,

interviews w'ith electrical maintenance and operation
indicated thai the cables are in good condition.
Assessment
application, the cables should be suitable

Assuming proper selection of cables sizes to the
for 20 years of life.
W-tel fAVAILABLE DOCUM ENT

61
JAMSHIO() UINII
I)C
l '
TATION BAFlRI S
l)escripthC)
l
The
by Furukawa (Ff' ) 2375)
manufactured
system
battery
VDC
220
a
Unit1 I has
rated
nominal voltage of each cell is 2 VDC,
hattcrics ac cad acid type, 110 cells;
capacity ;it10 hi. is 2000 amp-hir
200-230
thyristor type, self air cooled. S0O amp,
The uni has one three phase rectifier,
VDC
DC
review, of plant records indicated that the
Interview with plant O&M personnel and
batteries and chargers are in good working condition.
Assessment
and adhere to manufacturer's recommended

Assuming
proper selection of components
O&M procedures, the system should be suitable,
sL'Si AVAILAi1LE DOCUvtENib
62
JAMSIIIZ() UNHIi
IG OARWMI)RIN(;
LOCAL CONTROL I( X[ES,
CONTROl. CABII"', CA iii.I: TRAYS, AND [)UC I
Descrilion
instruments, and co.ittrol switches

The l3oilcr-lurbinc-G erfatOU (13TG) board contains the
local control boxes arc wall
from the Boiler, Turbine, jind Generator Systems The
Cable trays run throughout (he unit
mounMtd o rack mounted near the applications
The underground cables arc routed in
without interfcring
with the equipment layout.
ductha nks with concrete manholes.
the of documentation indicated

Interview with O&M personnel, walk-downs, and review
the following:
as iccded to meet tiii
o The cable trays are not congested and arc covered
satisfactory.
application. The workmanship of the cable trays appears
indoor or outdoor apphcation

o Local controls boxes were properly selected for
at tile cable entries
as appropriate. Insulated conduit bushings
were provided
into the boxes.
the medium voltage

Tihe power and control cables run in ductbank separate from
arc left open exposing
cables. However, in some areas the
manhole covers
cables to the elements.
ma, 0-5V, 0-I0V) are

It appears that the low voltage signal cables (4-20 ma, 0-1
shielded.
are marked with

o Cables and wiring of tile BTG
board in tile control room
permanent identification tags in English.
Assessment
and adherence
Assuming proper selection of components, covering the exposed manholes,
BTG boardWiring,
control
to the manufacturer O&M procedures, tile local control boxes,
cables, cable trays, and ducts should provide 20 years service.
63
BEST AVAiLA[-,IF COPY
JAMSII(O)() UNIT I
PL..ANT COM['UTR SYS'EM
and utilizes centralized database CRT

lhe computer system is microprocessor based,
to display data and request printout, at the
screens are installed at the operator's desk
desk to change scttings. and provide
BTG board to display alarms, and at the engineer's
and
plant equipment condiiions. :eniperatures
oltwarc nainicnance.
Graphic displays of
the operatot interface
p)ressures at major points in the unit, facilitates

out every 5 minutes for plant efficiency
The plant performance calculations arc carried
upon calculations performed five minutes
factors The results are logged each hour based
program calculates th1 mount of thermal
before the hour. The turbine life consumption
start-up, shutdown, and opefation of the
stress occurring in main turbine parts due to
from low cycle fatigue caused by thermal
plant It also calculates the life consumption
for the operation and m intenance of the
stress of material. This information is useful
iurbine
and review of plant records

Interviews with plant O&M personnel, visual observations
indicated that the system operates satisfactorily.
Assessment

Assurning proper selection of components, adherence
should be suitable for 20 years of
procedures, and availability of spare
parts, the system
continued operation without major repairs or replacement.
64
BEST AVAILABLE COPY
.JAMS I101M()
UNIT I
IJTUI INI': & CI-NTIAL CONTROL
FlUll
[)lN(S
houses lie turbinc, genea tor,

The turbine buildinrg is a steel Frame stiructuI-C which
pumps,
water heat exchangers, air compressors, chillers, vq.rious
Condenser, bearing cooling
to run and control the turbine aid generator
HIf' and LP heaters and other equipmcnt
No rti/South direction, (parallel Ito the turbine
Ih " turbinec building is oriented in tie
i
rncator rotation axis).
27.1 meter high. Ground floor elevation is at

It is 74.0 meter long, 33.0 meters wide and
operating floor ai
floor at El. 5.50 meters.

i-0.0 meters Other floors are mezzanine
and deaerator floor a.El. 21.00 mctters
El I100 meters, heater floor at
El. 16.00 meters
buil.ding with 60 ton capacity Pic top of the
Thece is a bridge crane

inside the turbine
is 21.4 meters. Ihe width between columns
rad is at El. 21.50 ineters. The crane span

meters
A and G, where the crane isoperating, is 23.00
F.*EL
as closures of 1h turbine building

There are north and south side gable wall construction
surface by a cast-in-place concrete wall
The north side gable wall is covered on its outside
prefabricated reinforced concrete elements
up to El. 11.00 meters and above that level by
in the Unit
I technical specification
The south side gable wall was considered as temporary
the Unit I turbine building from
on the extension
side but remained in place separating
corrugated sheet metal panels. The
Units 2, 3 and 4. It is covered with painted

meter, below which there was a poorly
corrugated sheet mctal starts above El. 1.0
there is a passage-way with a wooden
constructed brick wall. At the ground elevation
I to Unit 2. There Isalso leftover forming
frame through the south gable wall from Unit

floor slab along axis P107 and P108.
wood from construction under the mezzanine

prefabricated reinforced concrete wall
The east and west side walls
are covered by
columns of tile turbine building structure.
elements which are bolt connected to the outside

wall units which provide sufficient
There are window bands

between the prefabricated
there are louvers which serve as
daylight to tile operating floor level. At lower elevations

Air is vented through covered air outlets at
tile fresh air intake for the turbine building.
reinforced concrete roof elements
tle roof. The roof is covered with prefabricated
insulation over the roof elements. The
supported on roof purlines. Thcre is bituminous
which arc mortared at their joints.
insulation is protected by brick tiles on the outside
meters high reinforced concrete slabs which
The mezzani,'3e and operating floors have 12
welded on the upper flange of tile
are rigidly connected to the floor framing by the studs
under the floor beams, was used only for
beams. The horizontal bracing, which is visible
65
BEST AVAILABLE COPY"
,IAMSIIOR0
"lu
itm-pOi-ary duty during
ngles bolted to the ba
cC
JNI'
CONTROL 1UII)"INGS
& (:ICNTIIAI.
IN'Jlll'l"
[-loo l )ea nis arc framed to the floor girders by double

il
ai(l welIedI to ihc girdcrs. T-hc pedestal foundations for heavy
concretC.
level aC raiscd [from the nat
equipment onthC ground floor
turbine pedestal.
on a reinforced concrcte
;re supported
common mat
the
for
except
and the gencratol
building
turbine
turbine
"'The
thc
lhe turbine pedestal is housed within
foundation.
top of the mat foundation
a solid limestone formation. The
rurbine
The mat foundation is built on
foundation is at El. -2.00 meters.
mat
the
of
bottom
ihe
is at El. -1.00 meter
at El. -3.2 meters and mat
at the mat foundation top is
area
condenser
and
)cdcestal
of mat was poured in ihree
605 meters. This thick portion
El
at
is
bottorn
foundation
layers.
of the turbine
looks like an "L" shaped extension
which
powerhouse.
main
Part of the
is re[erred to as the
on its own mat foundation.
It
located
is
view,
plan
in
the
building
is 26.0 meters
the North/South direction it
In
2.
and
I
Units
of
Central Control Building
direction itis 41.5
108, 201 and 207. In East[cst
107,
axes
column
the
wide b-twcen
and condensing
column P. It houses the chilling
through
J
column
from
long
meters
floor level there
at the ground level. At the mezzaninc
pumps and the air compressors
and showers
water analysis laboratory, lockers
rooms,
equipment
control
are battery rooms,
control room, computer
operating floor elevation, the
the
At
panels.
relay
and auxiliary
is 1.5 meters distance
with amenities arc located. There
room
shift
and
meeting
room,
control building. The two
building and the J axis of central
turbine
of
1-axis
the
bctwccn
roof. Th'e
jot,' from the foundation level to the
buildings are separated with an extension
to the turbine
The external walls arc similar
structure.
steel
a
as
designed
building is
concrete over
The floor slabs are cast in place
elements).
concrete
building (prefabricated
The roof covering is
with the welded studs onstcel.
the
steel beams compositely connected
Top of the roof is accessible from
building.
turbine
the
of
roof
the
also similar to
is a stair passageway
corner of the building. There
staircase located at the southeast
shaped extension.
building and the roof of its ""
bctween the roof of the turbinc
BEST AVAILABLE COPY

66
.JAM
"I'UIINl" & (-
I(ORO tJNIT I
ITAI CONTROI,
Comments aid (:trrcnt Condition
no cracks or displacement both from

indicated
areas
accessible
of
also no
Ground level inspection
its outside periphery There vere
at
as
well
as
building
turbine
inside of tile
rouhd level or on
at the equipment foundations at
deterioration
or
cracks, displaccients,
cast in place
there were hairline cracks on the
However,
elevations.
level
higher
at
due to
sla)s
wall which was probably caused
gable
the
of
side
west
the
concrete wall at
along the lower
A portion of crack-ng extenokd
construction.
during
concrcte
of
shrinkage of
some indication of deterioration
showing
flange
beam
steel
side of the mezzanine floor
the external paint
on the wall.
101 and
para.llel to the I-I axis betwccn Columns

wall
the
on
observed
was
slightly
A similar crack
floor beam and turns at 1/3 span
mezzanine
the
under
starts
crack
102. This
level.
corner of the trench at ihc ground
diagonal downward
to the top left
framing
designed and erected The main

adequately
be
to
appears
The steel structure
floor beams were
welded during erection.
Secondary
bolted.
are
beam connections
or peeling
There were no signs of chipping
painted.
were
elements
All steel structuralof the structure
of the paint and no observable corrosion

seem to have
was loose debris. Roof drain inlets
At the turbine building roof level there
and housekeCp
clog if proper inspection, maintenance
the
rather small holes which may easily
1.00 meter high are provided around
approximately
walls
Parapet
provided.
ing is not
the roof in the
rare
of drains will form
a pool effect on
clogging
any
that
so
perimeter
roof
by prefabricated wall elements on
built
are
walls
parapet
The
instances of heavy rainfall.
Vertical
butted tightly with veilical joints inside.
the outside, and other prefab elements
may
Any water seepage through these joints
caulking.
elastic
no
have
to
joints seemed
underneath.
start hidden corrosion of the steel structure

felt by
is well propor';oned. TIe vibration
The turbine pedestal concrete structure
indicated
surfaces
column was slight, the concrete
touching the surface of the pedestal
The space
or deterioratio:n were observed.
cracks
No
construction.
grating. The
good forming during
and the turbine floor is covered with
structure
pedestal
turbine
the
the
between
weight of one man. The grating over
the
under
deflect
easily
to
grating used seems
column foundation
proper support towards the outside
condenser piping area did not have
excessively.
this location the grating was deflecting
creating an unsafe condition. At
2")P.,
I '"
Proper corrective measures are required.
67
/.
JAMS! IOR() UNIT I
"I'UIIINj;E & CENTRAL CONTROL BUII)IN(;S
%
cs
nl I
not
turbine building, including oundalliions should
The reinforced concrctc portion of the
'"1Vc steel structure should serve equally
deterioratc for the next 20 years of operation.
maintenance cxcepl to follow ood housekeeping
long withoul any anticipated repair or
work
Roof insulation may require partial epair
tjlts ind repailnt surfaccs when requircd.
aifter 10 to 15) years
BEST AVAILABLE COPY

68
.]AMSI I()() tJNII.S 2, 3 & 4
?
l:CI-NERATOIR COMI'(NIN'S & S'SI'MS
.SIA
Boiler Works
were manufactured by the [latlbin
The Units 2, 3, & 4 steam generatois
steam jencralor
residual oil and natural gas The
The units are equipped for firing
of the following:
components and systems Cvaluated consist
Steam Generator
Superheater/RehCater Tubing
SuperhcaterfReheater
Headers
SuperheatrC/RcheatCr
Piping
Economizer Inlet
Header
Economizer Tubing
Steam Drum
Boiler Enclosure
Boiler Air and Flue Gas Systems
Forced Draft Fans
Induced Draft Fans
Steam Coil Air Heaters
Air Preheaters
Gas Recirculation Fans
Ducts, Dampers & Expansion Joints

Combustion System
Furnace Safeguard Supervisory System (FSSS)
;
and Auto RcgulatiC '
System
Control
and
Instrumentation
Boiler
Auxiliary Steam Systems

- Boiler Side
House Boiler
Soot Blower System
Boiler Structure
BEST tVAILARI
69
COPY
.1AM .I(
)IR,()
INII ')
., 3 & 4
S'IIAN- (I.NI'?AI ()IMS
) cs( r 1i io
and
cssentially duplicate hoIcls d.csigned
are
gelciatmis
steam
4
and
3,
Units 2,
680
PRC. Each boiler is designed toproduce
Works,
Boiler
[larbin
the
by
manufactured
cm' (2000 psi) and 541"C
hr.) main stcani at 140 kg per
pi
lb.,
(1,500,000
hour
pet
tons
lb pci hi ) at 23,9 kg pet
3 tons per hour (1,274,500

(1005F) Reheat steam flow is 579
(4831)
Design feedwater temperature is 2507C
cn' (340 psi) and 541C (1005F)
designed for natnial circulation. The
1HG-680/240-Y1
type
as
designated
arc
The boilers
same plan cross-sC(iional dimensions
the
have
pass
convection
furnace and front upflow
is 982
rear, downflow concctlion pass
The
deep.
meters
9.66
and
9.82 ineters wvide
front
.a back-jo-back arrangeieilnt with the
forms
and
deep,
meters
6.14
and
meters wide
circuits are fully
reheater, boiler, and economize!
superheater,
All
pass.
convection
drainable.
oil o
currently equipped to fire either residual
are
and
fired
tangentially
are
The boilers
natural gas.
the
and the method of firing indicate that
generators
steam
the
of
design
The overall
Or they
of Combustion Engineering Corporation
licensee
a
either
is
Works
Boiler
H-arbin
Engineering. This
company affiliated with Combustion
have a technical interchange with a
Engineering for at least twenty-five years
is a proven design of boiler used by Combustion
for a significant number of units.
//2 boiler has
of time. Unit
short period operating
a relatively
for
time period
the
in
operated
been
have
currently
are
4
boilers
and
The
had the one-year inspection. Units 3
prior to the first year inspection.
One leak
in the boilers since initial operation.
There have been only two tube leaks
to
on June 9, 1990. The failure was attributed
occurred in an economizer tube on Unit 2
the
Since there have been no similar failures,
external abrasion of the tube at a support.
of a
be
an isolated incident which is not indicative
to
considered
is
leak
tube
economizer
generic design problem.
3;T
70
\.A'-
,P.0
.IAMSIIOR () tJNIS 2, 3 & 4

ST[*AM C -N IAT()RS
NM) dtails
1991 in a su(pcrhe.lIcr tube 1in ln1 3
lhc wcond leak occurred Malch 10,
it is not considered W Dc ird lcalivc of a
are available concerning this [ailur,i howevei,
recurrig tube failure problen.
ycal
problems on boiler 2 I)O[ to. tie irst
There wee no reported major operating
Ihe
inspection as aliril)ulICd :O plug QaIeC of
ins peCion [he load limitation prior to (lh
air prehcaicr cold-end baskets.

ol
February 1991, both the waier and gas sides
During the first year inspection started 20
Were
repars
problems were found and no sr!niicant
the boiler were inspected. No major
req uire d
Assessment
the Units 2. 3. and 4 boilers, there are

Based on information currently available concerning
operation
to achieve satisfactory
no planned modifications or major repairs required
acceptance test on unit ;:2 boiler to verify

There was no report covering a formal
is
results of efficiency or performance testing
efficiency or guaranteed performance. The
determine whether
of the boilers, and to

essential to evaluate the operating characte.'istics
requirements.
or not boiler performance complies with contract
with the recommendations provmded

Assuming future operation of the boilers is consistent
for effective plant practices,
by the equipment supplier and within the general guidelines
inspections
for twenty years. Routine
operate satisfactorily
availabilit,.
be expectedarcto e:,sential
and
reliabili
the boilers can
bfoiler
maintaining
for
and normal maintenance
BEST AVAILABLE COPY
71
2,
JAMS!tORt() UNITS 2., 3 & 4

It()IlAIIR AIR AND FI-Jf: (;AS SYSTEMS
D)CSC1r i[tOll
gas
combustion air to tile boiler; direct flue
heated
providc
systems
gas
flue
and
The air
and iccirculatw
through the air hcater, and to the stack,
fiorn the outlet of the economizer,
the Jower furnace
economizer outlet and inject it into
a portion of the flue gas from tile
c
system is to exicnd the control ran,
recirculation
gas
the
of
purpose
Thc
of the boiler.
steam temperatures.
ot tile supcrheater and rcheatcr outlet
draft fans, two (2)
forced draft fans, two (2) induced
Major components include two (2)
air ducts,
vertical shaft regenerative air heaters,
steam coil air heaters, two 26-\11-1370
and the
joints,
fans arid ducts, dampers, expanson
recirculation
gas
(2)
two
windboxes,
outlet flue connected into the stack.
130 meters
boiler outlet to the stack is approximately
Tile boiler outlet flue connecting the
(425 feet) in overall length.
Comments and
Current Conditions
unit load
on unit #2 that began 20 February 1991,
Prior to the first year inspection outage
limitation
because of an induced draft fan capacity
was limited to between 80 and 100 MW
a
maintain
to
open and tile fans were unable
wherein the fan dampers were 100 percent
gear box
a noise was heard in the auxiliary drive
negative furnace pressure. In addition,
of the B prcheater.
cold end
#2, extensive damage

was found in ULe
During the first-year inspection of unit
baskets were
eighty-three enamel-coated, cold end
section of the air heaters.
One hundred
coating
Inspection determined that the enamel

found damaged in tihe two (2) air heaters.
plates were falling out of the baskets. Eighty
on the plates was pitted and that individual
during the
hundred (100) baskets were repaired
of the
were replaced, and one
percent
75
three baskets
approximately
outage. The repaired and replaced elements represent
total cold-end baskets in the two (2) air heaters.
and is now operating satisfactorily.
The gear drive on B heater was replaced
units are
satisfactorily at the present time. The
The air and flue gas systems are operating
capable of achieving rated capacity.
72
(,1
.IAMSIIO1() UNITS 2, 3 & 4

