Renovation & Modernisation of Thermal Power Stations

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Why R&M is necessary?

At the time of independence power generation in India was only 1350 MW comprising 850MW thermal and 500MW of Hydro units. To-day installed capacity is around 1.35 lakh MW
Growth has been through phases and each phase has brought some change in perception and technology to keep pace with development.
700

Phases of Power Plants:

Plant Load Factor of Thermal Plants is 65%, older plants are pulling down the overall performance

600 500 400 300 200 100 0

200 250 500 50 62.5 140

3rd & 4th

200 500 660

Unit Capacity in MW

30 50 60
1st & 2nd

60 120 210

5-year plan

5th & 6th

7th & 8th

9th

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Factors affecting performance of Ageing Power Stations

Components operating at high temperature and pressure like Boiler pressure parts, Turbine rotors, etc are subject to Creep which, if unchecked, can take the equipment to an unsafe zone of operation & leading to failure of the component & the equipment. Ageing & natural wear & tear of the Power Plant components. Changes of inputs & outputs within the battery limits of the Plant that may have taken place over a prolonged period of operation, such as deterioration of coal & water quality & power delivery requirements imposed by the regulatory authorities.

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Factors affecting performance of Ageing Power Stations

To comply with fast changing standards.

environmental / statutory of

Technological obsolescence especially in the area Instrumentation, which has a high electronic content.

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Management of Aging Power Plant

Performance of the plant both output & efficiency decreases with age. Apart from routine Maintenance there is a need to carry out Renovation & Modernisation (R&M) as well as Life Extension (LE) activities in an Ageing Power Plant. The Main Aim of R&M and LE is to improve the performance & bring it to up to the level of contemporary Units.

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NEED OF R&M
Simulation of Unit efficiency with ageing
38,0 %

37,0%

36%

35%

Gross Unit
34,0% 33,0%

Revision after each year(14 Days)

32,0%

Revision after 8 Years (70 Days)

Revision after 4 Years (49 Days)

31,0% 0

Revision after 12 Years (49 Days)

10

12

14

16

18

20

22

24 2000

26

Years after installation of unit Unit

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R&M POTENTIAL:-

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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 substantially improve generation , environment impact and efficiency .
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Current Status of R&M In India

1. Utilities generally take up R&M when the PLF deteriorates to extremely low level Or / and 2. The capacity has been severely de-rated Or / and 3. The plant is not able to meet the environmental & safety norms When the Units performance became unviable, Utilities resort to R&M as a substitute for O&M.

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Current Status of R&M In India

R&M in India is focused mainly on Restoration addressing: Availability improvement Regaining lost Capacity Obsolescence Life extension Environmental & safety issues.

No SPECIAL EMPHASIS is given to technology upgrades / efficiency improvements

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Current Status of R&M In India The current R&M Policy does not incentivise technology upgrades! R&M is generally allowed after the Unit has completed 100,000 hours or 25 years, under the following broad heads: Improvement in availability Life Extension Obsolescence Environmental requirement Statutory compliance
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Current Status of R&M In India

There is no policy or incentive for projects targeting:

Efficiency / Capacity improvement e.g. by uprating process parameters, redesign of boiler, improved design of turbine blades. Fuel switch-over / substitution e.g. retrofitting for Naptha firing, bio-mass co-firing Earning of CER (CDM) e.g. green house gas reduction
However, there have been a few Exemplary R&M projects like Kothagudam etc. where technology upgrades were undertaken. May 24, 2012 PMI Revision 00

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Current Status of R&M In India Kothagudam TPS- Unit 8 (110 MW)

LE carried out from August 03 to March 04 Expenditure incurred Rs. 90 crores
Sl.No. Parameter Performance Performance before LE-2002- after LE 2004-05 03 103 68 84 30 2862 120 84 93 36 2368 8
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1 2 3. 4. 5. 6.
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Maximum output (MW) PLF % Availability % Unit Efficiency % Unit Heat Rate kcl/Kwh

Aux. Power consumption % 10.7

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International Best Practices in R&M

Internationally, R&M program are focused on leveraging technological developments in various fields to upgrade candidate plants & bring them at par with contemporary machines with special emphasis on: 1. Upgradation of Process parameters to enhance efficiencies and reduce Cost of Generation 2. Addition of Green Power- Uprating 3. Re-powering with GT topping cycle 4. Compliance to latest environmental & statutory regulations CO2 reduction projects 5. Fuel Switchover provision for dual fuel firing 6. Life Extension

