NTPC.pps

GENERATIONRENOVATION &

MODERNISATION

R. K. JainR. K. JainDirector (Technical)Director (Technical)

NTPC LimitedNTPC Limited

India Electricity – 2006 India Electricity – 2006 1111th th May, 2006May, 2006

INDIAN POWER SECTOR•Present Status:Present Status:

– Per capita consumption about 600 units per annumPer capita consumption about 600 units per annum– Installed Capacity 1,24,287 MW (April, 2006)Installed Capacity 1,24,287 MW (April, 2006)

•India’s Projected Growth is 7-8 % of GDP – Projected power requirement India’s Projected Growth is 7-8 % of GDP – Projected power requirement by year 2012:by year 2012:

– Per capita consumption 1000 units per annumPer capita consumption 1000 units per annum– Installed capacity over 2,00,000 MWInstalled capacity over 2,00,000 MW

•Projected power requirement by year 2032:Projected power requirement by year 2032:– Per capita consumption about 3000 units per annumPer capita consumption about 3000 units per annum– Installed capacity about 6,00,000 to 7,00,000 MWInstalled capacity about 6,00,000 to 7,00,000 MW

However government of India is targeting double digit growth rate However government of India is targeting double digit growth rate (10%) and hence projections are likely to get revised upwards. The (10%) and hence projections are likely to get revised upwards. The above necessitates :above necessitates :

• Sustainable Large Capacity Addition Program at higher Sustainable Large Capacity Addition Program at higher efficiencyefficiency

• Upgrading fleet of Old Power Stations which are inefficient and Upgrading fleet of Old Power Stations which are inefficient and have poor availabilityhave poor availability

R&M and Re-powering•India has large number of old plants which are India has large number of old plants which are inefficient and running below design capacityinefficient and running below design capacity•Operating pressure and temperature of these Operating pressure and temperature of these old plants are lower and there is no reheating old plants are lower and there is no reheating in some of the unitsin some of the units•Fuel available at present is different from Fuel available at present is different from what plant were designed forwhat plant were designed for•Some of the equipments have degradedSome of the equipments have degraded•Re-powering of these plant can quickly Re-powering of these plant can quickly increase the power generation at relatively increase the power generation at relatively lower cost to consumerlower cost to consumer•Re-powering can increase the cycle efficiency Re-powering can increase the cycle efficiency and hence reduce emission of greenhouse and hence reduce emission of greenhouse gases and pollutantsgases and pollutants

R&M and Re-powering•R&M will involve up gradation of milling system, APH, ESP, R&M will involve up gradation of milling system, APH, ESP, firing system etc and refurbishment of turbine, condenser, firing system etc and refurbishment of turbine, condenser, pressure parts, fans etc. pressure parts, fans etc. •Re-powering may involve following changes in plant design Re-powering may involve following changes in plant design ::

• Adoption of higher steam parameters Adoption of higher steam parameters • Introduction of topping cycle, old turbine may be Introduction of topping cycle, old turbine may be

retained in bottoming cycle.retained in bottoming cycle.• Bottoming turbine cycle efficiency improvement by Bottoming turbine cycle efficiency improvement by

adoption of high efficiency blade designadoption of high efficiency blade design

Thus, Renovation & Modernization of old existing units is an important tool for capacity enhancement, life extension and improvement in availability, reliability & efficiency. Re-powering is challenging from technology as well as engineering point of view and offers huge potential for capacity addition augmentation.

RATIONALE FOR R&M

•New Plants –costly.

•Longer gestation period of new plant.

•Limited availability of new site.

•Old plants can be renovated and Modernised at lower costs and life extension achieved.

•Availability and efficiency can be improved.

•Minimum environmental impact and R&R problems for additional capacity.