11011-l-R AIR AND IJJEL GAS SYSTEMS
Avecsmcrit
unit #2 prior to the first year inspection has

Tie derioration of tile cold e.nd baskets on
for water washing. Janishoro Maintenance
been partially attributed to tile method used
tile boiler manufactuier to wash tile air
personnel advised that cold. water was used by
enameled surfaces, resuhing in accelerated
heaters Reportedly this caused damage to the
tie washing procedurC developed for the
corrosion Plant maintenance intends to follow
warm water for washing ih heating surfaces.
unit //1 air heaters which includes tile use of
cxperience with Ljungsirom air heaters, it
Based on experience at Jamshoro, plus overall
replacement at an cs,,iatcd interval of
,"anticipated that cold end baskets will require
Flstimated cost is S275,0010 per replacement
every five (5) years ol units //2, 1/3 and #4.
for the two (2) air heaters on each unit.
as of Seplcmber 1991. The
Units #'3 and //4 have not had the first year inspection
for a more accuratc projection of the
experience of these units will provide the basis
future operating regimen of the units, and
interval between basket replacement. The
fuel, will be factors in establishing the
whether natural gas or residual oil is the primary
service-life of the air heater baskets.
stack is an unusually long run of ductwork.
The flue connecting the air heater outlet to the
this flue is subject to corrosion

As
a result of firing residual oil containing 3% sulfur,
whenever the temperature drops below the acid dew point.
replacement at a point in time

It is projected that areas of the flue viii require partial
the
fuel. Assuming 25% replacement,
beyond 5 years if residual oil remains the primary
platework, internal struts, insulation,
estimated cost is $250,000 per unit covering
new
lagging, and installation.
BEST AVAILABIIRF COPY

73
/II
JAMSIHOR()
BOilER COM
IJN'S 2, 3 & 4
SYSTEM
.I
UST()N
)escription
residual oil and natural.gas. The tilting

Boilers 2, 3, and 4 are equipped for firing both
main and reheat steam temperatures over
tangential firing system is used for maintaining
oil guns are installed at four elevations in
the control range. Sixtccn (16) steam-atomized
of the main oil and gas burners is established
the four corners of the furnace. Ignition
ihrough high-energy spark ignitors.
Gas
exclusively since being placed- in service
Boiler #2 has been fired on residual oil
the unit is now capable of operation on natural
firing provisions have been completed and
on both gas and residual oil.
gas. Boilers #3 2nd #4 have been operated
the burner deck and via the control iooii!
Observations of burner operation from both
with either gas or oil operation. Fron
television monitors found no problems associated
oil leakage has occurred
at tle four corners
a fire hazard and maintenance standpoint,

the windbox and coated components
of #2 boiler to the extent that oil has run down
located underneath the burners.
The oil guns have been provided with actuators for remote insertion and withdrawal from
difficulty with some actuators, and it is
the firing position. Operations has experienced
to insert or retract the oil guns.
then necessary to manually assist the actuators
are in satisfactory condition. T1he burner
A.l indications are that the natural gas elements
minus 30a from the horizontal position
tilts operate through the design range of plus or
Assessment
provide satisfactory service for the life of

The oil guns, gas elements, and ignitors should
can be anticipated, especially the
the unit. Normal maintenance and parts replacement
subject to erosion by the fuel oil.
atomizing plates and the nozzle bodies which are
unit #2 and prevent future spills on an)
Steps should be taken to clean up the oil spills on
hazard that can
cause extensive damage if
of the boilers. Oil leaks and spills are a fire
ignited.
tL Sr A\vACILALwI- .O?
74
*JAMSIOR(
UNITS 2, 3, & 4
[.'URNACE SAFIEGUARD SUPERVISORY SYSTEM (FSSS)
[)eccri
piln
Relay Works (ARW) of China

The FSSS (MS-III) is supplied by Achang
control functions (or (4) elevations
provides boiler purge, ignition and furnace
iheF[SSS

guns, gas elements, spark
Each corner is equipped with oil

of burners (total 16 burners). cooling
air. The syctem cabine , located at the electronics
ignitors, flame detectors and
flame detector panels, unit logic panels,
room, consist of power distribution panels,
boxes
burner logic panels. Burner local control
elevation oil burner logic panels, and gas
selector switch, pushbuttons start/stop
are located near every burner with local/remote
system
oil gun, oil valve, and gas valve The
switches, arid indicator lamps for ignitor,
and temperature switches for oil/gas/air
utilizes various pressure, differe'tial pressure
and
high speed diesel (HSD) oil for igniting
process measurement.
The system includes
for the cylinder of oil gun and igniting actuator.
warming the boiler, compressed air system

for all burners. Elevation 2 and 4 burners
Steam atomization spray nozzles are provided
utilize residual oil and HSD.
utilize residual oil. Elevation I and 3 burners
Cornnients and Currtnt Condition
review of forced outage records,

Interview with plant maintenance and operating personnel,
operation and maintenance problem frequently
and walk through inspections indicated that
the areas of ignitors, oil guns, and valves.
occur in the burner management system in
guns during operation of Units 2, 3, and 4.
Visual inspection indicated leaks from the oil
oil guns.
The res'dual oil flow switch leaks in most of the
for Units 2, 3, and 4. The retractors is
Automatic burners retractors are out of service
accomplished by local manual.
and D are out of service, which affects the
Unit 2 pneumatic tilt drive for Comers
B, C,
steam temperature control.
The tilt drives for Units 3 and 4 work satisfactorily.

driven
three-way valve (ON/OFF/Purge) which is
Frequent problems are encountered with
by Skotch Inc. Portland, CT). TFhe valve
by electric hydraulic actuators (manufactured
When the valve is fully open, it allows the
controls the fuel oil and the steam atomization.
The motor which
fuel oil and atomizing medium to

reach the burner.
75
.........
.
.,,..
L.;.
JAMSIIORO UNITS 2, 3, & 4

FURNACE SAFELGUARD SUI'IRVISORY SYSTEM (FSSS)
up, taking the burner out of service and

drives tile hydraulic fluid pump frequently burns
problem could be caused by component
reducing the MW capability of the unit. This
of pressure limit switches is'esscntial for
selection or maintenance since the adjustment
driven by the clectrohydraulic actuator
reliable operation of the three-way valve
Asscssmcn
of
increased O&M costs. Assuming repair
The above mentioned problems will cause
of component, and adherence to the
existing problems, proper design selection
6perating procedures, the system should be
manufacturer recommended maintenance and
suitable for 20 years continued operation.
BEST AVAILABLO
76
COFnYf
.IAMSI IOR() UNITS 2, 3, & 4
I1OfLER INSTRUMENTATION
AND CONTFROL SYSTI':
AND AUTO REGULATION
[)escrip1ion
by Xan Instfumcni Factuly, Type YSEach unit has a boiler control system manufactured
is designed
25% to 100% of full load. The system
Automatic control range is from
80.
within
I2 Kgcmzg, steam temperaiure selpoint
to maintain steam pressure setpoint within
mm
SC, and drum level serpoint within 75
functions:
to provide the following regulation
The boiler control system is designed
water drum level, utilizes
Feedwater regulat ion: which controls
element (wateir
Cle
element is used for low loads. Above

level) and three element control. The single
steam flow, feedwatce n1ow), boiler feed.
30% load, three elements
(water level,
utilized to control ie drum level.
pump speed, and feedwater regulator are
air, induced air. , i.d

fuel oil systems
Boiler combustion control, in which the draft
at rated range.
are regulated to keep the furnace pressure

the superheat steaii and reheat steam
Boiler steam temperature regulation controls
be maintained at rated temperature
temperature at 541C. The main steam should
should be rmaintained at rated
at 100-40% load, and the reheated steam
is regulated by tilting burners and
temperature at 100-50% load. The main steam
and final superheat. The reheated
by superheat spray water of tile secondary
recirculation along with tilting burners
steam is regulated by flow control of flue gas
is also utilized under emergency
at low load. Rehcat
spiay water side A&B
rises abruptl.
condition when the reheated steam temperature

(10), the superheat steam temperature
When the burner moves upward one degree
rises 1.88C. When the burner
rises 1.380C, and the reheat steam temperature
steam temlcrature decreases
moves downward one degree (1o),
the supereliat
C.95C.
0.80C, and reheat steam temperature decreases
The aux liajy steam is supplied

Pressure regulation for HP auxiliary steam.
and boiler. The 1-P auxiliary steam
redundantly from tWo sources, the turbine
facility, water treatment plant,
supplies steam to the oil supply system, oil unloading
and evaporator.
SEST AVAILABLE COPY
77
JAMI(I OI() UJNITS Z, 3, & 4
[lOILER INSTRUM IENTATION AND CONTROl SYSl.\

AND AUTO REIGULATION
oil.
Atomizing steam pressure regulation for fuel
following control functions

The boiler control system also provides the
o
Control burner anglcs, each burner (4x4) total 16 burners can tilt up and
down 300
position. The burners in each elevation
maximum with reference to the horizontal
room. Steam temperature is changed
are synchronously controlled
in the control
by changing the [lame center "Fireball".
boiler furnace chamber Thc sclcciion

Secondary air dampers (cooling air) of the
consists of four sets, in which each set
operation for furnace secondary air baffles
at one corner of the furnace chamber.
controls five dampers of secondary air
indicated that the majority of the following

Interviews with plant operation personnel
operator attention to control the process:
regulators are on manual, which require constant
1)
H.S.D. Oil Flow
2)
3)
4)
5)
6)
R.O. Flow
Atomizing Steam Pressure
Inlet Damper of Forced Draft Fan

Side A
Inlet Damper of Forced Draft Fan Side B
Damper of Induced Draft Fan Side A
7)
8)
10)
11)
Damper of Induced Draft Fan Side B
H. P. Aux. Steam Press
R. 1-1. Temp - Damper Side A
R. I-1. Temp - Damper Side 13
R. H. Spray Water-A
12)
13)
14)
15)
16)
R. H. Spray
Superheater
Superheater
S. 11. Spray
S. 1I. Spray
17)
18)
Low Load Ecedwater Valve
Steam Coil Air Heater Outlet Temp
9)
Water-B
Sec: Spray-A
Sec: Spray-B
Water on Side-A
Water on Side-B
BEST AVA!ILABLIE COPY"

78
.1
IOILEIR INS'R
19)
20)
21)
22)
23)
24)
25)
26)
02 Station
Deacratoi Level Control I
Deacrator Level Control 2
Gland Scaling Steam Pressure Control
Condensc [xvcl Control
B.F.P. No. I Flow Control
B.F.P. No. 2 Flow Control
B.F.P. No. 3 Flow Control
and 4 trip recorders indicated a hisior' of co):.:ul and reg lh.n

RCvrcV of Units 2, .3,
malfunctioning.
the panel indicators, recorders: computer
The disagreement of instrumentation readings at
and 4, makes safe and economical operation
monitor, and local indicators for Units 2, 3
of the boiler and other regulation loops very difficult.
correspondence to tlie contractor,
The plant operating staff documented these problems on
CIAEC.
Assessment
to manufacture's recommended
Assuming proper selection of components and adherence
20 years life with higher than normal
O&M procedures, the system could be suitable for
inconsic'ency and auto regulation are
O&M costs.
Repairs of the instrumentation readings
needed for safe and reliable operation.
B-LoS
79
AV,"!AVI- COIY
JAMSI[OR() tJNITS
AUXILIARY STEAM SYSTEMS
, 3 & 4
-
IiI.E.
SI )I
[Description
Units
consist of a single house boiler sdrving
The boilcr-rclated auxiliary steam systems
tile main steam generators
2, 3 & 4 and the soot blower system for
2-drum, natural circulation, type SZYZO-10
The house boiler is a Harbin Boiler Works
boiler produces
Per CMEC Operating Manual, hc
boiler rated at 20 tons per hour.
located in
with light oil through two (2) burners
saturated stream at 169-C, and is fired
operates
forced draft and induced draft fans, and
the front wall. The unit is equipped with
at the
furnace. Trip/trouble alarm is available
with balanced draft maintained in the
the control room.
annunciator window on the BTG Board in
(16)
of the steam eenerators consists of stxteen
The steam soot blower system for each
(20) type CC-I long
short retract blowers and twenrty
type RC-111 furnace waterwall
rcheater, and economizer cavities, plus
retractable blowers located in the superheater,
source of soot blowing steam is tile crossover
two blowers serving the air preheaters. The
inlet
outlet and the secondary superheater
pipe between the primary superheater
downstream of the desuperheater.

is good. The boiler was not operating at the
The physical condition of the house boiler
O&M personnel indicates the house boiler
time of the plant visit. Interviews with plant
operates on manual and not on automatic as designed.
During the walkdown
the soot blowers.
Mechanical problems were reported with
dnive
was oil leakage from the soot blower
inspection, a general condition noted
maintenance to correct the oil leakage and
mechanisms. The soot blowers require minor
mechanical problems.
BEST AVAILA B',L
80
(-"
CO",
JAMNI ()I(()
INIIS 2, 3 & 4
AUXILIAIRY 'STEAM SYS''E'MS . BOIL[ER SIDE
Asscssmcnt
Normal
arc suitable for exiended operation.
The house boiler and soot blower systems
icstoring
in good working order,
maintenancc is anticipated to keep the systems
reliability
boiler is recommended for saferv ahd
automatic operation of the, house
considerations.
i3ST AVA/ILA LiLE COP Y'

81
*JAMSII( O)
UNI' S
, 3 & 4
1ZI.
I LEI, STIZ UCTU
Description
boiler building is 30.0 meters

The boiler structures of Units 2, 3 and 4 are identical. Each
East/WNest direction, 56.00
wide in the North/South direction, 40.5 meters long in the
in the East[West direction. File
meters high. The boiler stcucture has a symmetrical axis

foundation separaie from the adjacent
boiler structure is supported on an independent mat
El -1.0 maeters Thc niat is onc
turbine building mat foundation. The top of the mat is at
on a solid limestone formation. The
meter thick reinforced concrete and supported
weight of the boiler is suspended from
structural steel is framed around tile boiler and the
contract with tie iemperatulC

the highest level beam allowing the boiler to expand and
changes it wdil experience in operation.
There are vertical and horizontal
There are nine platform levels at varying elevations.
the horizontal loads,
bracing systems which tie columns and beams together and carry'
including wind and earthquake, down to the foundation.
on all sides. The stairwell
ihe boiler building is covered by a metal roof but is open
standing elevator shaft supported
provides access to the platforms. There is also a free
connections.
horizontally by tile boiler structure through the horizontal beam
steel grating and are furnished
The platform floors and stairs are covered with galvanized
supports tile air hearers. air
with hand railings and toe plates. The boiler structure also
and flue gas ducts, steam pipes, burners and fans.
than that of Unit

The design of the Units 2, 3 and 4 structures are much different
weight, structural steel design is
Since the boiler structure is tall and carries considerable
for heavy, high structures
very important. Normally, rolled sections specifically developed
cross section in heavily loaded
are used. In order to provide sufficient material to the
Welded boxed girders for
columns, built-up closed box-type cross sections were used.
selection route. A boxed
beams and for diagonal bracing members followed tile same
increased torsional rigidity
section saves steel since it provides a larger moment of inertia,
the connection details and
and improved local and overall stability. However, it complicates
open in sone
the erection. The gussets became double walled, tile rlember end remained
3 L S!J', L.A, 1f: C

82
.IAMSI IO() tJNilS 2, 3 & -1
IO II.FI,S ]II tJC. I ,'-"
against corrosion. Not only

cases, leaving the interior of the boxed member unprotected
joints became welded. Welded
jton
teishop connections but the total ercction
work since tilenvironmental
erection joints are difficult to control to produce quality
heat arc difficult to 'control. These
(ffects, such as, high wind, blowing sand, and extreme
boiler structures The boxed ,:olumn
effects were very visible on the erection joints of the
plates ,ere welded on four faces of
pieces were butt -fitted without welds, and the cover
The cover plac appeared to have
the boxed section to provide the continuity required.
,,ere equally rough,
been trimmed on site due to their rough notched edgfes. The welds
The nain floor beams approaching the
and did not indicate good quality workmanship.
to transfer any niomlent. Most of the
face of the column did not appear to be well framed
crCa tr.,n eccentricity to i Ihe
beais were seated on brackets off the face of the column
2 Inches short or the. column ouiside
column. In many cases tile beam web was I 1/2 to
weather conditions and painting of
face. The ends of the boxed beams were open to the
the inside surface could not be confirmed.
Similarly, diaponal members of the vettical
were unprotected from the weather. \Vilh

braces had open end boxed cross sections h,,hich
up tile boxed sections, may
such practices even the root of tie shop welds, which make
of the weld. This will
be in jeopardy since moisture intrusion may reduce the strength
bottom end of diagonal bnxed
result in the strength of the member
being reduced. The
placcd over the column
members at the ground level were closed with the concrete

is open. any rain water or
anchors. However, where the top of the diagonal member
to fill the member with
moisture that gets into the opening has r1o other place to go except
undetectable rusting
water. Fine dust will also get inside. Moist mud can form creating
should be provided with
of thz member. A-s a minimum precaution, these hidden areas
drain holes.
wcic butted together.
Some column flange plates were misaligned in thickness as they
miadC up of two channels to
Horizontal bracing members under the platform level were
to connect teitwo channels,
form a boxed member. Since a single gusset plate was used
creating a dirt and moisture
the plate thickness kept the channel flange edges apart, again
or clean. TIhe gusset
trap to form inside the lower channel with no access to maintain
the boxed beam. Relative
plate was welded horizontally to the outside of one web of
member would have reduced the
stiffness of the web with no backing inside the boxed
may have been calculated and
effectiveness of the bracing member. Therefore, what
because of the poor detailing.
dcsig-ned on the drawings was not fully developed in practice
BE-ST AVAILABLE COPY

