1 NASL PEER REVIEW OF COAL FIRED THERMAL POWER PEER REVIEW OF COAL FIRED THERMAL POWER STATIONS & BEST PRACTICES IN POWER GENERATION STATIONS & BEST PRACTICES IN POWER GENERATION Hosted by Hosted by Ministry of Power Govt. of India & NTPC Limited Ministry of Power Govt. of India & NTPC Limited February 2008 INDIA February 2008 INDIA RENOVATION & MODERNISATION OF THERMAL POWER PLANTS RENOVATION & MODERNISATION OF THERMAL POWER PLANTS PRESENTATION BY PRESENTATION BY NTPC NTPC - - ALSTOM POWER SERVICES PRIVATE LIMITED ALSTOM POWER SERVICES PRIVATE LIMITED by by K. V. Ramachandra Setty K. V. Ramachandra Setty AGM Business Development AGM Business Development
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NASLPEER REVIEW OF COAL FIRED THERMAL POWER PEER REVIEW OF COAL FIRED THERMAL POWER
STATIONS & BEST PRACTICES IN POWER GENERATIONSTATIONS & BEST PRACTICES IN POWER GENERATIONHosted byHosted by
Ministry of Power Govt. of India & NTPC LimitedMinistry of Power Govt. of India & NTPC LimitedFebruary 2008 INDIAFebruary 2008 INDIA
RENOVATION & MODERNISATION OF THERMAL POWER PLANTSRENOVATION & MODERNISATION OF THERMAL POWER PLANTSPRESENTATION BYPRESENTATION BY
NTPCNTPC--ALSTOM POWER SERVICES PRIVATE LIMITEDALSTOM POWER SERVICES PRIVATE LIMITED
bybyK. V. Ramachandra SettyK. V. Ramachandra SettyAGM Business Development AGM Business Development
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NASL
NASL – Introduction
NASL Promoters’ strengths
Retrofit Solutions
Role of CDM
R&M/Retrofit solution – case Studies
3
NASL
NTPCNASLNASL
50% 50%
NTPC-ALSTOM Power Services Private Ltd.
Original Equipment Designer (OED) & Manufacturer (OEM) with over 647 GW installations world wide. Complete R&D back up and Service Provider with global reach, • Engineering & manufacturing• Research & Development• IPPs / EPC• O&M Services and R&M Services
Largest Power Utility in the country with over 27 GW installed capacity• Engineering• Quality Assurance• Project Management• O&M-Rich Experience• Performance Optimization &
Turn around
Brief History Established in September 1999Exclusive JV for R&M business in India & SAARC region Strategic alliance to meet requirement of R&M in India.
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NASLOur range of services for power plant
Turnkey solutions• R&M of power plants to originally designed performance
• Re powering, Up grading beyond original design capacity
• Up grading to meet Environmental norms
• Lease, Rehabilitate,Operate, and Transfer projects (LROT)
Solutions for power plant packages• R&M of power plants islands –
Boiler,Turbines,Generators, C&I, Environmental systems,BOP etc.
• Retrofit of major power plant components.
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NASLOur range of services for power plant (2)
Services• Technical audit of power plants• Residual life assessment and plant life extension studies• Performance improvement and upgrading studies• Functional & performance tests of major equipment• Setting of plant management studies
Operations and Maintenance• R&M related O &M for agreed duration.• Development & implementation of O&M solutions• Training of O&M personals• Inspection & capital over hauling with repair / replacement
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NASLTurnkey R&M Plant Integrator Capability
Boiler
Steam Turbine
Generator
Condensing & Feed heating plant
Control system
Electrical & BOP
Coal & Ash handling
Electrostatic Precipitator
Coal Power Plant
Flue Gas
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NASLRetrofits - Executed / under execution
Output capacity enhancement (MW) of machine.
Torrent AEC Sabarmati ‘D’ station 1x110 MW unit uprating to 120 MW.
Improved Boiler Efficiency and High efficiency heat transfer surfaces.