•R&M is an efficiency improvement tool and can improve generation by 30%, environment impact by 47% and efficiency by 23% (Source: TERI)

APPROACH TO R&M

Depends on •Age of the plant, its existing condition and generic problems in its inherited design•Operational History & Problems being faced to run the plant•Major modifications carried out from the original design condition•Type of fuel & its cost •To cater to changes in the input / output of the plant – coal, water, power evacuation•Source of availability of inputs for future •Cost of generation•Cost of Technology

WHY R&M?

•To restore the original rated parameters by one to one replacements

•Improve performance by introduction of new technology.

•To upgrade the units to comply with fast changing Environmental / statutory standards / guidelines.

•To cater to technological obsolescence.

•Mega R&M – Technology Upgrades. This would aim at both leveraging the technological advancements, as well as driving down the Cost Of Generation, while factoring in the emerging business scenario to meet the market determined price for power

Technological Options Clean Coal Technology To reduce SOX ,NOX & CO2 Emissions Energy extraction from coal

1.PC fired 2.Fluidized bed combustion-Reduces Sox, NOx

Emissions3.Indirect combustion through coal gasification

Sub Critical Steam Parameters To Supercritical Parameters Increase in Pressure and temperature to like 250bar and

565 deg C Re-powering Technology

For better efficiency, pollution control and less cost besides life extension

Technological Options

BOILER & AUXILIARIESReplacement/Augmentation Of Pressure Parts.Retrofitting/ Modifications Air Pre Heater.Augmentation Of Milling System.Provision Of Flame Scanners, ignitors.Renovation of Draft System.Retrofitting Of ESPs.


TG & AUXILIARIES Replacement of turbine blades with latest design. Modernization of condensors by change in type

and material of tubes, augmenting with tube cleaning mechanism.

Modernisation of power cycle equipments with more efficient pumps and improved Regenerative Heaters.

Modification of air evacuation system with Vacuum pumps.


Gas TurbineInlet Air Cooling system.Online Compressor Washing SystemDry Low NOx Burners.Improved metallurgy for improved life of Hot

Gas Path Components Improved efficiencyThermal Barrier Coatings of Blades & Vanes.Improved major inspection intervals.Multi Fuel Firing


ELECTRICAL Up gradation of insulation of rotating machines from Class

B to Class F. Up gradation of protection systems including diagnostic

tools. Replacement of HV , EHV circuit breakers with SF6 / Vacuum

breakers for stability and to overcome obsolescence. C&I

Modernization of obsolete C&I systems with State- of-Art-Technology.

MISCELLANEOUS Augmentation Of CHP Augmentation Of Water Treatment Plants Introduction of Ash Water Re-circulation System.

EXPECTED BENEFITS

Increase in generation with improved performance

Increase in safety, reliability, availability and operational flexibility

Recapturing and/ or enhancing of unit capacity

Extension of economic useful life by 15-20 years at comparatively lower capital cost

Benefit by way of additional life

Possibility of reducing cost of generation

R&M with Efficiency Increase

Fuel consumptionper kWh

0 20 40 years

Rehabilitation Rehabilitationw/o efficiency improvement

Rehabilitationwith efficiency improvement

Increased power output resulting from efficiency increase isfree of fuel cost, free of operational cost and free of emissions.

Mega R&M

Opting for higher steam pressure & temperatures due to the availability of better material suited for these parameters improves heat rate and reliability

Therefore, for old plant it may be worthwhile to consider mega R&M schemes to bring these plants up to the contemporary state of the art plants in terms of efficiency and availability

Typically, such mega R&M may include up-rating, re-powering, higher process parameters resulting in enhanced efficiency, improved operational safety, reliability, advanced diagnostics etc.

Mega R&M typically consists of replacements of major equipment / systems of the plant at marginally higher cost & longer shutdowns of the Units are inherent.