83
JAMSII)RO
"NIS 2, 3 & 4
I,II.iR ST'[R JCIUI
Ai
lhe hilet air intake
angles with spacCr plates

supporting structure back-to-back double
were used as a diagonal member.
much
T'he gussct plate at the end COflnction was
d to one
welde
This forced tile spacer platCs 10 be
thickness.
plate
spacer
tih
than
The two
thicket
tile spacers became ineffective"
Therefore,
angle.
other
the
;ingle, and not to
The member,
crossed section as was calculated
ingles are not forming a combined
'The spacers
thc forces for which it ,was designed
resisting
of
capable
not
is
ihereforc.
the proper thickness.
,hould be replaced with spacers of
structural
been connected arbitrarily to the
have
to
seem
supports
pipe
They are
Pipe snubbers and

the choice of pipe support elements.
by
supported
is
impression
members. This
ticd to each other
of the elements are not properly
some
of
ends
the
and
of the
long,
axis of channel section and some
weak
tile
using
formed
are
boxed
Cantilevered supports
the web flanges of tile untpiforced

to
directly
reactions
their
Pipe supports deliver
members.
continue tile
externally corroded In order to

all
almost
were
conduits
gratitn.
The unit 2 electrical

abruptly cut and stopped. Below
were
handrails
horizontal
routing of conduits,
to the weather.
thereby exposing the wire connections
covers
box
no
had
boxes
electric
greatly under
to slender 1" poles. They vibrated
attached
were
fix-tures
light
and
Fluorescent
of the fixtures were disconnected
Several
elevations.
higher
the
by them.
the effects of wind at
of the structure, they are supported
part
not
are
items
these
broken. Although
and stairs
working environment around platforms
safe
the
affect
will
problems
These
places. These areas
chipped off and cracked in many
Gloss paint of the handrailing was
support
of the Unit 2 structure, the galvanized
elevations
higher
At
require repainting.
of the g-alvanizing
corroding indicating poor qualiwt
already
were
grating
the
for
channels
process used
was as poor as in the Unit 2.

workmanship
welding
site
the
structures,
4
In Units 3 and
not seen
smooth. E-vidence of grinding was
were
edges
plate
cover
erection
the
None of
welds were of especially poor quality.
at any location. The vertical gusset plate
elevation spanning
located at approximate 20.0 meters
On Unit 3 boiler structures, a.beam
A
had an especially poor quality appearance.
3
axis
along
direction
in the North/South
a bracket plate underneath from the column4
and
beam
box
the
between
inch
one
space of
filled with perhaps
beam had been attempted to be
the
of
midspan
the
to
almost
upright
edge
by welding two channels in the
boxed
was
beam
The
weld.
or 5 passes of bad
to weld
was not obvious. Tying a long bracket
to fill
try
position. The function of the long bracket
to
practice
good practice. It is even a poorer
not
is
seam
weld
existing
the
along
84
tL?41 j,,L.,jL . CO '"
.JAMSII(OR()
URINE.([]NIIRATOI
UNITS 2, 3 & 4
COMI'ONI'N-I'S & SYSII:M.
is a -larthin rtjibinc Works (The

3, ,v , I,
Units
Each of thc turbinc-gcnerators of
5 3 8 type indoor unit
The turbine is
N210-132/538/
200MNW
China)
of
Rcpublic
People's
con densing type.
double flow exhaust, impulse, reheat.
casing,
three
compound,
tandem
a
cooled and has a
two pole unit type, which is hydrogeli
Thc generator is a synchronous,
A(.cexciter
Water cooled stator. The unit has a rotating
consist of tic
and systems evaluated in the siudy
components
turbine-Renerator
The
following:
High
Pressure Stationary Compopents
High Pressure (1-11)

Outer Cylinder
LAP Inner Cylinder
No. I Diaphragm Carmel
No. 2 Diaphragm Carrier
No. 3 Diaphragm Carrier
No. 4IDiaphragm Carrier
*No. S Diaphragm Carrier
Noz.zle Blocks
HP Diaphragms
Intermediate Pressure (IP) Outer Cylinder
IP Diaphragms
Main Steam Stop Valves
Control Valve Steam Chests
Reheat Stop Valves
Interce'ptor Valves (Shell Mounted)
Lead hping
-l1) Turbine Lead Piping and [P Turbine
Turbine Rotating Components

HP Rotor
IP Rotor
Low Pressure (LP) Rotor
IP Shrunk on Wheels
IP Shrunk on Coupling
LP Shr-unk on Wheels
and Couplings
HP Blades
IP Blades
..
LP Blades
86
L-L,_,.
JAMSI IOI,() UNITS 2, 3 & 4
"U ft I IN I.-(; EN [-RATOIR,
Low Picssuic Stationary ('Oi1 pone fnts
.x1haust Hoods
L1
L Mid Cylinder
No. 6 Diaphragm Carricrs
LB Diaphragms
LP Crossover Pipes
Generator and Excitation - Electrical & Isolated Phase Bus Duct
Generator Rotating Components - Mechanical
Generator Rotor Forging
Generator Retaining ,ings

Turbine Supervisory Instrumentation & Monitoring
Steam Turbine Controls and Coordinated Controls
Speed up
Mechanical Hydraulic (MIHC)
Electrohydraulic (EHC)
Coordinated Control (CCS)
High Pressure & Low Pressure Turbine Bypass System
Turbine-Generator Auxiliary Components/Systems
Hydraulic and Lubricating Oil System
Turning Equipment
Gland Steam Seal System
Turbine Bearings
Turbine Pedestals

Generator Hydrogen System
Generator Cooling Water System
BEST AVAILABLE COPY

87
JAMS! ORO UNITS 2, 3 & 4
BOILER STRUTFURE
and fii i ng it properly to tile

aibig gap with weld instead of removing the bracket
welds obscrved in Units 3 and
connecting member. Approximately 75% of the erection
be the work of unquali(ied welders.
4 did not have smooth surfaces. They appeared to
A ,scSS men
..,hoUld not deteriorate

Units 2, 3 and 1
Tihe reinforced concrete mat foundations of Boiler
within the next 20 year period.
reduced the des n strength value of
The erection practice and detailing used may have
boiler air intakc ,tpporting structure
tb: boiler structure. The diagonal member at the
All boxed members where
should be modified by installing the correct' size spacers.
holes. Thc stiuiure must be kept
Mioisture may accumulate should be provided with drain
recognize any cotosion damage that
under systematic maintenance inspection in order to
proper dcog,n, correction of
may occur, especially on the boxed members. Assuming
practc.-s,. the boiler steel
deficiencies, systematic inspections and preventive maintenance
unsuitability wmilh, the next 20 year
structures should not deteriorate to the point of
period.
BF[ST AVA!L.AthFcl
85
+ ,,,.,-,r,.+,.CO
3 & 4
.JAMSIIOI'() UNITS 2,
UI
'
II1(;II Ip1IRss tJJ
STATIONAIRY COMPONENTS
I)cscriptioln
Ptrc
1eof ths
Har
ubneWr'
Turbine Works
for cach of thcse three Harbin
components
stationary
outer cyjinder with a
PIF
The high pressure
following:
81 5 38 turbines are composed of the
connections, -P
N210-132/53
four (4) main steam inlet
with
and
joint
for diaphragms-stages
conv nilonal bolted horizofttal
and the locating bores
blocks
nozzle
10-12, IPouter cylinder with
inner cylinder withI assembled
diaphragm carrier for diaphragms-stages
2 through 9, No.
integral to tle
valve bodies fabricated
interceptor
with
joint,
carriers
conventional bolted horizontal
No. 2, 3, 4 and 5 diaphragm
connections,
steam
reheat
and 22
cylinder and with four (4)
and 20 and, stages 21
stages 16-18, stages 19
for
13-15,
for diaphragms-sta'cs
stages 1-12. IP diaphragms

impulse
for
diaphragms
and 1-11)
with two
respectively, nozzle blocks

control valve steam Chests
two
valves,
stop
two main
valve chests
impulse stages 13-22,
each side, two interceptor
on
valves-one
stop
reheat
interceptor valves each, HP
control valves each, two
cylinder -
each with two
outer
IP
the
with
fabricated integral
turbine lead piping
turbine lead piping and IP
and
with Jamshoro plant maintenance
Interviews
the
during
No problems were reported
period. On Unit 2
are still in the warranty
from the review of the
operating personnel on Units 2, 3 & 4 which
and
interviews
the
were uncovered from
2 HAP inner and
no significant problems
was reported on the Unit
deformation
Some
Units #2, 3
first year inspection report.
6 & 7, 1991 (See Jamshoro
June
of
incident
thermal
reported were small and
outer casings after the
The amounts of distortion

& 4 Turbine Rotating Components).
and
alignment of these-components
not
affect proper assembly
not unusual. This should
increase.
of distortion does not significantly
in the future if the amount
in good condition
noted above all appear to be
components
stationary
The deformation
The high pressure
and the maintenance reviews.
interviews
personnel
plant
as 4mm joint
based on the
2 (reported to be as much
No.
Unit
of
casings
with
of the HP outer and inner
to be excessive based on experience
appear
not
does
casing)
opening on the HP inner
similar components in secme.
BEST AVAILABLE COPY

88
j]AMSI I(R() U N ITS 2, 3 & 4

I IIC
'I
RE.S.SUR-
STATIONARY
-OMI'ON I"N r S
Assessment
Based on the evaluation performed using dcsign data, infornation obtairicd from the
similar
on Unit No. 2, industry expcfneCnGC with
interviews, reports on tile thermal incident
in the
units no major problems arc anticipated
dcsign units and the young age of these
to Units
practices as [or Unit No. 1 being applied
near future. Assuming similar operating
and the
metal life consumptions for the [4P casing
No. 2, No. 3 and No. 4, similar turbine
the same severity of start-ups for the next
main stop valve may be expected. Assuming
and
with a [minimum capacity factor of 60%
twenty-years and assuming base load operation
metal life
4 hot), it is expected that the turbine
10 start-ups per year (2 cold, 4 warm,
unit No. I
stop valves will be very low, similar to
consumptions for the IHP casing and main
at fuLurC
and' outer casings should be monitored
The distortion of the Unit No. 2 H-P inner
maintenance outages.
E,.ST AVIVLA I3_

89
DY
C ('
'
JAMSIIOR() UNITS 2, 3 & 4

,
ON
('OM
TURBINE ROTA'IIN
'
N' S
l)escription
duplicate Jamshoro Units No. 2,

The turbine rotating components for each of the three
rotor and the assembled rotaung blades. The
3 & 4 consist of the HP rotor, IP rotor, LP
with 12 integra, wheels and a integral coupling
I-l1 rotor is a single piece alloy steel forging
rotor made from an alloy sICel forging with
at the 11 end. The 11 rotor is a single flow
coupling at the lip end, three shrunk
seven integral wheels (stages 13-19), an integral
is a
on coupling at the LP end. The LP rotor
on wheels (stages 20-22) and a shrunk
23
steel forging with shrink fitted wheels (stages
double flow rotor made from an alloy
stages 28 through 32 on the H' end).
through 27 on the generator end and
the Unit No. 2 bowed I'll rotor that was

The only significant problem was that of
6 & 7, 1991. Interviews wih Jamshoro plant
discovered after the thermal incident of June
review of the first ycar inspection report on
maintenance and operating personnel and a
on the turbine rotating components of
the Unit No. 2 did not reveal an), other problems
the turbine rotating components of Units
Unit No. 2. There were no problems found on
plant maintenance and operating personnel
3 and 4 based on the interviews of Jamshoro
H-P bowed rotor was replaced with a new
and the maintenance records. The Unit No. 2
HP turbine rotor is being returned to the
rotor in August 1991. The old Unit No. 2
as a spare 1-lB rotor for the Jamshoro
Harbin Turbine Works for repair. It will be used
of Inquiry to investigate the cause
Units No. 2, 3 & 4.
WAPDA has initiated a Committee
of the Unit No. 2 I-P bowed rotor and to make recommendations.
[P rotor, LB rotor and all rotating blades

ilhe turbine rotating components, 1-11' rotor,
includes the
new 1P rotor in operation
currently all appear to be in good condition. This
known.
in Unit No. 2. No unusual conditions or problems are
'.ssessient
rotors and the IP rotors may be roughly
The turbine metal life consumption of the HP
for Units No. 2, 3 & 4 as was
approximated by assuming similar operating practices
is the Unit No. 2 HP bowed rotor which
experienced on Unit No. 1. The one exception
replaced with
a new HP rotor with
experienced plastic deformation but it has since been
virgin material.
E &AVAILABI.E COPY
90
JAMSI I()IO UNITS 2, 3 & 4
INL ROTATING COMI'ONENTS
"'UIUl
3 & 4 compared to Unit No.

Also assuming similar basic rotor geometry foi- Units No. 2,
No.
the HP rotors (not including the ncw Unit
1, tie turbine metal life consumpt ions for

by the number of start-ups experienced
2 HP rotor) and the [P rotors can be estimated
and
of start-ups for the next twenty (20) years
to date. Assuming the saime severity
per
ca[)acity factor of 60% and 10 Start-ups
assuming base load opciation with a mininlulin
for
that the turbine metal life consumptions
year (2 cold, 4 warm, 4 hot) it is expected
No. 2, 3 and 4 IP rotors will be very low,
the Units No. 3 and 4 H-P rotors and the Units
rotor
life consumption for the Unit No. 2 HP
similar to Unit No. 1. The turbine metal
IHP rotor because it is a new rotor just installed
will be less ihan that of the Unit No I
in August 1991.
3T AWVAILABI.iJ. 2..
3T
91
JAMSIIO()RO UNITS 2, 3 & 4
IOW IPRESSURE STATIONARY COMPONENTS
Description
Units No. 2, 3 & 4 Harbin Turbine Works

The low prcssure stationary components on tile
up of LP cxhaust hoods,
200MW tandem compound double flow turbines are each made
and LP crossover Pipes
LP mid cylinder, No. 6 diaphragm carriers, LP diaphragms
with two crossover pipe admissions on

The low pressure section is a double flow section
exhaust hood on each end with downward
the upper half LB mid cylinder There is a LP
carrers, one on each end,
exhaust to the condenser. There are two No. 6 diaphragm
on the IP end and stages 24 and 25 on tihe
containing two diaphragms (stages 29 and 30
tile LP admission diaphragtlls, one on each
geneiator end). The LP mid cylinder contains
28 on the IB end) Thrc:e re two latter
end (stage 23 on the generator end and stage
(stages 26 and 27 on Ohe generator end
stage diaphragms on
each end of the LP section
and stages 31 and 32 on the II end).
pressure stationary components of the

No problems were discovered with any of the low
conducted with plant maintenance
Jamshoro Units No. 2, 3 & 4 based on the interviews
inspection repot of the Jamshoro
and operating personnel and the review of the first year
Unit No. 2.
above
on Jamshoro Units No. 2, 3 &
The low pressure stationary components described
4 all appear to be in catisfactor-' condition.
Assessment
stationary components of Jamshoro

No major problems were found on the low pressure
This assessment is based on
the
Units No. 2, 3 & 4 nor are any anticipated in the future.

interviews, review of maintenance
information obtained at the plant during personnel

low pressure stationary components.
records, and industry experience similar with other

Units No. 2, 3 & 4
arc expected to
The low pressure stationary components of Jamshoro

operation without major repairs or
be suitable for the next twenty (20) years of continued

should regularly
be performed at
replacements. Normal maintenance and inspections

scheduled major maintenance outages.
92
E-LECTIIICAL. &
ISOLATED I'IIASE BUS DUCT
GENERATOR AND EXCITATION
Dcscrip(ion
Three (3) Generators:
50
247 MVA, Type GFSN-210-2, inanufaci!,red by IEEMW,
0.85
rpm,
Hz, 15.75 5%
kV, 9.056 kA rated cuY'ent, 3000
field current, class
power factor, 470V field voltage, 1830A
of insulation "F'for the stator and ituor. 3-phase, 2 poles,
hydrogen and water cooled.
Three (3) Main Exciters:
exciter, 1165
Type JL-1165-4, manufactured by HEMW. AC
kW, 431V, 1562A. 0.91 pf. 160 -iz
Three (3) Pilot Exciter:
exciter, 46
Type TFY-46-5a, manufactured by IlIW, AC
kW, 161/93V, 165-285.8 amp, 0 875 pl. 500 Hz.
Isolated Phase Bus Duct:
by Fuxitn
The isolated phase bus duct is manufactured
enclosed bus factory, type GFM-20-1, aluminum conductor,
rise less
rated 20 k\', 150 kV BIL, conductor temperature
b'js circuit
than 600 C with aluminum enclosure. The main
current.
is rated at 10,000 Amp with 400 kA s\qnmetrical
560 kA
The sub bus circuits are rated at 2000 Amp with
symmetrical current.
hrough inspections, and revwtw of plant