Miscellaneous Works Ranchi 33 KV substation worksGRASIM Nagda MS Piping works
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NASL
NASL – Introduction
NASL Promoters’ strengths
Retrofit Solutions
Role of CDM
R&M / Retrofit solution – case Studies
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NASLNTPC – Operational Performance
Turn Around AbilityCapacity UtilizationUnchahar Plant PLF
18.0
95.6
0
20
40
60
80
100
120
Taken over in 1992 2006-07
%
Talcher Plant PLF
18.7
88.81
0
20
40
60
80
100
Taken over in 1995 2006-07
%
Tanda Plant PLF
14.9
91.14
0
20
40
60
80
100
Taken over in 2000 2006-07
%
67.3
80.484.38
69
81.8
86.2
69.9
81.1
86.54
72.2
83.6
88.7
72.7
84.41
88.79
74.3
87.51
91.2
73.6
87.5489.91
76.8
89.490.09
60
63
66
69
72
75
78
81
84
87
90
93
1999-2000
2000-2001
2001-2002
2002-2003
2003-2004
2004-2005
2005-2006
2006-07
All India PLF NTPC PLF NTPC AvF
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NASLALSTOM - Technology Range on Boiler
Combustion Engg.[ CE ] & Air Preheater Inc.[ API ] USA are both ALSTOM group Companies, with complete range of Upgrades for Boilers, Bowl Mills & Ljungstrom Rotary Air Preheaters on OEM / OED basis
20 - 50% efficiency improvement potential by midlife rehabilitation
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NASLNational Perspective Plan for R&M/LE
CEA has formulated a National Perspective Plan up to 2010-11 for Renovation & Modernisation (R&M) and Life Extension (LE) of thermal units of various Thermal Power Stations to be implemented during IX, X & XI Plans. Life extension of thermal units is to extend the economical life by another 15-20 years and to recapture/up-rate the capacities by implementing comprehensive R&M Plans
Elimination of restriction of turboset operational parametersElimination of restriction of turboset operational parameters
Lifetime extensionLifetime extension
Improvement of rotorImprovement of rotor--dynamic behaviourdynamic behaviour
Main purposes for modernisationMain purposes for modernisation
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NASLALSTOM Turbine Retrofit solutions for 120 MW
HP part retrofit includingprotection system and thermal limitations unit
R01R01 IP part retrofit includingprotection system and thermal limitations unit
R02R02 LP part retrofitND56 - impulseND63 - reactionND31 - reaction
R03R03
Condenser retrofitCB type
R04R04
List of developed packages List of developed packages -- RETROFITRETROFIT
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NASLALSTOM Turbine Retrofit solutions for 120 MW
M05M05 Modernisation of gland steam system
M04M04 HP & LP By-pass system
M07M07 Control of by-pass system (EHC)
M17M17 Condenser modernisation
M11M11 Modernisation of LP part outlet
M05M05 Modernisation of gland steam systemM05M05 Modernisation of
gland steam system
M08M08 Modernisationof HP part
M01M01 Oil system modernisation
M12M12 Modernisationof LP part inlet
M13M13 Cooling of LP casing
M05M05 Modernisation of gland steam system
M14M14 Holes for endoscope inspection
M16M16 Hydraulicprestress of casing bolts
M18M18 Forced cooling system
Modernisation of control system (EHC)
M03M03
Modernisation of IP part and HP-IP pedestals
M09M09 Modernisation of LP part blading system (impulse)
M10M10
Control systemmodernisation
Binary control andstarting automatics
M06M06
Control systemmodernisation
Measurements: sensorinstallation, signal trans-mission and display
M19M19Adaptation forprocess steam and
heat extractionM15M15
Modernisation ofIP-LP and LP-Gen
couplings for SHK typeM02M02
List of developed packages List of developed packages -- MODERNISATIONMODERNISATION
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NASLALSTOM Turbine Retrofit solutions for 120 MW
120 MW turbine after full shaft120 MW turbine after full shaft--line retrofitline retrofit
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NASLALSTOM Turbine Retrofit solutions for 120 MW
blading system with Baumann stageblading system with Baumann stage
thin stator blades with nonthin stator blades with non--aerodynamicaerodynamicprofiles and low efficiencyprofiles and low efficiency
no sealing of rotor blades at shroudsno sealing of rotor blades at shrouds
the stellited inlet edges of the rotorthe stellited inlet edges of the rotorblades of the two last stages are theblades of the two last stages are thesource of damages of condenser pipessource of damages of condenser pipes
Original LP part Original LP part (before LP retrofit)(before LP retrofit)