Plans for R&M•The importance of R&M was recognised by The importance of R&M was recognised by the Government of India way back in 1984 the Government of India way back in 1984 when PHASE-I R&M Programme for 34 thermal when PHASE-I R&M Programme for 34 thermal power stations in the country was launched by power stations in the country was launched by the Central Electricity Authority as a Centrally the Central Electricity Authority as a Centrally Sponsored Scheme Sponsored Scheme

•The Government of India has now accorded The Government of India has now accorded high priority to R&M and Life Extension (LE) of high priority to R&M and Life Extension (LE) of old existing power plants. The funds in the old existing power plants. The funds in the form of loan assistance at concessional form of loan assistance at concessional interest rates are being provided by the interest rates are being provided by the Government through Power Finance Government through Power Finance Corporation (PFC) for R&M worksCorporation (PFC) for R&M works

LIFE EXTENSION PROGRAMME DURING 10TH PLAN

S. No. PARTICULARS

i) Number of thermal power stations 32

ii) Number of thermal units 106

iii) Estimated Cost Rs. 9200 crores

iv) Total Capacity involved 10,413 MW

v) Average PLF of the units before LE programme 49%

vi) Anticipated PLF after completion. 75%

vii) Anticipated additional generation/ annum 23700 MU

viii) Capacity expected after completion of LE works 10,747 MW

S.No. PARTICULARS



iii) Estimated Cost Rs.977 crores

iv) Total Capacity involved 14270 MW

R&M PROGRAMME DURING 10TH PLAN

S.No. PARTICULARS



iii) Estimated Cost Rs.977 crores

iv) Total Capacity involved 14270 MW

11TH PLAN PROGRAMME

Sl. No. Particulars LEP R&M

i) Number of thermal power stations 18 12

ii) Number of thermal units 34 31

iii) Estimated Cost Rs.6000 Crores Rs. 751 Crores

iv) Total capacity involved 6,000 MW 7,090 MW

Thermal Units for R&M in 10th and 11th Plan

0

29

20

5

10

15

20

25

30

No

of u

nits

110 MW andBelow

200 & 210 MW 500MW

Unit size

No of units for R&M in 11th Plan

Total M W for R&M in 11th Plan

0

6090

1000

110 MW and Below

200 & 210 MW

500MW

4

43

10

05

1015202530354045

No

of u

nits

110 MW andBelow

200 & 210 MW 500MW

Unit size

No of units for R&M in 10th Plan

Total M W for R&M in 10th Plan

360

8910

5000110 MW and Below

200 & 210 MW

500MW

reduced fuel consumption

operation free of restrictions

POWER PLANT R&M OBJECTIVES

environmental control updating

availability improvement

RESULTS

increased power output

reduced power generation cost

efficiency upgrading

increased electrical output

emissions within new norms

life extension

improved reliability

plusCDM BENEFITS

Challenges in R&M

•Limited Agencies for R&M Limited Agencies for R&M implementation in the country.implementation in the country.

•Prohibitive cost of New Technologies Prohibitive cost of New Technologies impediment for introduction on wider impediment for introduction on wider scale.scale.

•Unfavorable cost benefit analysis.Unfavorable cost benefit analysis.

•R&M activity to be linked with R&M activity to be linked with planned shut down.planned shut down.

CDM Potential in R&M

Offers substantial CDM benefits through Offers substantial CDM benefits through reduction/substitution of coal by:reduction/substitution of coal by:

Enhancement of efficiency by upgrading cycle parameters

Co-firing of biomass with coal in coal fired furnaces

R&M SCENARIO IN NTPC•Department formed in 1995 to Cater to R&M of its Department formed in 1995 to Cater to R&M of its own Stationsown Stations•R&M is identified as Key Thrust Area as the many R&M is identified as Key Thrust Area as the many NTPC plants are crossing 1,00,000 operating hoursNTPC plants are crossing 1,00,000 operating hours•R&M of power plants of 10,799 MW capacity has R&M of power plants of 10,799 MW capacity has been undertaken / in progressbeen undertaken / in progress•R&M of power plants of 7,642 MW capacity is R&M of power plants of 7,642 MW capacity is under planningunder planning•The cost of R&M may be up to Rs. 1.5 crores per The cost of R&M may be up to Rs. 1.5 crores per MW depending on the life and condition of the plant.MW depending on the life and condition of the plant.

