Fighting power crisis Mardan tech can help

on 03/04/2014

Pakistan produces 6,900 MW of hydro power. Huge potential lies unused all over. Mega dams like Bhasha and Dasu etc require billions of dollars and also years to complete. So what good can we get from our streams and rivers. But thanks to a small, modest workshop in Mardan, Pakistan can also generate many thousands more MW hydro power from small hydro plants installed all over the country, particularly in Khyber, Azad Kashmir and Gilgit.

The workshop in Mardan has made over 1,500 micro hydro power plants (MHHPs) to date. It consists of only basic workshop machines like lathe, drill and welding transformer. There are thousands of such workshops in Pakistan which can make turbines ranging from 10 to 300 KW. We can tackle the 4,500 MW power deficit quickly, if we make 15,000 more MHHPs with 300 KW turbines. Heavy Mechanical Complex Taxilla, Karachi Shipyard & Engineering Works, precision engineering in PIA and Mughalpura workshop of Pakistan Railways can also make typical mechanical components like shafts, rotors, casings, couplings and gears of much better quality than given by MHHPs.

Generators can be made in Gujrat by fan manufacturers and engineers can develop proper assembly lines with quality control measures to continuously produce MHHPs. This will also create thousands of jobs for unemployed youth, technicians and welders. Kalam, Swat is blessed with abundant waterfalls and fast flowing streams capable of producing power. We can use MHHP electricity to meet Kalam’s power needs and disconnect the city from WAPDA power. Power thus saved can be diverted to power starved industrial hubs in Faisalabad, Sialkot, Gujrat, Gujranwala, Lahore and Karachi.

Similar plants can be installed in other Swat cities like Bahrain, Madian Miandam, Mingora and Saidu Sharif etc. And same can be done in Azad Kashmir, Gilgit and Balitistan. And lower plains – Punjab and Sindh – too can benefit from Mardan technology. Power plants with 300 KW turbines (or with more/ less capacity) can also be installed along canals to service nearby towns/ villages sparing their power for bigger cities. Mardan technology can rid Pakistan of power shortage easily and quickly. It may be noted here that all ingredients needed to produce 4,500 MW are available locally; we just need to make a start.

Power house machinery Not made locally, why?

on 03/04/2014

Many engineers wonder why we (government and generating companies) do not use locally made power plants though local industry can produce machinery and equipment for small hydro power plants. Yes, local firms lack the ability to make big power plants on turnkey or EPC (engineering, procurement and construction) basis, but why is the country forced to rely on expensive foreign contracts even in small power stations.

The point was raised by two WAPDA engineers, who would not let us mention their names here. Apart from the present and past governments, the blame is also shared by gencos, they said. The government also faulted in another matter. It preferred importing big thermal plants and their parts/ components. As a result, local engineering firms could not acquire the know how to construct large power plants – thermal or hydro – on their own. 1994 Power Policy focused on thermal power and neglected hydro power.

1995 Hydro Power Policy and power policies of 1998 and 2002 did give local firms some incentives by way of tax concessions etc, to import hydro power plants machinery and equipment but no incentives were given for local manufacturing. In the meantime, all contracts for hydro projects by WAPDA and independent power producers were given to foreign contractors on EPC basis. According to the two senior engineers, the 2002 Power Policy also aimed at developing power projects able to generate at least 2,000 MW in joint ventures with foreign companies.

This should have helped local industry to assimilate requisite technology. But it did not yield expected results and local engineering industry failed to avail the opportunity on a large scale. Local units like Heavy Mechanical Complex (HMC) Taxilla, Karachi Shipyard and Engineering Works, Descon and Heavy Electrical Complex also at Taxilla are able to make hydro mechanical systems (gates, cranes, penstocks, inlet valves, etc), and hydro electro mechanical equipment (turbines, generators, transformers etc) and many other parts and equipments. Quite a few turbine runners, the most critical component, have been produced locally for replacing imported ones in mini and small power stations in Azad Kashmir (Kundal Shahi) and in Khyber (Dargai and Kurram Garhi). Some have also installed small hydro power plants.

HMC installed 40 turbo generators at 23 mini hydro stations in Gilgit Baltistan region, jointly with Switzerland’s Escher Wyss and UK’s Biwater. Local construction companies like Habib Rafiq and Al-Tariq Constructors can also construct small and medium hydro power plants. Descon mostly focuses on project and site management, installing and commissioning plants. NESPAK does feasibility studies, project designing, management and overseeing construction of hydro power projects. Government’s plan to strengthen HMC (cost Rs 21.54 billion) is under implementation presently.

The plan will enable HMC to develop power plants (hydro power) keeping in view projections made in National Energy Security Plan 2005-2030. Engineering Review was told that an important part of strategy is to get HMC to make small hydro projects on turnkey basis. 16 MW Naltar-III hydro project (cost Rs 1.37 b) would be constructed in Gilgit Baltistan. HMC and its consultant, Nespak, have already begun working at the site. Foreign consultants have pointed out hundreds of hydro power schemes with generation capacity of 5-50 MW, technically and economically feasible.

