BESTWAY CEMENT LIMITED - CHAKWAL WASTE HEAT RECOVERY POWER PLANT Pending Issues

Sr.# Equipment
Late Reply/Comments on WHE Foundation and T.G Building.

Reference

Description
Your late reply to the BCL's Civil Drawings of T.G Buildings cause of overall delay in project.

24164-A0E931 dated 05.08.2008

Rated Capacity of Steam Turbine

BCL/CHK/IAA/WHRPP/60 dated 02.07.2009

The capacity of the Steam Turbine mentioned in contract clause (3.1) 16,550 KW whereas the Supplied Steam Turbine has capacity 16,000KW as shown on the name plate. Clearances of Steam Turbine Diaphragms and clearances of rear and front pedestals were made at site because the assembly of the steam turbine was not checked at manufacturing workshop due to this we spent lot of time to make these clearances. The estimated rectification cost is Rs.10 Million. Moreover the erection and commissioning was delayed and extra time of supervisor was consumed. Special tools for maintenance is an integral part of Steam Turbine but supplied special tool is not sufficient for the Maintenance. Also we faced so much problem during the erection of Steam Turbine due to insufficient tools and tackles.

Clearance of Steam Turbine Diaphragms

BCL/CH/Mech/WHRPP/ dated 29.04.2009 BCL/CH/Mech/WHRPP/ dated 04.05.2009 BCL/CH/Mech/WHRPP/ dated 07.05.2009 BCL/CH/Mech/WHRPP/ dated 08.05.2009 BCL/CH/Mech/WHRPP/ dated 16.05.2009

Steam Turbine Tools

Generator Space Heaters

BCL/CH/Elect./WHRPP/08/48 dated August 20, 2009.

No arrangement of installation of space heater is available in generator frame; also the Clarence between space heater and 6.3 KV terminals is too low. Generator Air Cooler Fins deshaped and clogged by grouting material under the supervision of erection supervisor. New Air Coolers should be arranged by Kawasaki. This time no spare I/Os with base available for any stand by arrangement.

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Generator Air Cooler Spare Inputs /Outputs in DCS Inlet Gas Dampers

BCL/Ch/Mech/WHRPP/ dated 19.08.2009

BCL/CH/Mech/WHRPP/ dated 06.08.2009 Kawasaki letter # 24164-AOE884 dated 06.08.2009. BCL/CH/Mech/WHRPP/ dated 17.08.2009

The Inlet Gas Dampers supplied were inferior quality and need replacement. Side stream filtration system is an essential part of cooling tower to avoid the foreign object to the cooling water system. So you are requested to provide the side stream filtration system. Filling material solution was arranged by us because supplied material was less in quantity. The price of purchased solution was Rs. 253,500/31114MV (Mixed Steam Piping Drain Valve) 31115MV (Temp. Regulating Valve for Gland Seal Desuperheater) 31123MV (Turbine Exhaust Port Water Spray Valve) Spindles for these valves were manufactured in our plant workshop with Stainless Steel material. The cost of these spindles are Rs. 50,000/-

Cooling Tower BCL/CH/Mech/WHRPP dated 27.05.09

Motorized Valves

BCL/CH/Mech/WHRPP dated 06.07.09

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Equipment
Booster Pump & Return Cooling Water Pipe Line

Reference
BCL/CH/Mech/WHRPP/ Dated 04.06.2009 & 18.08.2009

Description
The design/ drawings of return cooling water lines from 4 Nos boilers to T.G Buildings was not given. Also 02 Nos of booster pumps had to installed for return water piping. The cost of return piping and booster pumps will be born by Kawasaki. The Generator Rare Bearing Housing was inspected on 18.08.2009, the inside condition of the bearing housing was very poor. This also resulted in delay of oil flushing. It should be arranged to avoid future problems. Oil leakage observed from the Seal of Main Steam Stop Valve which needs to be rectified. The supplied gasket material is not in good condition for governing and control oil valves. You are requested please to replace these gaskets with good quality. Due to revisions at later stage, control & lube oil piping had to modify, hence flushing get delayed. These Piping should be seamless, whereas Kawasaki drawings show welded which cause oil flushing prolonged. Strainer element of circulation pump of PH#1 found damaged and there is no spare filter was supplied by manufacturer. You are requested please to arrange the same. Cooling Tower Water Treatment unit including Sulphuric Acid Storage Tank, Acid Transfer Pumps, Acid Dosing Pumps, pH and Conductivity Meter etc are the integral parts of Cooling Tower System. But this whole unit not supplied by Kawasaki. These material used during commissioning

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Oil flushing and rare bearing

BCL/CH/Mech/WHRPP/ dated 19.08.2009

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Main Steam Stop Valve

BCL/CH/Mech/WHRPP/ dated 19.08.09

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Control oil and Governing Valve

BCL/CH/Mech/WHRPP/ dated 19.08.09

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Revision of Piping drawings

BCL/CH/Mech/WHRPP/ dated 30.06.2009

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Control Oil and Lube Oil Piping

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Circulation Pump

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Cooling Tower Water Treatment

UPVC Pipeline 1/2 inch + Fitting 18 Teflon Pipe 10 mm, 12 mm (200 meters) 19 Cooling Tower Louvers -

These material used during commissioning

Cooling Tower Louvers are an integral part of cooling tower. It should be provided by Kawasaki. Standby Chemical Dosing pumps should be provided by Kawasaki for smooth operation of WHRPP. Gas Analyzer is an essential part of testing of Boilers hot gas. It should be provided by Kawasaki. piping arrangement of Steam Water and Feed Water Piping on Pipe Rack were changed due to this project got delayed.

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Standby Chemical Dosing Pumps for Cooling Tower and Boilers (08 Nos.) Gas Analyzers for testing of hot gases for Boilers AQC & PH

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U Bend in Feed Water and Steam Pipelines

Report# KPS-WHRB-SV-01-005 dated 07.05.2009

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Equipment

Reference

Description
Many times Air Vent and Drain Points were made as per instructions of Kawasaki Supervisors due to this commissioning of WHE got delayed. As claim raised by our contractor due to modifications because more days were consumed. Regarding the rubber expansion joint of cooling tower, cooling water pump Kawasaki given no design data. As it is a matching part of the pump, Kawasaki should had been specified proper specifications of the said joint. As we faced so much problem during purchasing, as there was no proper specifications mentioned in the drawing. The Following Instruments should be provided by Kawasaki to monitor the quality of steam, feed water and inlet gases for the WHEs:1. pH meter 2. Conductivity Meter 3. Dragger Tube Apparatus 4. Magnetic Stirrer 5. Digital Balance 6. Dissolve Oxygen Apparatus 7. Comparative Disk. 8. Lovibond Apparatus

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Feed Water Air Vent and Drain Points

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Flexible Joint of Cooling Water Pump

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Instruments for Testing