Gen. Dept., GEB,HO,Vadoda ra 1 Presentation To The Hon.CERC on performance of GEB Managed Thermal Power Stations New Delhi Nov.11,2003
Feb 04, 2016
Gen. Dept., GEB,HO,Vadodara 1
Presentation To
The Hon.CERCon
performance of
GEB Managed Thermal Power Stations
New Delhi Nov.11,2003
Gen. Dept., GEB,HO,Vadodara 2
Introduction GEB Established under Section 5 of
E(S) Act 1948 in 1960 Present network
Available Generation(MW)
8576
Transmission network(CKM)
30862
Distribution Network (RKMs)
206543
Consumer Population 7332979
Gen. Dept., GEB,HO,Vadodara 3
Power Scenario of Gujarat during 2002-03
Installed Capacity MW - 8576 Max.Daily MUs Catered - 173 Max.Daily GEB MUs Catered-
88.869 Max.U/R Demand MW - 9040 Max.Demand Catered MW - 7743
Gen. Dept., GEB,HO,Vadodara 4
Generation Capacity for Gujarat System in MW GEB GEN.capacity
4888 Pvt. Sector Capacity 2156 Central Sector (Share) 1532
Gujarat System Total 8576
Gen. Dept., GEB,HO,Vadodara 5
Generation and PLF for GEB Managed Thermal Power Stations
Year Gen.in MUS PLF% 1998-99 22518 63.74 1999-00 24139 63.70 2000-01 25640 67.85 2001-02 25749 68.14 2002-03 26338 69.69
Gen. Dept., GEB,HO,Vadodara 6
•
Our Good Performance attributed to the following activities
Maximize the utilization of available generation capacity Adopted good O&M practices as suggested by CENPEEP. Implementation of recommendations made by M/s TERI
for fuel stock management Carrying out R&M activities to improve Generation level
at all power stations. Use of washed coal up to 30% at Ukai TPS and imported
coal up to 25% at Gandhinagar TPS. Change of Milling system by MPSP system at Ukai TPS &
Wanakbori TPS. Energy and Thermal audit in thermal power stations. Intensive boiler tube thickness survey during AOH.
Gen. Dept., GEB,HO,Vadodara 7
Performance Optimization with participation of working level engineers from operation, maintenance, C&I, O&E Deptt.
Fixation of monthly performance targets and action plan for major problem area by performance group.
Routine performance testing on boiler system with accurate instrument
Feed back of work done to promote efficiency,heat rate improvements
Implementation of recommendations made by Centre for Power Efficiency & Environment Protection(CENPEEP) for performance optimization
Gen. Dept., GEB,HO,Vadodara 8
Implementation of recommendations made by M/s TERI for fuel stock management
The stocks are not spreaded to entire length of the yard and are well organised and consolidated
Coal is stacked in smaller and regular shapes preferably trapezoidal or conical shapes to facilitate accurate measurement
Coal stocks are kept compressed by using dozers to remove air pockets to avoid fires
Bulk densities of compressed coal stock is determined regularly to arrive at an average figure for reporting actual physical stock
Gen. Dept., GEB,HO,Vadodara 9
Implementation of recommendations made by M/s TERI for fuel stock management (contd..)
Direct feeding of Indian coal is done to bunkers as far as possible to avoid unnecessary stocking/reclaiming
Coal stocks are used on first come first out basis to avoid deterioration in coal quality resulting in lowering of TPS performance
Ground stocks are minimised to reduce rehandling costs
Coal reject is being monitored vigorously so that it remains within the limit of 0.5 to 1 %
100 % coal reject utilization.