Nonetheless, there is still a need for an effective institutional and regulatory frame work to boost indigenization of production of machinery and equipment for hydro power generation. Starting with small hydro plants, the right environment will enable local engineering industry to do power projects on EPC basis. This would lead to import substitution, cut capital costs, and reduce power generation costs.

Pioneers in plastic pipes Zaka Sons leading since 1950

on 03/04/2014

There has been tremendous growth in the industrial, commercial, government projects, housing sector and public amenities in Pakistan. This growth needs pipelines to convey water and sewerage for infrastructure development works and to protect telecommunication and electrical cables. Zaka Sons (Pak Arab) was formed with the aim of producing full range of Plastic pipes & Fittings to meet these needs. We are engaged in pipe industry since 1950. As we have great experience in this field, we understand users’ needs of pipes and fittings.

We believe that every user should have the right to buy products having following features: 1- Durability 2- Easy installation 3- Easy repair and maintenance 4- Economical price 5- Long life To fulfill above features, we introduced complete system of PVC pipes and fittings first time in Pakistan in 1998 according to American standard ASTM 1785 and D-2241 SDR series for drinking water and sewerage lines respectively. We started their production in 2003. At that time people was used to deal with GI (galvanized iron) pipe and fittings for drinking water lines and asbestos pipes and cast iron pipes for sewerage lines.

Because of their unique features, use of PVC pipes and fittings grew very fast during the last decade. Another milestone of Zaka Sons (Pak Arab) is production of CPVC (Chlorinated Polyvinyl Chloride) pipes and fittings in year 2005. Our pipes could bear the flow of water up to 93° C, generally used for hot water supplies in industries where flow of acids takes place. Zaka Sons was then the only manufacturer in Pakistan manufacturing CPVC pipes and fittings. To cater the needs of very high pressure water lines able to deliver huge quantities of water, Zaka Sons (Pak Arab) launched PVC pipes of half inch dia to 24” diameter in 2008 according to British standard (BS-3505). These pipes replaced MS (Mild Steel) pipes which are difficult to install and repair and maintain.

Here flow of water may also be disturbed after some time because of rusting, corrosion and other issues. We are a trend setter in Pakistan. Our tremendous growth in PVC industry has motivated hundreds of other manufacturer to establish their factories all over Pakistan. And this initiative of Zaka Sons (Pak Arab) has increased employment level all over Pakistan. As we said we take initiative in many works as needed by customers. We have also started manufacturing of PE (Poly ethylene) pipes for huge water supply lines and we have capacity to manufacture pipes of 20 mm to 250 mm diameter. We are also working on production of large diameter PE corrugated pipes.

These will insha Allah be launched in 2014. We are also manufacturing pipes for chilled water supply and noise free pipes which will not allow external temperature to affect the internal temperature of water flow and also reduce the noise rising from the flow of water in sewerage system respectively. We are also working on a project of plasticizing irrigation canals. For this we will manufacture PVC sheets for irrigation system by which plenty of water will be saved from being absorbed by land during its flow. This unique project is one of the big projects of Zaka Sons. We have completed our feasibility report on this project, and will insha Allah start working on it in 2014.

Consultants & architects Many Pakistani consulting engineers and architects recommend our brand Pak Arab for their projects. The only reason for their priority is the confidence they have in our brand. We do not compromise in quality of our products. Quality of our end products is high because we use high quality raw material. One of the core raw materials – PVC resin – is purchased from Engro Polymer & Chemicals Ltd, the only manufacturer of PVC resin in Pakistan. For CPVC pipes and fittings we import CPVC compound. We have skilled labor and qualified staff as well as all imported machineries that add value to our brands.

The above facts prove our claim of being the market leader, trend setter and pioneers in plastic pipe industry in Pakistan. We believe that only quality of product is the base of success and we do not compromise in quality. That is why although, prices of our products are relatively higher than products of other brands, our sale graph is continuously moving upward. We will welcome any query from our honorable clients as well as all consulting engineers, architects and builders. And we request them all to always suggest quality Pak Arab products to their clients.

Why are fire equipments important? Increasing fires in Pakistan

on 03/04/2014

Firefighting is the act of extinguishing fires. A firefighter fights fires to prevent loss of life and destruction of property and environment. Firefighting needs highly technical skills. It requires professionals who have spent years in training in both general firefighting techniques and specialized areas of expertise. Pakistan is lucky to have Fakhri Brothers, Karachi coming in the business of marketing of fire handling and fire fighting hardware. Speaking to Engineering Review, Fakhri Brothers Chief Diwan A Fakhri told many things about fires and how to tackle them.