Interviews with plant O&M personnel, walk
problem with the generator exciter
records revealed that there is a persistent overheating
reported that in some cases,
carbon brushes in Units 2, 3, and 4. The O&M personnel
result of this problem. This problem
they had to operate the units on reduced load as a
According to the Report of First
was addressed on Unit 2 during the First Inspection.
ring were precision ground and the
Inspection of Unit 2, the carbon brush and slide
however stated the overheating
overheating phenomenon was eliminated. Plant personnel
was removed to reduce the
still exists. During out- visit, Unit
2 excitel enclosure
tenperature.
walkdown visual inspections, and review

Interviews with electrical maintenance personnel,
the isolated phase bus duct.
of plant trip report, indicates no problem history with
93
.*AMSI[OIM()
UNITS 2, 3, & 4
GENI,RATOR AND EXCITATION

ISO[LATE)
-EL-cTRICAI- &
IlHIASE BUS DUCI'
Assess ment
needed to
of carbon brushcs and slidc ring i
grinding
precise
as
such
repair
Normal
selection of
repairs arc made, proper design and
overcome the overhcating.. Assuming
recommended maintcnance and operating
components and adherence to the manufacturer
to
isolated phase bus duct arc expected
and
system
excitation
generator,
proccdurcs, the
be suitable for 20 years continued operation.
94
JAMSII()RO UNITS 2, 3 & 4
GC-NEIjATO R IOTATING COMPIONENTS . MECIIANICAL
Dcsc' +plion
T-hc
generator
rotating components-mechanical
on the Harbin
Works QFSN-210-2
and the generator retaining rings. The
generator consISt of the gencrator rotor forging

generator retaining nngs are high strength
generator rotor forging is alloy steel and thc
to contain the rotor coil ends at operating
alloy steel rings shrunk on to thc rotor body
duplicate units and have duplicate generator
speeds. Jamshoto Units No 2. 3 & 4 are
rotating components-mechanical
rotating components-mechanical noted

There is no history of problems on the generator
on interviews with plant operating and
above for the Jamshoro Units No. 2, 3 & 4 based
records.
maintenance personnel and the review of the maintenance
the generator rotor forging
The generator rotating components-mechanical which consist of
the Jamshoro Units No. 2. 3 & 4 all
and the generator retaining rings
at each end for
appear to be in satisfactoWr condition.
Assessment
and the review of records, the

Based on the information obtained for personnel interviews
rotor forging and the generator
generator rotating con- 1)onents-mechanical of the generator
2,3 & 4 should be suitable for 20
retaining rings for the duplicate Jamshoro Units No.
and replacements. The condition of
years of continued operation without major repairs
examinations
monitored by non-destructive
rings should be carefully
inspections
the generator retaining
and
maintenance
Routine
outages.
during regularly scheduled mintenance
during scheduled maintenalCe
should be performed on
the generator rotor shaft forging
outages.
BLS[ AVAILAIE3 COPY
JAMSIIOi(O UNITS 2, 3, & 4
& MONIIORIN(G
ItBINIE SUI'[:VIS()zY INSTRUJMENTATION
of cabinets, scnsor , indicators,

The steam turbine safety monitoring system consists
the following parameters
of
monitoring
recorders and alarms. The system provides
o
LFcceritricity or rotor
o
o
o
travel o[ control valves servo

motors
W
Left/right
Travels of reheat intercept valve servo motors
Oil level in oil reservoir

Absolute expansion H-[1) & [P cylinders
Mechanical synchronizer travel
o
o
o
o
Differential expansion (IP/IP/L-P)

Vibration of (9) bearings
Load limiting indication
Overspeed emergency governor action
parameters:
The system provides.protection function of the following
Speed:
when over
Alarms when over than 110%, and trips turbine
116% of rated speed.
Axial Displacement:
at
Alarms at +0.8mm and -1.0mm, trips the turbine
& -1.2mm.
Low Lube Oil Pressure
Vacuum Drop in
Condenser:
4-1.0mm
the AC
the lube oil pressure is lower than 0.6 Kg/Cm',
When
\
When lower than
motor driven oil pump automatically starts..
automatically starts
0.5 Kvf/Crr? the DC motor driven oil pump
oil pressure is lower
and the turbine is tripped. When the lube
of the turbine is
than 0.3 Kgf/Cm the rotor turning gear
KgfiCm2 is utilized.
stopped. Pressure regulator with range 0.2
ata the
Alarm at 0.25 ata, and when lower than 0.35
0-760mam Hg
turbine is tripped. Pressure regulator with rang
is utilized.
.IAMSIIORO UNITS 2, 3, & 4
& MONI'I()IUN(;
"rURBINE StJP'ER[VISORY INSTRUMENTATION
(-ommcnls and Currcnt Condition
"Id status reports of

Intervievs With plant O&M personnel, review of correspondence
that tile daia acqLiSition system
instrurncntation, and walk through inspections Indicated
This Isa common problem on
and indicators reading do not agree.
computer, recorders,
to bc akcin by operating
actions
all 3 units. This causes confusion as to appropriate
personnel.
Specific problems on the units arc as follows:
Unit 2:
Unit 3:
turbine bearing high

Vibration recorder out of order, the
teinperature scanner is
vibration prevailing, and the generator
out of service.
beating metal temp
The eccentricity indicator and recorder,
and turbine digital

recorder, FP cylinder metal temperature
speed meter arc out of service.
The most senous is the
has been disabled by

condenser vacuum protection which
3 (per plant records).

CMEC since commissioning of Unit
Unit 4:
records and monitors

Inconsistent readings between indicatois,
and turbine speed
for condenser vacuum, lube oil pressure
Assessiment
to put the above mentioned instruments

Calibration, repairs or replacement are needed
of the plant, correction of deficiencies,
back into service. Based upon tile newness
and compliance with the manufacturer
assuming proper selection of instrumentation
supervisory system should be suitable for 20
recommended O&M procedures, tie turbine
years continued operation.
kAB LL C 0i.Y
B E S~/AlL"
JAMSIIOR,() UNITS 2, 3, & 4

STEAM TURBINE CONTROLS ANI) C(ORDINA'r)
CON'I'OLS
)escription
5 3 8 is equipped with both electrohydraulic (EHC)
The steam turbinc type N210-122/538/
A common actuatol is used for both
and mechanical-hydraulic control systems (MI-CG).
systenis. The
switching valve to transfer between the two
the El-IC and MHC with
over the full speed range from turning gear
speed-up system performs closed loop control
the warming speed, warming time,
to synchronous speed to automatically control

rate for passing through the critical speed
peCce -.. ge speed variation, and acceleration
is
3000 rpm, the spccd-up system control
zones. When the steam turbine reaches
automatically switched over to EL-IC system control.
automatically loads the |urbilhe with initial

When the unit is synchronized, the El-iC system
system frequency bias
load. The unit could be operated with or without
by setting tihe MW while the MW rate ratio
The unit picks up load with sliding pressuic
with ftxed MW itre ratio controlled
is controlled by the bcilcr. The unit could be loaded
that bumpless transfer is achieved.
by the EI-C. The MHC tracks the EL-IC such
(CCS)
feature to operate the unit with
The system also has a coordinated control system
coordination between boiler-turbine-generator.
personnel, review of records, and walk

Intcview with plant
through inspections indicated the following:
are not satisfactory for Units 2,

Operation and performance of the above systems
to CMEC dated 9/9/91 that
3, and 4. It was reported in a letter from WAPDA
changes
Unit 2 MW varies sharply in response to small frequency
loops, such as fuel oil and steaml
The CCS cannot be activated since several
Even if the loops are on
temperature control loops, are on manual at all times.
to the satisfaction of the
auto, the CCS has not
been tested for reliable operation
operating personnel.
-0
Y*j~
JAMSI(R() UNIfTS 2, 3, & 4
CONTROLS
STEAM TUIR BINE"CONIIOILS AND COORDINATEID
The O&M personnel reported that tie tracking system of the MHC docs.not work,
to MC,
which means lhat in case of failure of the EL:-IC and automatic switchove
a 15
.,here
incidents
two
reported

MW upset takes place. The O&M )ersonncl
thc
activate
To
producing 150 M\v
MW bump was experienced while tie unit was
pilot valve at the turbirC
MiIC, the operator had to manually lift the changeover
front.
days
between MI-IC & EHIC once every two
The O&M manual calls for switching over
lack of records which support the
to prevent the convertor from jamming. Due, to
requested the plant opeation to demonstialc
unreliability of the Ef-IC & MI-C system, we
2 was on line. The plant operators dcclincd
the switchover from E-IC to M-IC while Unit
the bump would take place and did not want
our request on basis that they felt confident
to risk upsetting tile system.
Assessment
response problcm and the MIIC

Re pairs are needed to resolve the ELHC frequency
attributed to either original design or not
tracking problems. These problems could be
an assessment of the coordinated control
following O&M procedures. We cannot make
operational according to the plant records
system (CCS) since the system was very seldom
tihe CCS is not in seivice increases the
and operators experience. However, the fact that
manual control of the Units 2, 3, and 4.
operating cost and the risk of human error in
O&M proccdures arc adhered
Assuming the ahove problems are resolved, manufacturer's
these systems should be suiable for 20
to and based on the newluC; of the equipment,
years continued operation.
bLSI AVA ILABL.
CCJH
.JAMNI(ORO UNITS 2, 3, & 4
iiiC;Ii
PRES3URE & L.OW PRESSURE" TURIINIL
IYI'ASS
SYSTE'M
Dcstription
the
by Sulzer of Switzerland and onsiStS of
The turbine bypass system is manu(aciurcd
following:
includes high pressure (HPi)

Electronics cabinets in tie equipment room which
controllers
low pressure (LP) bypass pressure and temperature
-IP & L bypass clectrohydraulic servo valves.
DesupcrlhcatIg stations.
and
startup of the boiler and in case of turbine

The -IP bypass system is mainly used during
directly to the reheater and controlled to
trip or load rejection. The steam is bypassed
The HP bypass system enables the boiler
match the prevailing conditions in the reheater.
atd turbine to be started independently.
Comments & Current Condition
of plant records indicated that the bypass

Interviews with plant O&M personnel and review
system is in satisfactory condition.
Assessment
and adherence to the manufacturer's

Assuming proper design and selection of components,
the system should be suitable for
recommended maintenance and operating procedures,
20 years continued operation without major repairs or replacement.
100
1173 L
JAMSHORO UNITS 2, 3 & 4

jrRI3 Nt.(; ENIlRATOR AUXIIIARY COMPONENTS/SYSITM1S
Description
3 8 53 8 type
Harbin Works N210132/5 /
The turbine-generator components/systems on this
indoor unit consist of the following:
Hydraulic and Lubricating Oil System
Turning Equipment
Gland Steam Seal System
Turbine Bearings
Turbine Pedestals
Generator Hydrogen System
Generator Cooling Water System
The hydraulic and lubricating oil system includes:

Main Oil Tan.k
Main Oil Pump
Oil Coolers
Auxiliary Oil Pump
Turning Gear Oil Pump
Emergency Oil Pump
Turbine Oil Storage Pump
Oil Transfer Pump
Oil Conditioning Equipment
Relay Dump Valve
turning gear which has

a turning
The turning equipment is a motor operated gear driven
speed of approximately 3 rpm.
Thie gland steam seal system. includes:

Gland Steam Seal Regulator
Gland Steam Exhaust Blower
Gland Steam Condenser
IBF'T AVAIL 1.
COPY
(5) journal bearings. The number

This tandzm compound three (3) casing turbine has five
tilie number two journal bearing
two bearing is a combined thrust and journal bearing.
fixed type.
is the self aligning type and the other four (4) turbine bearings arc.
& 4
JAMSItOI(() UNITS 2, 3
'
\IS
"'Ul(l INN'-(;I-RN-I ATOR AUXILIARY COM'ONENI/SysI
lul and between tie

at the governor end of the I-Il' sect
pedestals
turbine
sliding
arc
There
-1 sections is of
pedestal between the IF and the
i-P and tihe IP sections. The turbine
the fixed type

The: generator seal oil system includes:
Bearing Drain Enlargement Equipment
Seal Drain Enlargement Equipmentv
Seal Oil Control
The generator hydrogen system includes:

Hydrogen Supplying Unit
Hydrogen Gas Control Cubicle
Hydrogen Gas Dryer
Hydrogen Gas Storage Tank
Gas Analyzer
Control Panel
system that cools the generator stator.
separate
a
is
system
water
cooling
The generator
should open automatically on low hydrogen

In Units 2, 3 and 4, the hydrogen valves, which
to
The control room operator is-required
pressure, currently operate only on manual.
the
and dispatch an operator to manually open
observe the hydrogen pressure indication
valve as the unit MW increases.
auxilary
problems with the turbine~c-neratot
There were no other reported
3 & 4 based on the
on the Jamshoro Units No. 2.
components/systems noted above
the Jamshoro
operating personnel and the rc\'.cw of
interviews with plant maintenance and
Unit No. 2 First year inspection report.
turbine-generator componetits/systems for
With the exception o[ the hydrogen valves, the
condition.
appear to be in satis[actoty operating
the Jamshoro Units No. 2, 3 & 4 all
No unusual conditions or problem;I were uncovered.
JAMSIIORO UNITS 2, 3 & 4
COMI ONI-,NS/SYS'EMS
IURBINE-GENERATOR AUXI-LARY
Assessment
should be restored. Thc remai1ling turbineAutomatic opcration of the hydrogen valves

&
the three (3) duplicate Jamshoro 'Units 2,'3
generator auxiliary components/systcms for
any
(20) years of continued opcration without
4 are cpcctcd to be suitable for twenty
arid inspccions should be regularly
major repairs or replacements. Normal maintcnancC
pcrformcd at scheduled maintenance outages.
BEST AVAILABLE DOCUMFMT
/(
JAMSIIORO UNITS 2. 3 & 4

' r
S & SYSTEMS
BALANCE 0F iPLANT COMPONEN
instrumentation and controls. and civil

The balance of plant mechanical, electrical,
structures evaluated consists of the following:
Feedwater System
Condensate pumps
Feedwater heaters
Dearator
3oiler feedwater pumps
Cooling Water System
Cooling tower
Circulating water pump
Condenser
Cooling Tower Structure
Instrument Air-System
Fire Protection
Chemical Feed System and Sampling Rack
Water Pretreatment System
Coagulation Sedimentation Tanks
Water and Wastewater Treatment Systems
Water Treatment Building
Emergency Diesel-Generator
Power Transformers
6.6 KV Metalclad Switchgear
(MCC)
400V Power Centers, 400V Motor Control CentersBESf
AVAILA
LE DOCLJINI '"
JAMSI{ORO UNIT I
SYSTEMS
BALANCE OF PLANT COMIAONENTS &
Unintcrruptible Powcr Supply (UPS)

220 KV Underground Cable
6 6 KV Cable
DC Station Batteries
Control Cables, Cablc Trays and Ducts
Local Control Boxes, BTG Boardwiring,
Plant Computer System
Turbine and Central Control Buildings
REST AVAILAB3LE DOCUMEN"
/ /)

FEEDWATER SYSTEM
I)cscription
economizer
from the condenser Outlet to the boile.r
The ecedwater system conveys water
steam jet air
well as condensing the steam in the
as
heating
of
stagcs
eight
inlet through
addressed
steam condenser. The major components
gland
turbinc
the
and
coolers
cjeclor
fccdwater
feedwater heaters. dearatol and boilr
in ihc report are the condensate pumps,
pumlps
foi each unit Under
condensate pumps are provided
driven
motor
capacity
50%
These
with the third
load, two pumps would be opeimng
normal operating conditions at full
with stainless steel
are vertical centrifugal nulr-stagc
pump in stand-by mode. The pumps
impellers and shafts.
heaters per unit.
three high pressure closed feedwai
Thre are four low pressure and
have
2,-2)
(1/ I &
type. The two lowest pressure hcatcr
All heaters are vertical "U" tube
high pressure
copper nickel alloy tubes; the ihrece
tin brass tubes. Heater
3 & 4 have
heaters have 15 Mo3 alloy tubes.
tank. The
mounted on a separate horizontal storage
The dearator is a cylindrical tray type
in the effluent not vieaier than 0.005 cc/I.
dcaraor is designed to maintain oxygen content
for each unit.

boiler feedwater pumps are provided
Three horizontal barrel type multi-stage
pump.
hydraulic coupling and feedwater booster
Each pump includes a variable speed
third pump
would normally be operating with the
Under full load conditions, two
pumps
in stand-by.
indicate any
of First Inspection of Unit 2 did not
A review of the rather sketchy Report
three trips
A review of the unit trip records noted
system.
feedwater
th1e
with
problems
operating and
feedwater pumps. DiscussionSs With
boiler
tile
by
caused
were
2
of Unit
valve.
trips were duc to a leaky fecdwater control
maintenance personnel indicated the
solved the
control valve was replaced and this
Maintenance personnel stated the feedwater
problem.
units.
problems with this system for all three
Ph,nt personnel indicates no other major
~ ~ ~ t.tC' '
;; ,.I , 'tl
4.J
JAMSIHORO UNITS 2, 3 & 4