NTPC R&M Project under CDM:NTPC R&M Project under CDM:NTPC has taken up Badarpur R&M project under CDMPIN is already prepared

NTPC’s EXPERIENCE SO FARNTPC Talcher TPS (4x60+ 2x110 MW)NTPC Talcher TPS (4x60+ 2x110 MW)R&M ScopeR&M Scope•Extensive RLA and R&M of SG and TGExtensive RLA and R&M of SG and TG•Retrofitting of existing ESP and addition of new fieldsRetrofitting of existing ESP and addition of new fields•Replacement of Static Excitation System, Power & Control cables, Replacement of Static Excitation System, Power & Control cables, replacement/ Retrofit of HT/LT Switchgear ,Augmentation of H2 plantreplacement/ Retrofit of HT/LT Switchgear ,Augmentation of H2 plant•Renovation of Cooling TowersRenovation of Cooling Towers•Augmentation of Ash HandlingAugmentation of Ash Handling•New AWRS New AWRS •New Railway Siding inside the plantNew Railway Siding inside the plant•New Coal Handling Plant New Coal Handling Plant •R&M of SwitchyardR&M of SwitchyardR&M cost - Rs 1.50 Crs/MWR&M cost - Rs 1.50 Crs/MWPLF is around 88% as against 19% during takeover in Jun PLF is around 88% as against 19% during takeover in Jun 1995.1995.

NTPC’s EXPERIENCE SO FARNTPC Tanda TPS (4x110 MW)NTPC Tanda TPS (4x110 MW)R&M ScopeR&M Scope•Extensive RLA and R&M of SG and TGExtensive RLA and R&M of SG and TG• ESP RenovationESP Renovation•Replacement of 6.6 KV & 11 KV Switch gearReplacement of 6.6 KV & 11 KV Switch gear•Replacement of LT Switch GearReplacement of LT Switch Gear•Renovation of Fire Fighting systemRenovation of Fire Fighting system•New Stacker ReclaimerNew Stacker Reclaimer•Additional DM StreamAdditional DM Stream•New DDCMIS for Units 1&2 and Upgradation of DAS for Unit 4New DDCMIS for Units 1&2 and Upgradation of DAS for Unit 4•Clarification of CW Make up water system & Effluent Treatment plant Clarification of CW Make up water system & Effluent Treatment plant

R&M cost - Rs 1.17 Crs/MWR&M cost - Rs 1.17 Crs/MWPLF is around 85% as against 21% at the time of PLF is around 85% as against 21% at the time of takeover in Jan 2000takeover in Jan 2000

EXPERIENCE OF TECHNOLOGY UPGRADES•The 60 MW boilers at Talcher TPS have been redesigned The 60 MW boilers at Talcher TPS have been redesigned taking into account the current coal characteristics. Milling taking into account the current coal characteristics. Milling system have been upgraded. system have been upgraded. •The 110 MW Units at Kothagudam have been upgraded to The 110 MW Units at Kothagudam have been upgraded to 120 MW by PPIL with a Turbine HR less than 2000 120 MW by PPIL with a Turbine HR less than 2000 Kcal/Kwh.Kcal/Kwh. •110 MW Unit at AECO, Sabarmati has been upgraded to 110 MW Unit at AECO, Sabarmati has been upgraded to 120 MW by NASL with Turbine HR improvement of 120 MW by NASL with Turbine HR improvement of approximately 140 Kcal/Kwh.approximately 140 Kcal/Kwh.

•No. of 200/210 MW LMZ Units have been upgraded to 225 No. of 200/210 MW LMZ Units have been upgraded to 225 MW in other countries with considerable improvement in MW in other countries with considerable improvement in Heat rate. These are now being planned in India.Heat rate. These are now being planned in India.

Government’s Initiatives

Partnership in Excellence Partnership in Excellence CEA has identified 26 stations which are operating at a PLF of less than 40%. These stations would have a “Partnership in Excellence” with better performing utilities, so as to achieve an improvement in performance in the shortest possible time. Subsidized funds would be made available for this programme through PFC / REC. The target is to achieve a PLF of 60% in two years time.