Increasing-fires-in-Pakistan-2There are four elements needed to start and sustain a fire and flame. These elements classified in the ‘fire tetrahedron’ are: 1. Reducing agent (fuel), 2. Heat, 3. Oxidizing agent (oxygen), 4. Chemical reaction. Prime purpose of a fire detection system is to provide an early warning of fire to a building’s occupants so that they may escape safely. Fire detectors are designed to detect one or more of the three characteristics of a fire. Smoke, Heat, Flame. No one type of detector is the most suitable for all applications, final choice depends on individual circumstances. Heat detectors operate by physical properties of: Expansion of metals. Melting of solids. Expansion of liquid or gases.

Changes in electrical characteristics of materials. Smoke detectors are of two general types. Ionization detectors. Optical beam type detectors Flame detectors are of two general types: Infra-red detectors. Ultra-violet detectors. Just how important are fire extinguishers to the general public? They are very important! , added Diwan Fakhri, but are often ignored, even by the fire community.

These overlooked life saving devices play a vital role in keeping us safe. It is time fire extinguishers get the respect they deserve. With all the benefits that fire extinguishers provide us, it is surprising that we don’t appreciate them much. In fact, the only time we think about them is during an emergency. The only time we hear about them is when they are unavailable, or when they are unable to do their job. To ensure that these silent heroes are ready when needed, it is crucial to keep monitoring them 24/7, just like all of the other, less utilized parts of our fire protection systems. Fire incidents in major cities of Pakistan, particularly in Karachi, Lahore and Islamabad are increasing day by day.

This proves intense situation about lack of awareness and implementation of safety standards. Ignoring safety standards has become our national character. It is particularly a crime when government departments disregard safety necessities while planning and executing multi story buildings. He noted that most of the fire incidents are blamed to ‘short circuiting’ to shift responsibility but there are some theories that suggest that these fires are ignited for different purposes by many arsonists resulting in loss of innocent and precious lives.

Therefore we should tell municipal establishments to make it mandatory for all tall buildings to have their own firefighting equipment, and train everyone on how to leave a building during a fire. They should also ensure that fire exits are provided before approving the building plan to avoid loss of innocent lives, when a fire occurs. According to a report it is not just textile mills or other industries across Pakistan where fires cause main damage. Poorly constructed buildings too collapse on workers or residents.

In general, the problem is the same that plagues all matters of governance in Pakistan – failure to enforce the law. Be it an industrial disaster, a road accident or an air crash – common denominator is lack of adequate safety checks, said Mr. Fakhri. Textile factories are particularly at risk due to the lethal combination of chemical dyes and stacks of cotton often stored next to each other, ensuring deadly results. Fire exits, as in the case of the factory in Karachi, exist only on paper. That along with congested construction of industrial zones blocks escape and multiplies death toll. Our cities have limited number of fire engines to serve the growing needs of sprawling cities.

Lahore fares a little better in terms of equipment, but is no better in terms of enforcement of standards or disaster management. Observers see a common pattern. Industrial standards are disregarded to minimize cost as inspectors are paid to look the other way. Small and potentially easily rectifiable problems are made worse by years of neglect. Mistakes are covered up only to be repeated a few months later. That is why many disasters such as the September 11, 2011 Karachi fire are on the rise in Pakistan.

Conversion to coal Will do good to power

on 03/04/2014

Government of Pakistan (GoP) seems to have decided to convert all existing and new power plants to Thar Coal versus earlier plans of using imported coal. This is in line with the agreement between Pakistan Electric Power Company (Pepco) and Sindh Engro Coal Mining Company (SECMC).

conversion-to-coal-will-do-good-to-power-2Pakistan’s present power generation mix with 40% power coming from imported furnace oil is not sustainable and is reflected in country’s inability to utilize 100% of its generation capacity due to paucity of funds for buying furnace oil. Our furnace oil based energy tariff has gone up from 1.8 cents in mid 90s to over 15 cents at present. Thar has enormous energy potential. SECMC’s Thar Block 2 – only 1% of all Thar coal, can keep producing 4,000 MW for next 50 years. Total foreign exchange savings for 4,000 MW of Thar coal based power plants is estimated at over US $50bn for project life.

SECMC has studied Thar coal to confirm its technical, commercial and environmental viability. Government approvals have been obtained and mining is likely to start soon. G/o Sindh is working to complete the infrastructure. Mining time matches well with power generation project at Jamshoro. Genco is planning to convert Jamshoro’s oil based power plants, which will not only yield cheaper power, but also improve existing plants’ efficiency and make it a model for other Gencos and independent power producers (IPPs).

After Jamshoro, the Genco will also convert its Muzaffargarh units to Thar coal. This decision will unlock Thar’s potential and will enable GoP to meet country’s power requirements and produce other chemicals including petroleum products and urea. This will help GoP save billions of dollars spent on oil imports and thus have funds for developing industrial sector and the well being of people.