FE'I-DWATER SYSTE.].M
and
condition based on the data reqviewed
The fcedwater system appears in satisfactory
noted.
unit walk-through inspection.
No unusual conditions were
Assessment
and
proper design and selection of equipment
Based upon the age of the unit, assuming
operating procedure, the
recommended maintenance and
manufacturer's
the
to
adherence
be suitable [or 20
systems for all three units should
feedwater
the
of
components
major
major repairs or replacement
years continued operation without
BEST AVAILABM DOC1INAK
.IAMSIIOR(
t,I t.-) ., 3 & 4
COOLING WATEIR SYSTEM
Dcscription
bearing
cooling water for the condenser and the
The cooling water system provides the
in the icporl are the cooling rowe'r, circulating
coolers. The major components addressed
a separate
towCi structure is covered in dctail in
ware p)ulmps and condenser. Thic cooling
section
is
draft multi-cell cross flow type Fhe structure
induced
mcchanical
is
towe
cooling
The
PVC.
reinforced concretC and the fill material is
conditions, two
pumps are provided. Under normal
Three 50% capacity ciculating water
water pumps are
in stand-by.
pumps are operating and one pump is
vertical, single suction mixed flow type.
The circulating
box horizontal surface type The tube material

The condenser is a two pass, divided water
copper nickel in the air cooling section
is tinbrass in the condensing section and

Inspection of Unit 2 indicated low vacuum
sketchy Report of First
A rcview of the rather
flange connection between the 7th
leaking
in the condenser. During the inspection
a
found. The connection was repaired and
extraction valve and gland steam header was

to normal
subsequent operation indicated condenser vacuum
returned
due 10 triing of the
A re.Aew of the unit trip records indicated Unit 4 tripped twice

indicated this was
not a pump related
circulating water pumps. Maintenance personnel

wvatcr system.
units were attributed to the cooling
problem.
No other trips of the three
one fan motor shaft which caused some
Unit 3 cooling tower expericnced a failure of

be Fixed prior to acceptance of the unit.
damage to the tower. It is expected this will
scaling problem as did the Unit I
The condenser for Units 2, 3 & 4 did not experience
and maintenance personnel indicated no major
condenser.
Interviews with plant o.crating
problems with the cooling water system.
based
on the data reviewed and unit walkThe system appears in satisfactoiy condition
V2
C1.,
...
,.
through inspection. No unusual conditions were noted.
/1s
COOLING WATER SYSTEM
Assc,smenn
assuing proper
Bascd upon the newness of 1hc plant, correction of costing dcficicncics,
manufactureIrs rcommcndced
design and sclection of components, and adherence to the
thc cooling water systems
mainicnance and operating h)roccdure, the major components of
major rcpairs or replacement
should be suitable ror 20 ycars continued operation without
-,-T AV,*LftE DOCUMENT
109/
JAMSiiORO UNITS 2, 3 & 4

COOLING TOWER STRUCTURE
tDescription
the same except for rmino differences
The cooling towers of all units are in general
I for
Refer to the Description given for Unit
between the Unit I and Units 2, 3 & 4.
details.
this
tower, there was nc obseivable damage. In
Except in one cell in the Unit 3 cooling
sloped fiberglass baffle
unit, a shaft between tile fan notor and gear broke damaging the
wall, fan stack and fan blade.
leading from the inside to the top oi

The workmanship of tie welding for the staircases
cooling towers was of inferior quality.
supported from channel scctions Some of
The water splash boards are hung by rods or
the units
are only a couple years old.
these channels appeared to be corroding. Although
entry door [ramhe. incoming cooling
was also obvious on other steel parts such as

con osion
the cooiling towers

water pipes and hand railiigs at the roof level of
supported on a solid limestone formation.
Similar to Unit 1, these cooling towers are also
towers
or the adjacent pump house
There were no sign of settlement in either the cooling
appear adequately built and did .it
structurcs.
The concrete parts of the structures
indicate any major chipping, cracking or deterioration.
Assessnc nt
tower structures are expected to be

A-ssuming proper design and erection, the cooling
suitable for 20 year continued operation.
Miscellaneous components such as stairs,
normal maintenance and repairs as

handrails, hangers and other attachments will require
necessa ry.
R-DO(/,I
BST AVAII.Atl
110
"

INSTRUMENT AIR SYSTEM
I)
teion
The compressors are vertical, belt

ILach ujnit has two sets of instrument air compressors.
in
Compressor F-actory. Onc set is normally
driven, and manufactured by Shenyang Gas
to start on low air pressure The discharge
operation, the other is on standby, ready
air
Thc instrument air is dchulmidified by an
pli ssuIC of each compressor is7 Kgf/Cml.
dlycl
control
air to the boiler control system, burner
The ail compressors provide instrument
extraction steam line
,,ystcm,and reverse current valves of turbine
Unit
review of Unit 2 trip report rodcated that
Interviews vrvth plant O&M personnel and
instrument air pressure. The maintenance
2 was tripped on May 19, 1991 due to low
pretreatment facility was out of service
personnel indicated that the transfer pump at the
the instrument air compressor through the
at that time which provided cooling water for
the compressors wich in turn tripped
clallficr.
The low level of clarifier water tripped
the unit.
condition, however, thcc is no program in

The compressors in all units are in operating
maintenance on the compressors.
place to periodically change the air filters and conduct
compressors, without cros-rres to other units.
Currently, every unit is being served by two
are being planned for instaliacion to avoid
cross-ties
that the
indicated#2
The plant personnel
1991.
19,
May
on
Unit
of
that
to
trips similar
for Units 2, 3, and 4 has been reported
Frequent tripping of insrinment air compressors
to CMEC, dated July 7, 1991.
in Pakistan Engineering Services Letter JS/18/91-92
BEST AVAIAU-F_1)lC0tI M
.JAMSIIORO
UNITS Z, 3, &' 4
INSTRUMP NT AIR SYSTEM
Assessment
cxceptlion l01 poor

satisfactory condition with the
in
be
to
appears
systcm
The overall
In Uhits 2, 3, and
which is a general condition cxlsrig
workmanship of cable ten-ninations
air systems to
2, 3, and 4 require the instrunent
Units
for
documcnt
4. The conformance
was not
lines of neighboring units This evidently
be provided with interconnection

provided.
frequent
of components, normal repairs to alleviate
Assuming proper design and selection
operating
and
recommended maintenance
tripping, and adherence to the manufacturer
without majol
suitable for 20 years continued operation
be
should
system
the
procedures,
wilv increase the
cross-ticing the instrument air system
However,
replacement.
or
repairs
be installed.
reliability factor of the units and should
O1"j AVA LAB.ED)1J-t
JAMSI{ORO UNITS 2, 3, & 4
FIRE PROTECI'ION
Description
The system
coiqsts of the following:
(6) Erncrgency Fire Water Pumps

Pump
Motor Driven Emergency Frcsh Water Fire
(3)
Water Fire Pump
(3) Diesel Driven Emergency Fresh
Sets of Air Foam Extinguishing Equipment
(3)
(65) Hose Connections
(38) Sets of Air Foam Hydrant; with
Trucks
(3) l elighting
(2000
qulrment with Local/Remote capability
l
Lxtriguishing
Chemical
of
Diy
Sets
(6)
Kg each)
(3) File Protection Panels
Wheel Cary Power Chenical (50 Kg each)
(6)
each)
(1 6 2 ) Hand Carry Power Chcnical (8 Kg
Current Condition
that the plant

of records, and walk-downs indicated
Interviews with plant personnel, review
they were subject to theft.
stores the fire hoses in a warehouse because
due to the oil spillage
The fuel oil unloading receiving area is considered hazardous
throughout the area.
Assessment
of the
hose racks provided. Immediate clean-up
the
in
reinstalled
be
should
hoses
Fire
of
avoid potential fire. Assuming proper selection
fuel oil unloading facility is needed to
recommended O&M instructions and
components, adherence to the manufacturer
continue to operate for 20 years.
perodical functional te',, the system should
...
L!
,, r.,
JAMSIHORO UNITS 2, 3, & 4
CHEMICAL
-[ID SYSTEM & SAMPLING [LACK
Description
prevent scale formation-, corrosion,

Cednsate and feedwater arc chemically adjusted to
caustic embrittlement, and contamination of steam, such as silica carryover hich would
feed system cumbined with boiler blowdown,

deposit ol tile turbine bladeK. This chemical
recommendation provides
and boiler manufacturer
demineralized make-up water quality,
the basis for each unit water cycle quality.
release
feedwater to control the ph and to inhibit
The system feeds chemicals to the boiler
superheatcr, and economizer.
of oxygen in the boiler tubes, drum,
eedwater and
dissolved oxygen contained in the
Diluted hydrazine is applied to remove
an ammonium
during plant startup and shutdowi,
to control the ph value.
However,
of the feedwater.
pump discharge to control the ph

solution is injected in the condensate
from rust.
hydrazine is used to protect the boiler

concentrated
shutdown,
term
long
During
to remove
for inhibiting caustic embrittlement, and

The sodium phosphate solution is used
hardness of the boiler water.
boiler
of make-up water, condensate, feedwater,

The sampling rack supervises the quality
water and steam.
equipment:
The chemical feed system consists of the following

(1)
(3)
(6)
(3)
(3)
(6)
(3)
(3)
Pump (0.33 liter!.Tiinuie)

Hydrazine Solution Positive Displacement
Diluted Iydrazine Solution Tank
(0.66 liter/minute)
Phosphate Solution Positive Displacement Pumps

Phosphate Solution Tank (I i')
Amnmonium Solution Tank (1 ni)
Ammonium Solution Pump (0.33 liter/minute)
Stand-alone Control Panels

by Changzhou Power Machine Works,
Stand-Alone Sampling Racks manufactured
oxygen meters, hydrazine meters,
with ph analyzers, conductivity meters, dissolved
and
In the control room, there are oxygen
ph indicators, conductivity indicator.
hydrazine recorders.
((k
JAMSIHOO UNIIS 2, 3, & 4
CIIEMCAL FEED SYSTEM & SAMILING RACI
Cornrncnl[s and Curren( Condition
records indicated that

Interviews with O&M personnel, walk-downs, and review of plant
meters arc
arc on manual control. Thc conductivity
thc chemical feed and sampling rack
enclosed room ,whcrc temperature
hllc sampling rack is located inside an
out of servicc.
could reach 410C.
Assessment
and
rack room. Repair of conductivity meters
Proper ventilation is needed in the :ampling
increased
essential. The current condition vkill cause
restoration of automatic functioning is
O&M
of components, adherence to manufacturer's
selection
proper
Assuming
cost.
O&M
20 years.
procedures, the system is expccted to last
~KfAVAILAM)d[F
nlOCjrr
WATER I'E,,LA'IMENT SYSTEM
Description
at the Indus River to water reccivirg tanKs
Ihe water is pumped form the intake structure
to
coagulant. The clarified water is pumped
to eliminate flocculation, then treated by
water tanks.
clarified water tanks then to the service
coagulation sedimentation lank is 6 to 8.5 ph,

The quality of treated water at the outlet of
capacity is 2427.2 m1hr for two units,
suspended solid is less than 10 ppm, and treated
solid
c.quipment is 6 to 8.5 ppm, and suspended
quality of treated water at outlet of filter
is 1.0 ppm.
following equipment:
The pretreatment facilities consist of thI
m)
(6) Intake Water Receiving Tank (788.8
Transfer Pumps (HP LaserJet
Tank
Coagulation Sedimentation
(18)
IIHPLASEII.PRSnk (3000 m"
Cooling Tower Make-up Pumps (950 ml/hr)
(6)
ml/hr)
(6) Filter Equipment Transfer Pum, s (288-548

3
Vertical Pressure Filters (45 m /hr)
(9)
(6) Air Scrubbing Blower, Rotary Type (28 Nm'/min)
Storage Tank (1000 mi)
Semi-underground Treated (Clarified) Water

(3)
(6) Filter Backwashing Pumps (360 to 576 m'/hr)
Drinking Water Feed Pumps (180 m/hr)
(6)
to 200 m:/hr)
Treated (Clarifted) Water Transfer Pumps (110
(6)
(3) NaOH Chemical Storage Tank (10
m
NaOh Horizontal Unloading Pump (13.1 ml/hr)
(3)
(9)
Series
Dilute NaOH Tank (3 il)
(6)
(9)
Dilute NaOH Dosing Pump (0.126 m'/hr)

Dilute NaOH Tank Agitator, Puddle Type
(6)
Coagulant Tank (150 m')
(6)
Coagulant Dosing Pump (1 rm'fhr)
(6)
Coagulant Acid Tank.(30 i')
(6)
(6)
(3)
(6)
Coagulant Acid Dosing Pump (2.5 mnf[hr)

Coagulant Aid Tank Agitator
Concentrated NaOH Transfer Pump (13.1 m/hr)
Chemical Storage Yard Pit Pumps (15 to 25 ml/hr)
BEST AVAILABLE DOCUMT

116
.JAMSIIORO UNITS 2, 3, & 4
RACK
CHIEMICAL F[IED SYSTEM & SAJIPLING
ptionl
formatior, corrosion,
nsate and feedwater are chemically adjusted to prevent scale
Which would
carryover
silica
as
such
c embrittlement, and contamination of steam,
with boiler blowdown,
it on the turbine blades. This chemical feed system combined
manufacturer recommendation provides
ieralized make-up
v.ater quality, and boiler
isis for each unit water cycle quality.
to control the ph and to inhibit release

ystem feeds chemicals to the boiler feedwater
economizer.
ygen in the boiler tubes, drum, superheater, and
contained in the eedwater and

zd hydrazine is applied to remove dissolved oxygen
and shutdown, an ammonium
ntrol the ph value. However, during plant startup
to control the pH of the feedwater.
on is injected in the condensate pump discharge
to protect ihc boiler from rust.
g long term shutdown, concentrated hydrazine is used
embrittlement, and to remove
1odium phosphate solution is Lsed for inhibiting caustic
-less of the boiler water.
condensate, feedwater, boiler
sampling rack supervises the quality of make-up water,
r and steam.
chemical feed system consists of the following equipment:
I-ydrazine Solution Positive Displacement Pump (0.33 liter/minute)
Diluted t-ydrazine Solution Tank
Phosphate Solution Positive Displacement Pumps (0.66 liter/minute)
Phosphate Solution Tank (1 in')
Ammonium Solution Tank (1 m')
Ammonium Solution Pump (0.33 liter/minute)
Stand-alone Control Panels
Power Machine Works,

Stand-Alone Sampling Racks manufactured by Changzhou
oxygen meters, hydrazine meters
with ph analyzers, conductivity meters, dissolved
there are oxygen anc
ph indicators, conductivity indicator. In the control room,
hydrazine recorders.
.A-
'
.JAMSIIORO
UNITS 2, 3, & 4
\VA'I'P-IR!I.EAMENT
(3)
(6)
(6)
SYSTEM
ph Meters and Flow lntcgralig Mcetrs

Iocal Control Panels (as needed)
Servicc Water Tanks (1500 m')
Service Water Pumps (54 m'/hr)
the third is
sedimentation tanks are in service, and
coagulation
three
of
out
two
Normally
once every year and requires
ie cleaning of the tank is done manually
on standby.
3 pneumatic control system of tile mechanical
approximately 3000 person hours. Unit
indicators.
miscellaneous pressure, flow, and local
filters is out of service as well as other
pumps we-.re
coagufation tank raw water transfer
(65
six
of
out
(1)
one
July
in
2,
On Unit
periodic
control and requires a high degree of
in serVice. The equipment runs on manual
to the service operating conditions.
maintenance and parts replacement due
Assessment
and returned to service. Assuming proper

Al out-of-service equipment should be repaired
system should be suitable
water pretreatment system equipment, the
design and selection of
service
costs will be high due to the severe
for 20 years continued operation O&M
encountered.
117
JAMSIIORO
UNITS
2, 3 & 4
COAGULATION SEDIMENTATION TANKS
Description
The "coagulation
For each unit there arc three coagulation sedimentation tanks.
1, but there are some
sedimentation tanks externally look similar to the tanks of Unit concrete.
At the center
constructed of reinforced
arc
tanks
The
differences.
structural
diameter. The water
portion of the tank there is a cylindrical space with 7.8 meters inside
space. There is an agitator mounted on the
to be coagulated is pumped into this cylindrical
part. The platform is covered with an
cylindrical
tie
over
platlorm,
top
the
as
slab acting
covet
I tank does not have any slab or roof to
Unit
columns.
on
roof
concrete
elaborate
5.85 meters and the top of roof is at EL..
the agitator motor. The top of platform is a( EL
9.72 meters.
the
oriented wall like columns. Betw.Yeen
radially
on
supported
is
wall
The cylindrical
of the
into the shape of a cone. The bottom
radial walis, the cylindrical wall Bares up
of 15.60 meters is formed like a fat spherical
sedimentation tank with an inside diamctcr
pit. The
pump it out from the centrally located
bowl in order to collect the sludge and
of the
positioned troughs at the upper elevation
radially
the
on
collected
is
water
clean
trough
radial troughs are connected to a circular
coagulation sedimentation tank. All the
and
tank diameter at the top is 25.00 meters
which feeds the outlet pipe. The external
m thick
0.0 and El +3.50, the tank wall is 0.35
19.40 meters at the bottom. Between El.
and conical in shape.
or
tanks was fair. Therce were no criical leaks
The concrete forming of the coagulation
of the tanks reflected natural ground
seepage observable from tne walls. The surrounding
collect fine clay sediments and need to be
conditions with no pavement These tanks
Unit 1, but not as frequently. The automatic
routinely emptied similar to the tanks of
required
so that a long duration of down time is
sludge removal system is not functioning
During this process the walls and surrounding
in order manually to remove the sludge.
below the agitator is more difficult to access.
areas get dirty. The central cylindrical space
Assessment
They
tanks should all provide 20 years service.
Structurally the coagulation sedimentation
taaks of Unit 1 since they have less
are
superior to the coagulation sedimentation
structural steel parts to corrode and lesser dowitite due to sludging.,

SYSTEMS
WATER & WASTCWATER TREA'FMENr
)escription
less
produce treated water with conductivity of
The water trCalrilnt systcm is designed to
gcn
ox
of less than 0.015 ppm, and dissolved
than 0.5 us/cm at 25"C, with S102 (-,1licnn)
of less than 0.3 ppm.
per unit.
of demineralizing system arc installed
sets
(2)
two
t/hr,
25
is
capacity
design
hll
Boiler Works.
Tlh system is manufactured by WuXj

for
automatically, the chemical consumption
The system is designed to regenerate
Kg..
regeneration is HC 600 Kg and NaOlH 250
lie system consist of
to
120 m'/hr)
(6) Water treatment Supply Pumps (70
TO 64.1 mi/hr)
(6) Regeneration
Water PumpS (30.6
(6) Booster Pumps (30 6 to 64.1 ml/hr)
(6) Nion Towc.