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High End Technological Solutions for R&M

Enhancement of steam parameters
Major Changes Capacity Addition Cost

Case Study: 210/200 MW Unit: Pressure Increase

Equipment Type Upgradation

For LMZ Boiler: Water Circuit, Drum, 14.5 MW SG = Rs. 105 Cr Parameter Design Economizer, Super Heaters & / UNIT @ Rs. 0.5Cr/MW Upgraded To Steam Boiler Structure Etc. TG = RS.35 Cr 170 ATA / O Turbine Turbine: HP Turbine, LP Turbine, Total = Rs.140Cr 540 C / 540 O C (130 ATA / Valves, BFP, FW Heaters, FRS 530 OC / Etc. O 530 C ) Power Cycle Piping: Power Cycle Piping, Valves Etc. For KWU Boiler: Boiler Water Circuit, 7 MW / Design Drum, Economizer, Super UNIT Steam Heaters & Boiler Structure Etc. Turbine Turbine: HP & IP Turbine, BFP, (150 ATA / FW Heaters, FRS Etc. 537 OC / Power Cycle Piping: Power May 24, 537 OC )2012 Cycle Piping, Valves Etc. PMI Revision 00 SG = RS.105 Cr Parameter @ RS.0.5Cr/MW Upgraded To 170 ATA / TG = RS.15Cr 540 OC / 540 Total = Rs.120Cr O C
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High End Technological Solutions for R&M Enhancement of steam parameters

Case Study: 210/200 MW Unit: Temperature Increase
Equipment Type Major Changes Capacity Approx. Cost Addition SG = Rs.30 Cr TG = Rs.50 Cr Total = RS.80 Cr Upgradation Parameter Upgraded To 130 ATA / 560 OC / 560 OC

For LMZ BOILER: Super Heaters, 16.5 MW / Design Reheaters & Boiler UNIT Steam Structure Etc. Turbine TURBINE: HP Turbine, IP (130 ATA / & LP Turbine, Valves Etc. 530 OC / POWER CYCLE PIPING: O 530 C ) MS, HRH, Valves Etc. For KWU BOILER: Super Heaters, 12 MW / Design Reheaters & Boiler UNIT Steam Structure Etc. Turbine TURBINE: HP Turbine & IP (150 ATA / Turbine, Valves Etc. 537 OC / POWER CYCLE PIPING: O 537 C ) MS, HRH, Valves Etc.
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SG = Rs.30 Cr Parameter TG = Rs.50 Cr Upgraded To 150 O / Total= RS.80 Cr ATA O 560 C / 560 C

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High End Technological Solutions for R&M Enhancement of steam turbine capability
Case Study: 210/200 MW Unit:
Design Type Design Present Refurbishe Replacemen Capacity Condition d t Proposed Addition Condition HEAT HEAT RATE HPT WITH 5.5 MW RATE - 2038 KCAL REACTION (FROM 2142 KCAL / / KWHR BLADING DESIGN) KWHR OUTPUT- LPT OUTPUT- 215.5 MW REMOVING 204 MW BAUMNN STAGE

LMZ HEAT DESIGN RATE2062 KCAL / KWHR OUTPUT210 MW

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International Best Practices in R&M

Addition of Green Power by E.On, Germany

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International Best Practices in R&M

Performance Improvement of 500 MW units of Boxberg Power Station after R&M

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High End Technological Solutions for R&M

Gas Turbine Topping Cycle

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International Best Practices in R&M

Re-powering Experiences in Japan

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High End Technological Solutions for R&M

Supercritical Retrofit Technical Highlights:

Boiler Replacement of Pressure Parts, Main Steam Piping & Safety Valves Retention of the Structures & balance of plant Provision for biomass co-firing (optional) Turbine Replacement of HP & IP Turbine Modules, or introduction of Topup Turbine to reduce pressure & temperature before entry to the existing Turbine Introduction of additional Booster Pump & Feed Water Heater Retention of BFPs and feed water heaters Total downtime of the unit is approximately 6 months

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High End Technological Solutions for R&M

Supercritical Retrofit Likely Benefits:

About 7% increase in efficiency Upto 20% reduction in fuel consumption possible Lower fuel consumption reduces emissions CO2, NOx, SOx & particulates Increased margins on balance of plant Other operational advantages because of once through technology Can be developed as a CDM project to earn CER Service life extension of 20 years

Approximate investment: Rs.1.5 Crore / MW

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R&M Business Plan of NTPC

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The Changing Business Scenario

EverIncreasing Cost of Fuel

Competition From New Generation of Plants (Cost of Generation)

Probable New Environmenta l Regulations like NOx

Fuel Security (Gas / Naptha)

Compliance with Kyoto Protocol / G8 Resolution

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R&M Business Plan of NTPC

DESTINATION Competitive cost of generation in NTPCs ageing fleet and achievement of targeted performance level in a safe and reliable manner. Strategies Planned and time bound R&M on a Project mode to extend life, overcome obsolescence and bring the ageing Units close to that of contemporary units through Cost-Effective Technology Upgrades.

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22 units Age Profile of NTPC Stations have Age Of Units

0 to 25,000

crossed 150,000 hours

No. of Units Thermal

7 4 9 8 24 15 7 74

Gas Turbines
0 2 2 9 9 0 0 22

Comb. Cycle Steam Turbines

0 1 1 4 4 0 0 10

Total
7 7 12 21 37 15 7 106
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25,000 to 50,000 50,000 to 75,000 75,000 to 1,00,000 100,000 to 1,50,000 1,50,000 to 2,00,000 More than 2,00,000 Total
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59 units of NTPC has crossed 100,000 hours of operation

Target
Competitive COG in NTPCs ageing fleet and achievement of targeted performance level 2nd intervention: 200,000 / 100,000 hrs of operation for coal/gas : Target efficiency improvement, reduced APC, uprating etc.

1st intervention: 100,000 hrs of operation: Address ageing, technological obsolescence, environmental regulations

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1st Intervention: After 100.000 hours The first cycle of R&M in NTPC stations are generally targeted towards: 1:1 Replacement to take care of ageing; e.g. HP & LP heaters, condenser tubes, economiser coils, BFP cartridge etc. To cater to the issue of obsolescence; e.g. DAS, FSSS, recorders etc. To comply with environmental & safety regulations; e.g. augmentation of ESP, upgradation of ESP controllers etc. To extend life; e.g. replacement of battery banks, motor rewinding, turbine diaphragms etc.

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Power Plants Undergoing 1st Phase R&M

Sl.N o. 1 2 3 4 5 6 7 8 9 Station Capacity Approved Cost Under R&M (Rs. Cr) MW 2000 241.96 2100 144.45 2100 94.00 1260 131.00 600 102.83 420 78.78 1000 102.87 460 689.82 440 515.50

Singrauli Korba Ramagundam Vindhyachal Farakka (200) Unchahar Rihand Talcher (T) Tanda

*Talcher (T) & Tanda being old taken over stations, the magnitude of R&M works has been high
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2nd Intervention: Mega R&M. Mega R&M

There have been steep breakthroughs in Power plant technology which have brought considerable enhancement in efficiencies & reliability. Therefore, for old plant vintages 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, reliability, etc. Typically, such mega R&M may include uprating, repowering, 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.
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Major Targets for Mega-R&M

Achievement of competitive cost of generation
Efficiency Improvement Reduction Of Auxiliary Power Consumption Availability Of More Than 90% On Sustained Basis Increasing Mean Time between Overhauls O&M Cost Reduction Zero Forced Outage By Design

Enhancement Of Unit Capacity Life Extension For Another 20 Years for coal / 10 years for gas stations. Making the Plant Future Ready. Addressing Present & Future Environmental Concerns Carbon Tax. Earning CDM benefits

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Up- coming Mega-R&M up to 2011-12

Sl.No. Station Station Capacity (MW) 5 X 200 3 X 200 3 X 200 2 X210 413 652 645 648 817
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1 2 3 4 5 5 6 7 8
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Singrauli (Mega at 200,000 Hrs) Korba (Mega at 200,000 Hrs) Ramagundam (Mega at 200,000 Hrs) Badarpur (Mega at 200,000 Hrs) Anta Gas Auriya Gas Kawas Gas Gandhar Gas Dadri Gas

THANK YOU

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