Gen. Dept., GEB,HO,Vadodara 10
Major R&M activities on hand RLA study for renovation of 2x120
MW units of Ukai TPS (BHEL) RLA study for renovation of 2x120
MW units of Gandhinagar TPS ( NTPC)
Renovation programme for 2x 70 MW units of KLTPS
Repowering of 4x63.5 MW units of Dhuvaran TPS
Gen. Dept., GEB,HO,Vadodara 11
Year Aux. Cons %
Savings in Rs.Crores
Sp.Oil Cons
ml/kwh
Savings in
Rs.Crores
1998-99
9.96 - 3.94 43.87
1999-00
9.71 10.50 3.41 10.93
2000-01
9.62 4.04 2.03 33.79
2001-02
9.37 12.30 1.01 27.62
2002-03
9.38 - 0.94 2.40
Saving due to reduction in aux.consumption and Sp. Oil consumption compared previous year for GEB & GSECL Thermal Power Stations
Gen. Dept., GEB,HO,Vadodara 12
Stationwise performance UKAI
Year Gen MUs
PLF %
PAF %
Aux. Cons
%
Heat Rate Kcal/K
Wh
Sp.Oil
Cons. Ml/
KWh
1998-99
4251 57.09
68.23
10.07
2760 4.82
1999-00
4445 59.50
70.97
10.04
2536 3.90
2000-01
5380 72.25
79.89
9.30 2595 1.76
2001-02
4750 63.80
69.36
9.17 2608 0.86
2002-03
5313 71.36
79.52
9.26 2590 0.94
Gen. Dept., GEB,HO,Vadodara 13
Stationwise performance G’nagar ( Unit 1 to 5)
Year Gen MUs
PLF %
PAF %
Aux. Cons
%
Heat Rate Kcal/K
Wh
Sp.Oil
Cons. Ml/
KWh
1998-99
4693 68.74
88.43
10.05
2455 7.58
1999-00
4397 57.54
78.27
10.66
2456 8.14
2000-01
4676 61.35
84.81
10.88
2489 4.52
2001-02
5315 69.74
85.58
10.16
2513 1.52
2002-03
5858 76.87
85.90
9.71 2505 0.99
Gen. Dept., GEB,HO,Vadodara 14
Stationwise performance Wanakbori ( Unit 1 to 7)
Year Gen MUs
PLF %
PAF %
Aux. Cons
%
Heat Rate
Kcal/KWh
Sp.Oil
Cons. Ml/ KWh
1998-99 (Unit
1-6)
8422 76.30 81.01
9.91 2501 0.62
1999-00
9954 77.09 81.07
9.31 2528 0.70
2000-01
10453
81.17 83.82
9.01 2472 0.57
2001-02
10993
85.37 87.65
8.91 2464 0.38
2002-03
10725
83.29 86.73
8.94 2459 0.58
Gen. Dept., GEB,HO,Vadodara 15
Stationwise performance- Sikka
Year Gen MUs
PLF %
PAF %
Aux. Cons
%
Heat Rate Kcal/K
Wh
Sp.Oil
Cons. Ml/
KWh
1998-99
894 42.51
51.83
10.88
2480 6.21
1999-00
961 45.57
53.62
10.99
2501 2.47
2000-01
1097 52.20
60.36
10.96
2506 2.50
2001-02
1139 54.19
63.74
10.89
2665 2.36
2002-03
1130 53.73
60.46
10.63
2724 1.44
Gen. Dept., GEB,HO,Vadodara 16
Stationwise performance- KLTPS
Year Gen MUs
PLF %
PAF %
Aux. Cons
%
Heat Rate Kcal/K
Wh
Sp.Oil
Cons. Ml/
KWh
1998-99
1010 53.61 71.0 12.61
3329 10.75
1999-00
963 51.01 68.06 13.16
3349 7.30
2000-01
966 51.27 70.63 12.95
3404 6.75
2001-02
981 52.06 66.68 12.31
3250 4.37
2002-03
1037 55.08 79.63 12.83
3662 3.68
Gen. Dept., GEB,HO,Vadodara 17
Stationwise performance- Dhuvaran TPSYear Gen
MUs
PLF %
PAF %
Aux. Cons
%
Heat Rate
Kcal/KWh
1998-99
2185 46.71
73.97
10.65
2933
1999-00
2358 50.28
81.44
9.63 2879
2000-01
2350 50.25
81.16
10.22
2978
2001-02
1792 38.32
65.84
9.97 2993
2002-03
1386 29.63
61.69
10.99
3001
Gen. Dept., GEB,HO,Vadodara 18
Stationwise performance- 135 MW Utran Gas based TPSYear Gen
MUsPLF
%PAF
%Aux. Cons
%
Heat Rate Kcal/K
Wh
1998-99
960 81.14
90.66
5.06 2020
1999-00
1059 89.33
92.95
4.70 1919
2000-01
718 60.70
78.37
5.42 2029
2001-02
779 65.85
79.16
4.70 2165
2002-03
888 75.10
84.80
4.98 1961
Gen. Dept., GEB,HO,Vadodara 19
Performance for 200/210 MW thermal units (13 units,cap-2710 MW)
Year Gen MUs
PLF %
PAF %
Aux. Cons %
Heat Rate Kcal/KWh
Sp.Oil Cons. Ml/ KWh
1998-99
15290 69.82
81.29
9.72 2572 3.05
1999-00
17114 72.09
80.59
9.50 2487 3.00
2000-01
18551 78.14 79.90 9.19 2498 1.59