(6) Cation Tower
(6) Mix-bed Tower
(6) Vacuum Degassing Towers
Injection Type
(6) Vacuum Generating Equipment, Steam
(6) NaOH Tank, Pumps and Accessories
(silica meters, ph meters, etc)

(3) Control Panels and as needed Instrumentation
110 mfhr)
Discharge Pumps (50.5 to

(1) Wastewater pit with (6) Wastewater
(3) Mix Air Blowers (360 m'/hr)
(6) Demineralized Water Tanks (1000 m)
to 60 m'/hr)
(6) Demineralized Wzter Transfer Pumps (35
and review ot teiprali.t

Interview with plant O&M personnel, walk-downs,
indicated that O&M problems exist in the system.
LIC systems
[or manual and automatic operation,
Even though the systems are designed
of operating
This requires the constant attention
only [unction in the manual mode.
in Units 2 and 3, all the alkaline concentration
personnel to keep it running. For example,
119
WATER & WASTEWATER TREATMENT SYSTEMS
is out
order. Service water tank level indication
and silicon analyzer mecrs were out of
for tie NaOI-I njcctor-s arc out of
of service. Outict caustic soda concentration indicators
concentration indicators for the ICL
Additionally, outlet hydrochloric acid
sCr,,1cC
but the
4, the meters and indicator arc in SCtVice
injcctors arc out of service. In Unit
function
operators and can not cOMtnnLIOusly
systcl is operated manually by the
cally
ate
at(
required
repaired or replaced and the suipplicr be
Ic out of service instruments should be
operation
specification requirements for automatic
to make necessary modifications to meet
selection of
repairs are made, proper desimn arid
to reduce operating costs. Assuming
recommended maintenance and operation
components and adherence to the manufacturer
system should be suitabe of 20 years life
persincl, the water and wastewater treatment
I 'TAVIAILAEt.E DOCUNIMTN
120
WATER TREATMENT BUILDINGS
Dcscription
for each unit Thcse bbildings are

Ail individual water treatment building is provided
to tile Unit I water ireatment building.
duplicates and are similar in construction and shape
building.
They are located south of Unit I water treatment
(omments
and Current Condition
observed extcrnally oi internally. It was

No defects or deterioration on the structu.es were
underside of the conctetc beams. One
observed that pipe hangers were attached from the
buried inside the mortar.covering the
pipe hanger was connected to an angle halfway
reinforcemen and then covered with
beam. If the angle was directly welded to the beam
jeopardized and in the long run the
mortar, the strength of the frame may be critically
weakened beam may fail and not perform as designed.
Assessment
the underside o( concrete beams

The mortar of the suspected pipe hanger location on
to determine I ihe hangers were
should be removed and attachment locations investigated
for the next 20 years of
properly installed. The water treatment buildings are suitable
properly executed and the
plant operation, if it is proven that hanger attachment was
strength of the beam is not reduced.
i121
g
DAVA
EP
.JAMNI IOR() UjNTS 2, 3, & 4
EM El((G ENC
DI ES El(
-lAO R
It4T-N
Description
manufactured by Guizhou
Each of Units 2, 3, and 4 has ajl emergcncy dicel-g'cncrator
to 'hc Jnit I AOOV critical
Diesel Factory. The Unit 2 diesel generator is also connected
bus.
The diesel is
08 pover faril~.
The gcnerator is rated 500 kW, 50H1Z, 400\1, 903 Amp,
svsterl.
750 1-1P 6 cylinders, water cooled and with a coiptressed all stariint!
Thc diescl-gencrators were specified fot automatic start and autioiatic sop
whn
normal
power is restored for the 400V critical bus w'ction
ilhere are two air compressors for each diesel
per WA.PDA corresIn Unit 2 one of the two air compressors has been damaged
16, 1991. This has rendered the diesel
pondence PD/re(0)/OPER:-2/15419-20 dated June
enough pressure to roll
generator inoperable since one air compressor does not provide
of fune 6, 1991
the diesel engine. TYhis has complicated the events during tile shutdo\'i.1
generator breaker
in which the turbine rotor bow occurred. The operator opened the
bus was
while the automatic transfer from auxiliary transformer bus to startup transformer
of service and therefore Unit
not accomplished.
The emergency diesel generator was out
:o restore power. It is
2 was in
blackout until the operator took corrective measures
. are incapable of
currently out of se-vice. Currently the diesel-gencrator for Units 3 &

tie power is lost all the
automatic start and therefore must be started manually. When

diesels. At the time
400V AC critical loads will be out of service until operators start the
was not yet identified.
of the site visit, the root cause of this inability to start automatically
Assessment
to automatically feed
It is essential for any power plant to have a reliable diesel generator
2 that occurred
on
the AC critical bus in case of emergency, such as the incident at Unit

air compressors and
June 6, 1991. Therefore, repairs or replacement

of Unit 2 starting
for the safe reliable
restoring Units 3 and 4 to automatic mode capability are essential

operation of Units 2, 3, and 4.
122
.JAMSI I(R()
['OWERI
JNITS 2, 3, & 4
TRANSFORMERS
Description
Units 2, 3, and 4 (3 sets) - Main Tiansfornmers:
MVA, 50 l-z; 220 , 10%

Manufactured by Shcnyang Transfolmer Works, OF//-, 250
by direct grounding, insulation class
kV/15.75 10% kV. wye/delta, high voltage neutral
side 1050 kV and on low side 150 kV.
"A", 12% impedancc, BIl- insulation level on high
Scventh Oil Refinery, winding
insulating oil type is DB-25 GB 2536-81 by Dalian
limit 50CC, each transformer has three
temperature
Ilse limit 600C, oil tinpCatueLC rise
current transforncis iated 600/5 A.
Units 2, 3, and 4 (3 sets) - Auxiliary Tiansfotrmers.
25 MVA, 50 Hz, 15 75 -i0%

Manufactured by Shenyang Transformer Works, ONAF,
transformer grounding, 10%
kV/6.91 10% k, (Ielta/,.ye, low voltage neutral by
radiators, insulating oil type is
impedance, insulation class "A", 150/60kV BIL, 10 cooling
has (3) 12000/5 C-l's and
D13-25 2536-81 by Dalian Seven,;-, 0.' Refinery, each transformer
(6) 15000/5 C"s, winding temperature rise limit 50-C.
Units 3 and 4 (1 set) - Starting Transformer:
Hz, 132 +10% k%//6.9
Manufactured by Shenyang Transformer Works, OFAF, 25 M\'A, 50
11% impedance, insulation
+10% kV, wye/wyc., high voltage neutral is by direct grounding,
oil type DB
class "A", insulation level 650/60 kV BI.., four cooling radiators, insulation
winding temperature rise
25 GB2536-81
by Dalian Seventh Oil Refinery, 2 CTs 600/5,
limit 600C, oil temperature rise ,init 50C.
Unit 2 (1 set) - Starting Transforine:
kV/6.9 10%
Manufactured by Shen,,ang Transfoimet Works, OFAF, 25 MVA, 220 .10%
1050/60 kV 131L
kV, wye/wye, high voltage ne::. by direct grounding, 11% impedance,
Seventh Oil Refinery.
5 cooling radiators, insulating oil type D13-25 GB2536-81
by Dalian
500C.
2 CTs 600/5 by SYTW, winding temperature rise 60C, oil temperature rise
123

POWER TRANSFORMI-RS
Commernts and Current Conditions
U1nits 2, 3,
Inierve-ws with electrical maintenance and operating personnel and rc\,'cw oI
ion of
potat
to
dtuC
1991
July 11,
and 4 ou age record indicated that Unit 3 tripped on
personnel stated that the tij[) was due to
the inaul transformer protection relays. Plant
"Thecause of the tiansoimewr trip was not
opcation of the tiansformer pressure relay.
tile transfoi mci was retufned
de t1(-frtined noiwas damage, if any, assessed. Subsequently,
to Stnfvicc
to be in satisfactory condition with

By visual inspection, tie power transformers appear
appears to have leakage at the
exception of Unit 3 main transformer oil tank. The tank
piping Joints
Assessment
if any change occurred due to

The unit 3 main transformer should be tested to determine
is required, and periodic
the titp. Repairs of existing leakage on Unit 3 main transformer
corrective measures and
oil salmlingi' and insulation integrity tests are needed to implement
corrective active identified are
avoid forced outages. Based upon the newness oL the plant,
and adherence to the
performed, aissuming proper design and selection of components,
proceiduCs, the )owet
manufaciu ci's recommended maintenance. and operating
without majol lepairs or
transformers should be suitalile for 20 years continued operation
replace mentis.
e'['ST AVA,
124
'
i
JAMSilORO UNITS 2, 3, & 4

6.6 IKV MN'-I'ALCIL.AD SWITCI IGEARIt
I)escription
switchgear assembhles manufactured
ihere arc five (5) sets of indoor, drip proof metalclad
kV, 2500 amp, 50 Hz, 31 5 kA. irntcrrupting
by I3cjing Swtchgear Factory and rated 6.6
breakcs iracd at 1 k\, 2500 amp,
capacity, 60 kV BIL. Sixty-four (64) vacuum circuit
load
time 0.075 sec, nl)inmp timic 0 06 scC, no
and 40 kA intcirupting capacity, interrupting
We svitchgear
voltage are proiddl Um ihliv
cloming tine 0 075 see, 220 VDC control
,assemnblies.
(oimcnts
alnd Current Conditions
and oplmann lwtin mncl and r eview of the

Interviews with plant electrical maintenance
21, 1990 was due a io fault on the 6.6
outage records indicated that Unit 3 trip on March
that this
was a [aia accident and was caiused
kV tie breaker The plant personnel sta ted
in which otn sid"
was hot
by a Chinese technician working on the tie bicakci
.kdovtn and visual inspcciion of the 6.6 k\"
No unusual conditions were obse ,'ed du iig wal
electrical imait enarce Iersonnel are ,not
switchgear. I-lovvcr, it appears that the plant
settings and vacituln Ibicaker mainrienance.
familiat and haven't received training in relay
and the 1ruglish tags aie nioit plcmariert.
Also, generally the cables are tagged iri Chinese
Assesstmniti
assu"ing
Based upon the inewless of tile plaiit and
components, the 6.6 IV switcligear should be suitable
tie
without rnajo iepairs or replacetinent. However,
and
should receive training on protection relay settings
125
pinlmtl dcs in and ,e lection of

for 20 years continued operation
e.lectrical maintenance personrnel
breaker ma"rnerta ce.
JAMSIIO(() UNITS 2, 3, & 4

400V POWER C-N'TE'-IS & 400V
MOTORz
ONrZOL ClE-NTER-lS (MCC)
Description
centers, ianufacured 1iy Shenyang

Nincteen (19) 600V, indoor/drip proof powc
include nincteei (19) 6.6
L.V. Switchgcar Factory, arc provided. The power ccnters
brcakers rated 600%1, 40 kA interrupting
kV/400V transformers and 20(0 ali (:iiuleit
ng from 630A to 3000A. Control
r a ,utrigs
capacity, with continuous curf
from the 220 VI)C svsterl
voltage for the circuit brcakcrs air derived
\
(i:S, ma iInu factu red by Shenyang I

Twenty-niiine (29) 400V notoi coniii1ol cCn
Ni4CC maim coppei busc. are rated for 600V
i
Switchgear F-ctory, arc provided The

for 400A
and 1500A and the branch coppjt wuss are rated
Comrents and Current Conditions
and visual inspection of tihe power

Interviews with O&M personnel review of plant records,
throughout plant, indicated that
centers and motor control centers in the various location
with ie cxception of the residual oil
physical condition of the centers arc satisfactory
open and tile 400V control center
unloading facility. At this location, the building is left
aid dust. Morcover, the cable ducts
is exposed to time clements and contaniniracd with dii
are filled with oil which creates a haza rdous condition
felt that tie cooling tower
Ir, discussion with plant electrical maintelnaice personnel, they
with adequate overload protection
fans and the intake water pumrips are nol piovidcd
The Ipoblein wats addresseCd
causing premature failur-s of tiet oiCis ini hOi loca t ions.
Il ttei JS/25/90-90 dated August
to CMES on Pakistan 'ngineering (onsuliiii, Services
overload piotection for cooling, tOWe[
5, 1991, which called upon CMES to cplace all the
maintenance personmd also reported
fans and intake water pumps motors. Tlhe electrical
do not function.
that the breaker remote controls for the intake pump notols
3T AVAI 1'
126
J
(II
7NT
-JAMSHIORO UNITS 2, 3, & 4
400V POWER CENTERS & 400V

MOTOR CONTROL CENTERS (MCC)
AssCssment
of the frequent failure of the

An engineering study is needed to determine the root cause
iThe study should include:
intake water pump and the. cooling tower fan motors.
o
and vcrifying the proper

Evaluating the
load required to meet the application
selection of motors.
provided for the motors and

Evaluating the overload
and short circuit protection
cables.
assure proper service life of the

Cleanup of the residual oil unloading area is required to
newness of the plant, correction
motor control center in that location. Based upon the
of the power center and MCC
of current deficiencies and assuming proper selection
components, they should provide 20 years service.
1F7
JAMSI[ORO UNITS 2, 3, & 4

UNNTERRUI'FIBLE POWER SUPPLY (UPS)
Description
by Siemens. Ech unit has

Tihe UPS system equipment, Model B311 is manufactured
modules. The main components consist of
consisting of 10 kVA
redundant 30 kVA UPS
batteries.
and
rectifiers, inverters, static bypass switches
personnel and review of the forced

Interviews with plant maintenance and operation
reliability of the UPS even though tile
outages history for Units 2, 3, and 4 indicated low
have occurred due to.failure of the
UPS has redundant inverters. Several forced outage,
System (FSSS).
UPS which tripped the Furnace Safeguard and ;afety
of adequate documentation to repair
The electrical maintenance personnel indicated a lack
of UPS components which require
and troubleshoot the UPS, and that frequent failure
above normal stocking of spare parts.
and 4 has been addressed in a letter
The
frequent tripping of the UPS for Units 2, 3,
dated July 20, 1991.
JS/18/91-92 from Pakistan Engineering Services to MES
Asse:.-ment
from
sheets should be obtained
cut
and component
drawing,
Adequate
the cause-of the UPS
CMES/manufacturer. Further investigation is needed to establish
failure, installation problems, or
low reliability. This could be a reslt of components
In any case, the current condition is causing
O&M procedures not being followed.
availability. Based upon resolving
increased O&M costs and i reducing Units 2, 3, and 4
proper design and selection of
current problems,
the newness of the plant, assuming
components, and adherence to the mAnufacturer recommended

operation.
procedures, the system should be suitable for 20 years continued
128

132 KV & 220 KV UNDERGROUND CABLES
Description
underground cables arc routed:

Four (4) circuits of forced oil cooled 220 kV
switchyard
From main transformers of Units 2, 3, and 4 to the
From Unit #2 starting transformer to the switchyard.
cable is running from Units 3 and 4

One (1) circuit of oil cooled 132 kV undecground
common starting transformer to the switchyard
manufactured by Shrnyang Cable
Tile cables run in an underground concrete tunnel,
the minimum is O.2xlO Pa. Current
Works. The maximum oil pressure is 6x10s Pa, and
kV cables and 435A for the 132 kV
carrying capacity at 55C is 690 amp for the 220
cables.
Comments and Curreot Condition
and review of the forced

Interviews with plant maintenance and operation personnel,
on March 31,
1991 was due to oil
outage records, indicated the forced shutdown of Unit 3
and Unit 3 went back on line.
leakage from the 220 kV cable. The leakage was repaired

the following for the 220
The electrical maintenance personnei
run daily checks including
kV cable tunnel system:
Oil tank pressure
Oil leakage
Sheath grounding
Lighting system
Drain pump motors

Tunnel fans
Other abnormal conditions
seepage in the 220 kV cables to
Visual inspection of the underground tunnel indicated oil

the Units 3 and 4 main transformers
a=- i' ;
]-;Fv~~i
. -
,,;,"
_.,j/ :
c,;,
,~
132 KV & 220 KV UNDERGROUND CABLES
Assessment
repais are made proper

Normal repairs of the current seepage is needed. Assuming,
recommended
design and selection of components and adherence to the manufacturer
cables should be suitable
maintenance and operating proccdui-es, the 220 kV and 132 kV
13EST AVAILABLE DOCIIMENT

130
.jAMSIIOR()
UNITS 2, 3, & 4
6.6 I(V CABLES
Description
the 6.6 kV/400V transfo(..fmers in the

The 6.6 kV cables are used as subfeeders connecting
400V power centers, cabling from the low voltage side of the auxllary transformers and
kV cables are >.LPE insulated,
for the feeders to the 6.0 kV motors. The 6.6
manufactured by Shenyang Cable Works.
operation personnel rc\calCd single phase

Interviews with electrical mainterrce and
6.6
kV feeder running underefound-from the
6.6
2
Unit
the
with
problems
grounding
and control center
kV switchgear to the intake water 400V power
Assessment
of cables type and fating to meet the

Assuming proper design of cables and selection
years continued operation. Appropriate
application, the cables should be suitable for 20
faults. At the present time repairs
instrumentation should be purchased ',or locating cable
water pump stalion The root cause
are needed for Unit 2 6.6 kV feeder to the intake
be determined
to preclude similar failure
of this failure. in the underground cable should
in other underground cables.
LL
AVA~LA~