Role of NTPCRole of NTPCNTPC has been entrusted the responsibility of 14 stations out of the identified 26. Site office has been opened at all the 14 stations and experts have been posted at all sites. The teams will aim to implement the customized O&M systems and will carry out one cycle of overhauls.

Government’s Initiatives

R&M of SEB stationsR&M of SEB stationsThe 10th Plan envisaged R&M of an installed capacity of 11,055 MW with a target of achieving 75-80% PLF and 20 years of Life Extension.

Role of NTPCRole of NTPC NTPC has taken up consultancy services for a few of these stations.

NTPC initially took up four power stations for R&M/LE (Total – 1332.5 MW). Subsequently another six stations (1512.5 MW) were taken up for R&M / Life Extension (LE) / Re-commissioning / Residual Life Assessment (RLA) Funds being provided by PFC / REC

APDP-R&M

Highlights of AchievementHighlights of AchievementProj. PLF

bef.PLFaft.

% imp.in PLF

SOC bef.

SOCaft.

% imp.in SOC

APCbef.

APCaft.

% imp.in APC

CTPS3x140MW

23.97 72.66 203.13 28.60 0.80 97.20 22.30 11.43 48.75

DTPS1x140MW

36.78 65.41 77.84 5.28 1.88 64.40 12.59 9.88 21.52

GTPS2x210MW

45.00 84.00 93.19 3.00 0.70 76.67 12.40 10.23 17.50

International Best Practices in R&M

Internationally, R&M program are focused on Internationally, R&M program are focused on leveraging technological developments in various leveraging technological developments in various fields to upgrade candidate plants & bring them at fields to upgrade candidate plants & bring them at par with contemporary machinespar with contemporary machines

International best practices range from one-to-one International best practices range from one-to-one replacements to Mega R&Mreplacements to Mega R&M

In USA and other advanced countries utilities have In USA and other advanced countries utilities have largely gone for Mega R&M because of the age of largely gone for Mega R&M because of the age of their units & rapid changes in their business their units & rapid changes in their business environment which required them to remain environment which required them to remain competitive and efficientcompetitive and efficient

Hence, Mega R&M schemes such as up-gradation Hence, Mega R&M schemes such as up-gradation of process parameters, improved balding in of process parameters, improved balding in turbines, Re-powering, & even installing machines turbines, Re-powering, & even installing machines of higher capacity on the same footprint were of higher capacity on the same footprint were adoptedadopted

Case Study of a German Power Plant

Improvement of efficiency and environmental conditions by retrofitting the units

This was mainly achieved due to using low NOx burners in boiler, redesigning of LP turbine and cooling tower modernisation

The emission levels of the units was reduced drastically due to use of low NOx burners, installing Flue Gas Desulfurification plant and optimisation of operation of ESP

Flue gas discharge through cooling towers, automatic concrete cutter for existing chimneys

Conclusion

Implementation of the R&M Schemes has Implementation of the R&M Schemes has benefited the stations by way ofbenefited the stations by way of

•Overcoming Technological obsolescence.Overcoming Technological obsolescence.•Low cost capacity additionLow cost capacity addition•Extending the life of equipment / Extending the life of equipment / components.components.•Complying with Statutory and Environmental Complying with Statutory and Environmental NormsNorms•Sustaining availability and improved Sustaining availability and improved performance performance

There is huge potential in India for R&M There is huge potential in India for R&M activities because of large number of old plants activities because of large number of old plants which are inefficient and running below design which are inefficient and running below design capacitycapacityR&M to be planned in advance before major R&M to be planned in advance before major deterioration or breakdown of unitdeterioration or breakdown of unitUrgent need to enhance manufacturing Urgent need to enhance manufacturing capacity to handle load of R&M / Creation of new capacity to handle load of R&M / Creation of new manufacturing basemanufacturing base

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