2001-02
19047 80.23 79.15 8.99 2500 0.543
2002-03
19796 83.39 86.99 8.98 2496 0.675
Gen. Dept., GEB,HO,Vadodara 20
Performance for 120 MW thermal units (6 units, Cap-720 MW)
Year Gen MUs
PLF %
PAF %
Aux. Cons %
Heat Rate Kcal/KWh
Sp.Oil Cons. Ml/ KWh
1998-99
2881 45.69
63.76
12.04
2624 11.11
1999-00
2644 41.93
58.07
12.12
2544 7.85
2000-01
3054 48.43
66.86
12.02
2569 4.23
2001-02
3150 49.95
68.17
11.64
2635 2.79
2002-03
3230 51.21
67.50
11.23
2652 1.79
Gen. Dept., GEB,HO,Vadodara 21
Performance for 63.5 MW LSHS thermal units(4 units, Cap-254 MW)
Year Gen MUs
PLF %
PAF %
Aux. Cons %
Heat Rate Kcal/KWh
1998-99
1250 56.18
86.83
10.48
2577
1999-00
1225 55.06
88.69
9.35 3003
2000-01
1165 52.34
82.89
9.90 3108
2001-02
911 40.93
70.53
9.69 3245
2002-03
576 25.89
50.33
11.16
3081
Gen. Dept., GEB,HO,Vadodara 22
Performance for 140 MW LSHS thermal units(2 units, Cap-280 MW)
Year Gen MUs
PLF %
PAF %
Aux. Cons
%
Heat Rate
Kcal/KWh
1998-99
935 38.12
62.3 10.87
2752
1999-00
1133 46.20
74.85
9.94 2747
2000-01
1186 48.34
79.58
10.53
2858
2001-02
882 35.94
61.59
10.26
2716
2002-03
810 33.03
71.99
10.87
2936
Gen. Dept., GEB,HO,Vadodara 23
Outage details for 200/210 MW thermal units (13 units,cap-2710 MW)
Year Blr tube leakage
Forced Outage
Planned outage
Total Outage
1998-99
2.78 10.53 12.06 22.59
1999-00
2.29 5.70 10.88 16.58
2000-01
2.62 6.45 7.90 14.35
2001-02
2.65 6.14 9.69 15.83
2002-03
2.17 6.69 6.38 13.07
In percentage
Gen. Dept., GEB,HO,Vadodara 24
Year Blr tube leakage
Forced Outage
Planned outage
Total Outage
1998-99
6.01 17.73 18.59 36.32
1999-00
6.33 18.73 22.94 41.67
2000-01
6.42 17.75 15.40 33.15
2001-02
6.54 24.49 7.38 31.87
2002-03
4.59 13.25 19.29 32.54
In percentage
Outage details for 120 MW thermal units (6 units, Cap-720 MW)
Gen. Dept., GEB,HO,Vadodara 25
Year Blr tube leakage
Forced Outage
Planned outage
Total Outage
1998-99
0.45 13.17 00 13.17
1999-00
1.96 7.13 3.74 10.87
2000-01
3.82 17.12 0 17.12
2001-02
0.41 20.62 8.92 29.54
2002-03
0.13 37.25 12.45 49.70
In percentage
Outage Details for 63.5 MW LSHS thermal units(4 units, Cap-254 MW)
Gen. Dept., GEB,HO,Vadodara 26
Year Blr tube leakage
Forced Outage
Planned outage
Total Outage
1998-99
4.67 38.00 00 38.00
1999-00
1.67 15.86 10.15 26.02
2000-01
12.57 17.18 6.96 24.14
2001-02
3.38 18.86 19.54 38.40
2002-03
7.44 16.45 11.56 28.01
In percentage
Outage Details for 140 MW LSHS thermal units(2 units, Cap-280 MW)
Gen. Dept., GEB,HO,Vadodara 27
Year Blr tube leakage
Forced Outage
Planned outage
Total Outage
1998-99
6.01 18.96 9.86 28.82
1999-00
1.23 16.81 15.02 31.83
2000-01
0.86 20.70 8.32 29.02
2001-02
1.57 24.49 9.18 33.67
2002-03
1.92 17.65 2.63 20.28
In percentage
Outage Details for 70/75 MW Lignite thermal units (3 units, Cap-215 MW)
Gen. Dept., GEB,HO,Vadodara 28
R & M Activities carried out during last five years
Ukai TPS Replacement of water gland sealing with steam gland
sealing in 120 MW unit no.1 Introducing MPSP system in all coal mills. Replacement of bituminous class-B insulation of Generator
stator winding with epoxy class-F insulation in unit no.3 &4 Installation of Dual flue gas conditioning system to improve
flue gas SPM emission level in unit no. 4 Filling up of Dummy fields and providing microprocessor
based control in ESP of Unit 3,4&5 to improve the performance of ESP.