DC STATION I;ATTERIES
Description
Battqries Factory,
Each unit has a set of 220 VDC batterics manufactured by Shenyang
lead acid, 130 cells nominal voltage
located at the unit's battery room.
The batteries are
rate of 1600 amp-hr and maximum
of each cell is2V DC, rated -capacity at 10 hr discharge

discharge current of 2250 amp
Power Rectifier Works", rated

Each unit has a full wave rectifier manufactured by "Xian
3-phase 380V, 45-52.5 Hz, 200 amp, 200-260 VDC.
are filled with acid,

Interviews with plant maintenance personnel indicated that 122 cells
maintenance personnel check
of which 112 cells are in operation and 10 cells standby. The
the voltage daily.
personnel, revealed that
Visual inspection and walk through with electrical maintenance
in Unit 2 and the same
deterioration of cell poles
are obvious throughout the batteries
deterioration could be expected in Units 3 and 4.
Assessment
further investigation.
The deterioration could be a result of many factors which require
is expected in5 years for
However, based upon the current condition, replacement of cells
each unit.
U.S. excluding
Estimated cost of replacement for each unit is estimated at S100,000 F.O.B.
installation.
132
"
JAMSHORO UNITS 2, 3, & 4

LOCAL CONTROL BOXES, BTG BOARD WIRING,
CONTROL CABLES, CABLE TRAYS AND DUCTS
Descripiion
Power and Control Cables

for power and lighting
The conformance document Volume II Section V Item 12, called
PVC insulatcd, and the
cables 1o be rated at 1000V and 50OC, aluminum or copper,
direct buried or duc
multiconductor cables to be copper, PVC jacketed cable for
the rated voltage.
installation, and maximum voltage drop not to exceed 2.5% of
[oI the
The conformance docuoment VolInume Ill data sheets didn't include SClCa1rcMis
shielded cables for

220 VAC and 220 V]DC control cables or specifications for low voltag~e
Duc to the lack of
instrumentation applications, computer, and communication cables.
markings on the cables, ratings could not be determined by visual inspection.
indicated the
Interview with O&M personnel, walk-downs, and review of documentalion
followi n:
o
The cable trays are congested and in some areas are loaded above the top of the
tray.
Some cable trays welded parts and surfaces have sharp edges which could damage
the cables.
Some areas of the cable

trays are exposed to the elements and accumulated
considerable debris.
Local control boxes located throughout the plant have no gaskets on the access door
assembly to prevent moisture and dust from accumulating inside control boxes.
or conduit
The control cables entering the boxes are installed without conduit
insulating bushings and thus the cables arc in direct contact with sharp edges of the
box.
BEST AVAILALL ujiw Y
JAMSHORO UNITS 2, 3, & 4
LOCAL CONTROL BOXES, BTG BOARD-WIRIN(;,

CONTROL CABLES, CABLE TRAYS AN) DUCTS
The medium voltage cables, power cables and control cables run in the same
ductbank, and in some areas the manholes and duct covers are Idt open and
exposed to the elements.
I appears that the cable trays are not classified into high voltae tray, low voltage,
power and control cables tray, and low level signals tray. All the cables run togethcr
indiscriminately.
Thecre is no evidence that the instrumentation cables (4.20 ma. 0-1 ma, 0-SV, 0
10V) are shielded.
Cables and wiring of the BTG board in the control room arc not marked with
perrnanent identification tags and some of the temporary marked tags are already
faded away.
Cables in some cases are marked in Chinese numbers only.
Assessment
During the 20 years life span, the above conditions will cause higher O&M cost as some
of the cables Aill be subject to failure. This will also cause unreliable control and
measurement of processes which has a direct affect on the availability and reliability of the
units. It is recommended that a maintenance program be established to test the cable
insulation integrity on a periodic basis in order that corrective action may be taken before
failure occurs. Without a detailed analysis of the ampacity of consideration for each circuit
it is not feasible time to predict the number cable of failures over a 20 year time frame.
BEST AVAILABLF. (COPy
PLANT COMPUTER SYSTEM
I)escription
sequence
Each unit has a computer system which provides data logging, graphic displays,
The
of events,
turbine startup sequence monitor, alarming and performance calculation.
system consists of the foHowing:
(6)
(6)
(3)
CPU is manufacwured by "Intel" Type IS13C 86/35

Fixed hard disk unit is manufactured by "Japan FUJITSU" Type Winchestcr M2242A
Input/output cabinets are manufactured by "New China Company"
(9)
CRTs are manufactured by Hitachi, Ty-pc HM-3719A
(9)
(3)
(6)
(6)
(3)
(3)
(3)
Dot Matrix printers manufactured by "Sta'r Micronics Company"

Dot Matrix I/O printers manufactured by "Texas Instruments"
Trend Recorder manufactured by Japan, Type YEW-3061
Floppy disk drives manufactured by Japan, Type Shugart 45
Color copier by Japan, Type Multicolor
Operators console by "New China Company"
Operators desk, (3) printer desk, (3) engineers desk
The process input/output unit has the following capabilities:

Analog Input Points:
RTD Points:
Thermocouple Points:
Digital Inputs:
Pulse Inputs:
Analog Outputs:
Digital Outputs:
128 (1 to 5V or 4-20 ma)
48
272
192 wetted by 24 VDC (48 per module)

24 (8 per module)
16
48

Interviews with O&M personnel, review of plant records, and walk-downs indicated that
the plant computer systems for Units 2, 3, & 4 operate satisfactorily.
BEST AVAIL.AFKI.F COPY
JAMSI[ORO UNITS 2, 3, & 4
PLANT COMPUTER SYSTEM
Asscssmcnt
Assuming proper selection of components, adherence to manUac~urCrs rtcommended

O&M procedures, and continuing supply of spare parts, the system will be. suitable for 20
years of continuing operation.
BEST AVAILAB31l F COPY

136
7,
BEST AVAILABLE COPY

TrURIIINE & CENTIAI
CONTROL BUILDINGS
Description
The width of turbine building is 36.0 meters between axes A and GI. The 'height is 28.5
63
meters which is 1.4 meters .higher than Unit 1. The length of Unit 2 and Unit 4 is
meters and that of Unit 3 is 72 meters Between the ending and beginning axis of two
consecutive Units there are 2 meters spaces. The mezzanine Boor level is at EL +5.00
meters The operating floor level is at EL A-10.00 meters The dearator unit is at floor
elevation EL +18.00 meters There is only one gable wall at the south end of Unit 4.
There are two bridge cranes, each with 75/20 ton hook capacity. The top of the rail is EL
is 21.00 meters The bridee crane span is 26.00 meters
The walls along axes A and Gt, as well as the gable wall one metei south of the last
column axis 408 is covered by prefabricated reinforced concrete wall elements. The roof
is covered with cast-in-place concrete. The roof and floor slabs are finished using a metal
deck. There is bituminous insulation over the roof which is further protected by brick tiles.
The turbines and generators are supported on reinforced concrct: pedestals. Each turbine
pedestal is housed inside the turbine building below the operating floor level. The pedestals
are not connected with the steel structure of the turbine building except at their common
mat foundation. Each unit is separated with expansion joints from the foundation up to
the roof.
A common control building serves Units 3 and 4. This building is 40.0 meters long
between axes H to N in the North/East direction and 26.00 meters wide in the North/South
direction. From axes Glto 1 there is 1.50 meter distance.

There were no cracks or displacement observable at the ground level. There were also
no cracks, displacements or deterioration noted at the equipment foundation. Higher floor
slabs, walls and the roof had good appearances without any apparent defects.
The turbine building steel structure appeared adequate, but the erection showed signs of
problems. The presence of empty bolt holes at vertical brace connections above EL + 10.00
meters between column axes F1 and GI also occurred in Units 3 and 4. At some joints,
gaps between tie two connected parts wre very large. Erection accuracy appeared to be
very questionable. Since the joint holes could not be matched properly or, as it appeared
JAMSIIORO UNITS /2,
3 & 4
I'URIBIN[" & CENTIRAL CONT'ROL BUILDINGS
in some cases, (here were no enough available bolts, welding was used instead. Normal
steel joint practice never combines the capacities of bolting and welding together since the
load transfer to tile bolts can only occur after weld receives its ultimate load and starts
failing.
A.nothcr poor detailing practice was observed at EL - 10.0 meters column row 17l Here
tile column splice location was selected too low, such that the flange splice plates on
column face looking towards G1, was cutting deep into the oncoming gusset plate, making
the erection difficult and that section of gusset plate not functional.
Furthermore, thc steepness of the vertical bracing between column A and BI. neat Unit
Plate
4 condenser entry, resulted in a gusset plate with a long narrow appearance
buckling consideration alone would probably not allow such a practice. At a nearby
location the diagonal member of vertical bracing was connected with a kinked gusset
plate, which creates torsion in columns.
Most of the welded erection joints had very rough and poor quality appearances. It is not
known if the welders of these joints were qualified welders or not. It is also questionable
if the erection practices followed resulted in safe and acceptable connections in the turbine
building vertical bracing system. The vertical bracing system transfers the horizontal loads
such as wind and earthquakes to the columns and foundation.
Assessment
Assuming proper design and construction, the reinforced concrete parts o the turbine
building of Units 2, 3 and 4 as well as the attached control room and amenities building
for Units 3 & 4 should be suitable for the next 20 years.
The erection practices observed cast some doubts about the actual strength of some
bracing joints. In the event of severe horizontal loads on the structure the ability of these
joints to perform their intended [unction is questionable. This is not to say that the overall
safety of the turbine building is in jeopardy since there should built-in redundancies in the
total frame work so that loads will redistribute along a stronger path if a one local joint
failure occurs.
A detailed evaluation of the bracing joints and implementation of corrective actions IS
required to assure a continued 20 years of suitability. Without this, major repairs may be
_OI"Y
BEST AVAI_.A12Li.
required.
.)
1:
.jAMSltORO UNITS 1, 2, 3 & 4
COMMON FACILITIES
0 the following:
hc common components and structures evaluated consist
Stacks
River Intake Structure and Piping
Intake Water Receiving Tanks
Water Pretreatment Buildings

Clarified Water Storage Tanks
Demineralized Water
and Service Water Storage Tanks
Residual Oil Unloading System-
Residual Oil Unloading Area Structures
Residual Oil Storage Tanks
Pipe Rack Bridge
BEST AVAIL ARLF.
I:PY
JAMSIIORO UNITS 1, 2, 3 & 4

STA C I(S
Description
Units I and 2. Similarly

There are two concrete stacks. Stack 1 supports the flues of
fromI each other
Stack 2 support the flues of Units 3 and 4. Each flue is independent
inside each stack.
data below were obtained
Both stacks are similar in shape, size and height. The geometric
shown in the technical
from the drawings prepared for Units 2, 3, 4. Thc height
in the drawings from
specification for the stack of Unit I is the same as the height shown
Unit I siack ll"-following
Units 2, 3, 4.
With the absence of geometric iuformation for
evaluations are generically made for both stacks.
There are three major distinct parts for each stack. These are:
a)
b)
c)
a)
b)
Reinforced concrete chimney and foundation
Inner flue with lining and insulation
Platfc . . . .-"
the
The reinforced concrete chimney is 147.00 n h igh from the top of
foundation to the top of chimney. At the base the external diameter is 15.20
is
meters with a wall thickness of 0.70 meters. The top external diameter
is
11.40 meters. and wall thickness reduces to 0.25 meters. The foundation
5.50 m thick and has the octagonal shape with 30.00 m external diameter.
The thickness of foundation tapers down to 2.00 in at the outside periphery
of the foundation. The stack foundation is built on the solid limestone
foundation. There is one opening for a steel door at the ground elevation
and two openings for the flue duct entry opposite to each other in the
North/South direction with the bottom
at EL 8.38 meters. The height of
these openings is 6.40 meters. The width is estimated to be 3.0 meters.
on the
There are t vo flues with an outside diameter of 4100 um. supported
foundation with anchor bolts at El -0.00 meters. Each flue is horizontally

supported by a steel guide frame against the concrete stack at elevations
36.00 meters, 73.00 meters 100.00 meters and 147.00 meters. The top of the
flues reach EL 150.00 meters with an slightly conical ending which has a 3600
mm. outside diameter. Each flue is free to expand or contract vertically.
JAMSHORO UNITS 1, 2, 3 & 4
STACKS
c)
at.every 6.00
A ladder attached to each flue provides
access to platforms
meters or less throughout the stack.
steel' The upper

The flue, are built out of 14 mm. thick corrosion resistant
mckel chromium
portion, closer to the weather exposure, was built using
flues have a 50 mm.
steel. Internally, including the bottom hoppers, the
degiecs C. Externally
gunite type lining which is heat resistant up to 1000
on tilc flue by 3.5
there is 50 irn. thick fiberglass insulation, firm!y attached
by 20 mm x
mm. diameter welded Nelson studs. Tie insulation is covered
each platform
25 mm wire mcsh. Oil areas within 3.00 meters lhight abovc
thick alumiium plates
level, the cxtcrnal insulation is covered by 0.5 mm
at EL 1.60 meters
instead of tle wire mesh.
There is an inspection manhole
for each flue.

a)
technique
Tle reinfoiced concrete chimneys were built using the slip form
where tile inside and outside forming was supported from the reinforcement
height of the
of the stack portion, already cast in place. Only a few feet
and tile
chimney is formed as a rng at one time. As this portion is built
to a new
concrete is sufficiently cured, the forming is raised as a unit up
a
height. This technique saves construction time, expense and provides
stacks
uniformly smooth and even surface. In the case of the Jamshoro
acceptable
both radial and vertical surface evenness was maintained to an
as tile
limit. Tle toundations support the weight of the structure as'well
dynamic effects of wind and earthquake forces on the solid limestone
foundation.
b)
The flues are supported and protected to some degree from external effects
were
by the reinforced concrete chimney. The materials used for the flues
selected to be resistant to the corrosive environment of the sulfurous gas
a
exiting the boiler. The internal surface of the flues is further coated with
draft
special lining to reduce the effect of tile hot gases. To provide good
is insulated
and to minimize the heat loss along
the path of flue, the flue
externally. The flues are in good functional cordition.
-kV5
1 i- hIL
L !
JAMSHORO UNITS 1, 2, 3 &
STACKS
c)
rcpalr of the chimney

Platforms and ladders, provided for inspection and
and its integral parts, appeared in good condition.
Assessment
a)
should 13st more than 20

The reinforced concrete chimney and foundation
years.
b)
The flues should last for the 20 y.ear period of operalion
c)
Platforms and ladders should last more than 20 years.
BEST
Al\Vl ...,F ,"OPY
.JAMSIIO,)
UNITS 1, 2, 3 & 4
CLARIFIE'D WATER STORAGE TANKS
Description
There are two rectangular prismatic concrete tanks with a common rmiddlcwall.
They
tanks, chemical
store clarified water after it passes tile receiving tanks, sedimentation
long and
treatment and filter equipment. Each of the tanks is 21 meters wide, 40 meters
is 20 cm thick
6.9 mcters high. The walls and bottom slab is 50 cm. and the roof slab

was
There was water seepage at one of the pipe locations at the storage tank Ai attempt
and against
made to repair the seepage by externally pouring concrete around pipe exit
leak did
tank wall. EvidentlN, the tank was full when the repair was attempted and the
not stop.
was
No external settlement, cracks or deterioration were observed. No internal observation
made.
Assessment
The clarified water storage tanks are suitable to last for the next 20 years of operation.
The leak problem should be solved by proper repair.
BEST AVAILABLE COPY

147
JAMSIHORO UNITS 1, 2, 3 & 4

RIVER INTAKE STRUCTURE AND PIPING
Description
tile Indus River. The river is

Tile water needed by the power plant is pumped from
3 km. cast of tie plant site. A
flowing in a North/South direction. It is approximately
Along the side of the road
road connects the plant sit6 with the river intake location.
going to tile river.
Parallel to the
there is the boiler blowdowrT water pipe over ground
cable ducts and intake water pipes
road but underground there are buried conduits, power

for each plant unit.
grade val,c pits formed as concrete

At a few places along tile road, there were below
In these pits tile intake pipe and cables

shafts roughly 2 meters inside diameter and depth.
0.3 meters high.

were visible. Tile shaft contained water almost
This araa is flooded
water levels in the Indus River which is

almost to tile edge of the
road during the high
the river
regulated by the Kotri Barrage dam gates 3 km. down
Some statistics about water level are as follows:

Flood Level 23.2 meters
High Water Level 20.8 meters
Low Water level 18.9 meters
Lowest low water Level 14.8 meters

above ground and
Close to the river shore the intake pipes and control cables rise
structures. The down
approach the intake pipe bridges. There are two parallel river intake
Power Services Co.
river side intake structure was designed and built by Tokyo Electric
uI river intake structure
Ltd. Japan and carries the intake pipes for Units I and 2. The .
Institute Ministry of Water

was designed and built by North East Electric Power Design
to supply water for
Resources and Electric Power Changchun Peoples Republic of China
Units 3 and 4.
200 meters from
The river intake structure, which is also called intake tower, is located
tower. Half of these
the shore in the Indus River. There are 8 pumps on one intake
others, are used during
pumps are deep water pumps used during low water levels and the
intake pipe of one
high water levels. Four pumps are connected with one header to a 22"
concrete piles each 1200 Im.
powerhouse unit. The intake structure is supported by ten
to drive the piles
O.D. The steel jacket frame over the concrete piles served as a template
at El 25.20
at the correct position in the river and as
form work for the intake platform
meters. The top of the intake tower measures 9 meters
JAMSI[ORO UNITS 1, 2, 3 & 4
RIVER IN'AKE STRUCTURE AND PIPING
in length parallel to We river.

in width perpendicular to the nver flow and 19.2 meters
melers. The tip oftthc concrete
The river bottom elevation at intake location is El. 10.00
conduit cables and a"footway.are
pile is at El. -6.70 meters. Intake pipes, power and
truss
"down river" bridge by four simple span
carried from intake tower to the shore on the
three simple span truss type steel

type steel bridges and on [ti "up river" bridge by
50 meters. Each pier has a pile cap
bridges. Tile bridges are supported on piers at every
1.2 meters thickness. The pile cap is
measuring 4.5 m width and 6 meters length and
elevations at bridge support locations
supported by four concrete piles. The river bottom
meters. Corresponding pile tip
are El 10.7 meters, 12.8 meters, 17.6 meters and 21.00
3.0 meters. Concrete pile lengths
elevations are -4.5 meters, 0.0 meters 1.9 meters and
span of each steel truss bridges is
inside rock surface vary between 5 and 7 meters. The
supports or truss plane
48.5 meters. Tile truss height is 4.0 m and bridge width between
meters.
is 4.00 meters. The bottom of truss lower chord is at El +25.6
The plant personnel stated

The total intake facility is in good condition and is operational.
how the corrosion protection
there is corrosion protection for the buried intake pipe; but
is provided was not visible.
tower were all in good
The pipe bridge structures, the bridge piers and the intake
was no apparent damage
condition. The design and workmanship
appear good. There
or deterioration of any kind.
Assessment
sound. The structural

The river intake water bridge and tower facilities appear structurally
next
20 year period
elements of intake facilities should be suitable for service during the
of operation.
is difficult to estimate
The life span of the intake pipes, especially the underground portion
amount of sand sucked
since they are buried and not visible. Additionally, there is a high
pipes Will be under
in from the river and transported through the pipe. Externally the
will wear the pipe over
corrosion influence; internally the amount of sand flowing through
time.
.JAMSII()RO (NIIS
1, 2, 3 & 4
INTAKE WATER IRECEIVING TANKS
Description
unit built above ground with

lhere are two open top rectangular concrete tanks for each
supplying water to each tank header. It

a common wall in between. The intake pipe is
of the depih
and 5.5. meters high. Half
is approximately 20 rnctcrs .',ide, 4.0 meters lon[
half is above ground level.
of the tank is below ground level and lhc othcr
Comments and Currcn t Condit ion
constructed. There. was no leakage

The receiving tanks of all units appcar adequatcly
rapidly filled with the incoming sind from the
observed through the walls. Tthe tanks arc
Emptying the tanks is done manually.
Indus River, sometilmes in as little as IS days.
Assessment
and should last [or the next 20 years

Structurally, the receiving tanks are in good condition
of sand entering the tank.
Operating costs will be high due to the large quantities
RFIST AVAILABLE COPY
JAMSI IOR() UNITS 1, 2, 3 & 4

WA'FR PIR-'TIATMENT BUILI)INGS
Desc riptiin
reinforced concrete frame

The water pre-treatment buildings for each unit are single story
control equipment for pretreatment
structures The buildings house the necessary
from sodium chloride.
operations In pail of tihe facility, chloride is produced
Conncnts and (Clirrent Condition
The concrete framing and ihe walls

Currently tile buildings arc in fairly good shape.
arc no signs of detcrioration Since
appear to be sound Extcrnally or internally there
salt, the environmcnt is very corrosi'c
chloride is m nlJ(-ictured fron industrial quality
floor level. Since exposcd.stecl surfaces
Thcre arc checke ed plate covered trenches at the
and replaced as required. The ccilin
Will COrrode:, these components must be maintained
in some parts a porous surface look.
concrete of the huildi rg displayed uneven, rough and
reinforcing bars were detectable from the
which indicates pout Workmanship. Although no
to the affects
underside of the ceiling, the porous and rough concrete surface is susceptible
repair
and
maintenance
of corrosive imnes Therefore the ceiling may require
Assessment
semice for the next 20 years

The water pretrcatment buildings should provide satisfactory
performed.
provtoed maintenance and good housekeeping practices arc
REST AVAILABLE COPY

I AA
.JAMSIIOR() UNITS 1, 2, 3 & 4

CLARIFIEID WATE-R STORAGE -TANKS
Description
Thcre are two rectangular prismatic concrete tanks with a commol ,1iddlewall
They
tanks, chemical
store clarified water after it passes the receiving tanks, sedimcntation
40 meters long and
treatment and filter equipment. Each of the tanks is 21 meters wide,
cm thick
6.9 meters high. The walls and bottom sla) is 50 cm. and the loof slat) is 20
Conments and Current Condition
An attempt was
There was watci seepage at one of the pipe locations at the storage tank
exit and against
made to repaii the seepage by externally pouring concrete around pipe
the leak did
and
tank wall. Evidently, the tank was full when the repair was attempted
not stop.
observation was
No external scttlcment, cracks or deterioration were observed. No internal
made.
Assessment
operation.
The clarified water storage tanks are suitable to last for the next 20 years of
The leak problen, should be solved by proper repair.
REST AVAI ARIF rOrV
1A-7
JAMSIIORO UNITS 1, 2, 3 & 4

TANKS
DEMINERALIZED) WATER AND SERVICE WATER STORA;E
Iescription
For cach unit there arc two dcrmincralized water storage tanks each with 1000 cubic meter
capacity. Thcsc tanks arc located cast of thc water treatmcnt building of each unit.
the
There is an external stair*welded on the tank wall, leading to the tank entry at
sCrnisphcrical tank dome. Each tank is supported on a base containcd inside a concrete
cylindrical wall which elevates the tank above ground level.
Thc service water storage tanks arc located cast of the demincralized tanks. There are
two tanks for each unit. These tanks arc similar in size and shapc to those of the
dernincralized tanks for the corresponding units
The tanks were welded on location. The appearance of the exterior painting on the tanks
indicated quality work. Tlie paint on the tanks of Units 2, 3 and 4 are not as impressive
as the Unit I tanks. The welded seams arc not ground flush. The plate thickncss changes
are externally visible which gives an unev6n stepped surface. This, however, should not
affect service life. There are no external defects or settlements in any of the tanks.
Assessment
Assuming proper design

and normal maintenance, the demincralized water and service
storage tanks should provide satisfactory service for the next twenty years.
BES1 AVAILA[ LE C()PY
148
.JAM SIIO()() UNIIS 1, 2, 3, & 4
RESIDUAL OIL UNLOAI)ING SYSTIEM
Description
The system consists of the following:

o
Residual Oil Unloading Facilitics
o
o
o
Residual Oil Receiving Facilitics

High Speed Diesel Oil Receiving Facilities
Oil Drain and Oil Separation System
Residual Oil Transfer System to Transfer the RO to Service Oil Tanks
Pressure gauges are installed
in strainer inlets/outlets, discharge and pumlp outlets of
pressure control valves. LOW pressure switches are installed on the punp discharges for
alarm purposes. Temperature sensors are installed to indicate temperature of residual oil
inlet/outlet, heating steam and drain.
Outdoor local control panels at the residual oil
transfer pump area and oil separator transfer pump area have the follow components:
o
o
o
o
o
Operating Swi.ches
Indicating Lamps
Ammeters
Strainer Differential Pressure Alarms
Motor Overload Alarms
The residual oil unloading area had considerable oil in trenches and on the ground.
(Reference Residual Oil Unloading Area Structures). This will lead to higher maintenance
costs and present a fire hazard. The area should be cleaned up. Interviews with plant
personnel, walk downs and review of plant records, indicated that the systems are in
working condition. However, plant personnel indicated difficulties are encountered in
unloading the rail cars especially in cold weather. Currently, oil is being delivered by truck
to a truck unloading facility.
4...
149
.3
, V,-ItSLL
JAMSII()l()
UNITS
I, 2, 3 & 4
RESII)UAI. 011 IUNILOADING ARIEA STrizUCiURES
Assessment
Assuming the area is cleanco up, good housekeeping practices are established, proper
- -. ponents and adherece to manufacturer's recommended
design and selection of sys
O&M procedures, the sys,,, snould be suitable for 20 years life.
Description
The residual oil unloading area is located at the west end of the power plant. It covers
the railroad unloading facilities and ->ceiving and transfer pump stations. Residual oil
unloading area facilities serve all [our units of the power plant. There are railroad tracks
running parallel to the North/South direction. Tracks arc numbered. 1 to #t4 from CasI
to west. The railroad unloading area is approximately 800 meters lonQ
Between rail tracks //3 and #4, there is a pipe trench below grade wiuch is almost 512
meters long capable of unloadig a total of 60 railroad tanker cars (30 cars per track) at
a time. The pipe trench is similar to a rectangular concrete underground tunnel with clear
inside dimensions of 3.20 meters width and 2.25 meters height. The trench bottom is sloped
from both ends towards the trench mid length. There are residual oil (R.O.) receiving
pipe, heating steam pipe, heating drain pipe, trace drain pipe, fire water pipe, air foam
pipe, an electrical conduit, a walk path and a saiall rain water trench inside the pipc
trench. At each railroad car park position, the top of pipe trench is 1.92 meters long and
has a full width access opening.
At the approximate midpoint, the pipe trench tunnel branches out wes(ward.and passes
nduits go through the tunnel then pass under the plant
under track #4. The pipes a:.
road through a concrete culvert and reach the residual oil receiving pump station area.
The oil pipe goes through the air separator units before entering the road culvert.
The residual oil pump station is a concrete structure built like a pit below road grade.
There are reinforced columns which support the reinforced concrete roof. There are no
walls above street lcvel. A smaller trench along the side of the road and the receivitn
pump station provide a catch basin for possible oil spill at street level and for rain. The
pumps in the receiving pump station transfer the arriving oil into four storage tanks each
designated for one power station unit. Next to the receiving pump station there is a
residual oil transfer pump station. The oil from the storage tanks is pumped through the
transfer pump station to the residual oil pump and heater area near the boiler units.
150
JAMSI ORO UNITS 1, 2, 3 & ,4
RESIDUAL OIL UNLOADING ARFEA STI,-U1UR.S
The residual oil unloading area is functional and intact. Thc reinforced pipct trench, the
connection tunnel undcr track //4, the culvert under plant road, the receiving and transfe
pump stations and, their walls, columns and roof appear in good condition. There were
no observable cracks, settlement or damage to any of the structures. During the site visit
there was no train unloading operation. Between and around the rail tracks there was
compacted soil with evidence of heavy oil spillage at most unloading locations. The spilled
oil, mixed with water, was several inches high throughout thc pipe ticnci. Thc oil spill
continued through the tunnel under the roadway around the rcceiving pump station area
but not inside the pump station itself
A truck unloading station is also provided. The tank trucks unload the residual oil to a
pump pit close to the receiving pump station. The pump pit is below the level of plant
road and protected on the road side by a concrete trench. There was oil and water
The trench is covered by grating made out of
standing inside this trench as well.
reinforced bars.
Assessment
The structures appear to be in satisfactory condition and should provide 20 years continued
operation. However, with the current condition there is a potential danger due to a major
fire. The area should be cleaned up immediately to remove this hazard.
ALE COF"'
.. gT V\JA
151
JAMSI
)I()() UNI
S I, 2, 3 & 4
RESI ) UAL Oi.11"SO RA(; 1
1)C%c
C I11 1i 0nl
There are four residual oil storage tanks, each used for one of the units of the power
plant They are located west of the residual oil unloading area. The stotage tanks were
built on-site by welding steel plates. They are cylindrical in shape with slight spherical
(dolie roofs leach tank has 27,000 cubic meter oil storage capacity Each tank is almosi
Oine- metci above ground and supported on compacted soil placed Inside a clindrica l
concreice wall which forms, the hcight above ground. It is not known what kind of corrosion
plotect on of the steel base plate is provided as it is in direct contact with the base fill
A levee like stone wall is between tw,o neighboring tanks. Concrete walls protect tie
stn o0nding areas from oil spills. Tanks for Unit I and 2 are further separated from tile
tanks fo[f units I and 4 by a plant road oii three sides. All tanks are pain.ted

The tanks appear to be in good condition. The welding, the geometrical shape and tile
pain application indicate good workmanship. The concrete foundation also appears to be
in good condition. There arc no signs of settlement or cracks. Thlce were no external
holes or reinforcing bars visible on the concrete surfaces which indicated good form work
and bar placin!
The levee like wall separating Tank i from Tank 2 contained a construction opening which
has not been closed. This opening should be closed in order to maintain the function of
ie wall
Assess
nicnt
The residual storage tanks appear to be in good condition and should provide satisfactory
service for 20 years assuming proper design and normal maintenance. Painted surfaces
should also be maintained at proper intervals.
During the lifetime of the tanks, internal
cleaning may also be required. Inspection of the base plate for any corrosion damage will
be difficult. Therefore the tanks should be kept under surveillance to detect any leakage
at an early stage to minimize environmental damage.
152
,JAMSI I
R() IJNI'I'.S I, 2, 3 & 4
'IPl- RACK IRIDGE
l)cscl iption
Thc main pipe rack bridge is
almost 600 ieters long routed in an cast/west direction
bctwccn the residual oil transfC pump area and the water ireatment building for Unit 3,
aild flonir,. over the nieutal ground oinlthe north side of the plant inside i'(,
;1k Is four Meter', wide and simple span truss type steel bridge system elevated on hcav-y
spans froma 10 meters to 17 mcefs The bridge structire
steel coluins with vai),irii
stlpports the residual oil pipe from the transfer pump station to the heater and oil pump
arcat ncar the plant site. It further suppors the heating steam pipe , air, foamo and fire
\water tipcs, and clectilcal conduits fioma the )lant site to the residual oil unloading area
The Cast half of the bridge carries the pipcs and conduits to and from the vater tfeatmcril
building towarcs ic Illain powerhouse A secondary pipc rack hridP', perpcrldiculat i
the main pipe rack III North/South direction, starts from the main pipc rack and contiflles
southward onl the cast side of the plant street passing behind the boilc buildinig of each
unit. Tis pipe rack mainly carries the [uel SUl)ply lines to tile boiler units from the
csidural oil puinmp andi heater area. It also carries 1)ipcs used fo Gic tboilcr make up
watcr and the cable conduits.
Comments and Currcnt Condition
The steel truss bridges and the supporting steel columns of the pipe rack appear
adequately designed and constructed. The columns arc supported on individual reinforced
concrete footing pedestals and foundations below grade. There w.ere no signs of settlement
or cracking. The pipe rack structure was painted and there was no evidence of peeling,
blisteting or cor-rosion.
Assessment
Assuming proper design and normal maintenance, the pipe rack bridgc system should be
suitable for the nex-t 20 years of operation
F 'jT.A\/,
[7
153
l.A
('l FV

PNABU386

Încărcat de

Informații document

Descriere originală:

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

PNABU386

Încărcat de

Drepturi de autor:

Formate disponibile

UNITED STATES AGENCY FOR

PRIVATE SECTOR POWER PROJECT

JAMSHORO POWER STATION

TECHNICAL DUE DILIGENCE

INTERNATIONAL RESOURCES GROUP, LTD.

BEST AVAILABLE DOCUMENT

Report was completed in

In general, Unit No. 1 appears to bQ of superior quality and exhibits better

It is assumed that all equipment currently in place was designed, manufactured

Based on appearance, operational records and staff testimonials, it appears that

BEST AVAILABLE DOCUMENT

BEST AVAILABLE DOCUMENT

UNITED STATES AGENCY FOR INTERNATIONAL DEVELOPMENT

PRIVATE SECTOR POWER PROJECT

TECHNICAL DUE DILIGENCE UPDATE

JAMSHORO POWER STATION

CONTROL WORKPLAN 2.33.0

BEST AVAILABLE DOCUMENT

PROJECT TASK AND DESCRIPTION

PLANT OPERATING AND PARAMETERS AND ACTIVITIES

PLANT COMMON FACILITIES

BEST AVAILABLE DOCUMENT

PROJECT TASK AND DESCRIPTION

BEST AVAILABLE DOCUMENT

BEST AVAILABLE DOCUMENT

PLANT OPERATING PARAMETERS AND ACTIVITIES

Design Capacity (MW)

Maximum Operating Capacity (MW)

Design Heat Rate

PLANT OPERATING DATA (ANNUAL)

BEST AVAILABLE DOCUMENT

BEST AVAILABLE DOCUMENT

BEST AVAILABLE DOCUMENT

BEST AVAILABLE DOCUMENT

PLANT COMMON FACILITIES

WAREHOUSES AND STORES -- The warehouse for Unit 1 contains an adequate

BEST AVAILABLE DOCUMENT

Total running hours since last overhaul.

Through June 30, 1993

BEST AVAILABLE DOCUMENT

BEST AVAILABLE DOCUMENT

FOLLOW UP VISIT TO JAMSHORO POWER PLANT

BEST AVAILABLE DOCUMENT

ITEMS NEEDING CORRECTIONS AT JAMSHORO POWER PLANT

Maintenance shop, no equipment, tools todate.

Air basket #11 unit 1 month outage to replace or clean.

Units 2, 3 and 4 hot spots need to replace insulation.

machine has cooled down.

Units 1, 2, 3 and 4 experiencing, short circuiting during rainey seasons.

overflow's into farm fields.

needed to make tie to units 2, 3 and 4.

Instrument air dryers on units 2, 3 and 4 need to be replaced.

to shut unit down.

Units 2, 3 and 4 thrust bearings and pilot valves need replacing.

Units 2, 3 and 4 all pumps need to have grease fittings added.

compressor sealed units have to be replaced.

experiencing lots of damage this could be

BEST AVAILABLE DOCUMENT

Mr. Dennis W. Evans

International Resources Group Ltd.

Private SecLor Power Project,

2nd floor, PIA Tower,

M.M. Chandio R.E.