Replacement of excitation system with static excitation system in unit no 1&2.
Gen. Dept., GEB,HO,Vadodara 29
R & M Activities carried out during last five years
Gandhinagar TPS Replacement of low temperature superheater in unit No
1 Replacement of suction type coal mill with new pressure
type coal mill in unit no.1. Work in progress for unit no.2 Replacement of top and middle air preheater blocks in
unit no.1. Work in progress for unit no. 2 Renovation and Modernisation of complete ash disposal
system in progress. Replacement of 2 nos. ABB make 220 KV circuit
breakers with SF6 circuit breakers.
Gen. Dept., GEB,HO,Vadodara 30
R & M Activities carried out during last five years
Wanakbori TPS Replacement of Air Pre heater elements in unit 1 to 6 Replacement of coal mills by MPSP system with
controlled rejection level in unit 1 to 6 Replacement of condenser tubes in unit 1 to 3 Replacement of HP heaters in unit 4 to 6 Replcement of Jyoti make 6.6 kV min.Oil Ckt.breaker
with vacuum SF6 circuit breaker Replacement of economiser coils in unit 1,2,3 Replacement of 1200 KW motors for ID and PA fans Providing 100% leak proof gas isolators in flue gas path
in unit 1 to 3
Gen. Dept., GEB,HO,Vadodara 31
R & M Activities carried out during last five years
Dhuvaran TPS Residual Life Assessment of all 6 units carried
out during 1999-00 Replacement of old unserviceable HP heaters
of unit no 1 to 4 Construction of new IDCT for unit 5&6 Replacement of 11 KV min.Oil circuit breaker
with Jyoti make Vacuum circuit breaker
Gen. Dept., GEB,HO,Vadodara 32
Materials management1. ARC for following consumable items to
reduce procurement process time and the inventory level
a) MPSP mills sparesb) Ash plant sparesc) Bearingsd) Welding electrodese) All chemicals
2. Procurement of spares from OEM3. Finalisation of orders within 90 to 120
days
Gen. Dept., GEB,HO,Vadodara 33
SERVICE LIFE OF GEB POWER STATIONS
SR. NO.
POWER STATION
SERVICE LIFE TILL DATE
01 UKAI 18 TO 27 YEARS
02 GANDHINAGAR 13 TO 26 YEARS
03 WANAKBORI 17 TO 22 YEARS
04 SIKKA 11 TO 16 YEARS
05 KLTPS 7 TO 14 YEARS
06 DHUVARAN 32 TO 39 YEARS
Gen. Dept., GEB,HO,Vadodara 34
O&M expenses for UKAI TPS
Year Capacity
in MW
O&m
Cost
Total cost
% O&M
cost of Total cost
O&M Cost per MW
Fixed assets
at beginning of year
% O&M
cost of fixed
assets
1998-99
850 60 544 11.02
0.071 417 14.38
1999-00
850 57 540 10.63
0.067 458 12.54
2000-01
850 55 665 8.29 0.065 490 11.26
2001-02
850 53 750 7.07 0.062 510 10.39
2002-03
850 61 833 7.32 0.072 573 10.65
Rs in Crores
Gen. Dept., GEB,HO,Vadodara 35
O&M expenses for Gandhinagar TPS
Year Capacity
in MW
O&m
Cost
Total cost
% O&M
cost of Total cost
O&M Cost per MW
Fixed assets
at beginning of year
% O&M
cost of fixed
assets
1998-99
660 55 677 8.10 0.083 681 8.05
1999-00
660 41 492 8.30 0.062 703 5.81
2000-01
660 80 577 13.94
0.122 725 11.09
2001-02
660 44 756 5.82 0.067 735 5.99
2002-03
660 51 774 6.59 0.077 817 6.24
Rs in Crores
Gen. Dept., GEB,HO,Vadodara 36
O&M expenses for Wanakbori TPS
Year Capacity in MW
O&m
Cost
Total cost
% O&M
cost of Total cost
O&M Cost per MW
Fixed assets
at beginning of year
% O&M
cost of fixed
assets
1998-99
1260 58 1129
5.15 0.046 694 8.37
1999-00
1260 63 1243
5.04 0.05 717 8.73
2000-01
1260 64 1205
5.34 0.051 799 8.05
2001-02
1260 61 1445
4.22 0.048 811 7.52
2002-03
1260 69 1473
4.68 0.055 902 7.65
Rs in Crores
Gen. Dept., GEB,HO,Vadodara 37
O&M expenses for Sikka TPS
Year Capacity
in MW
O&m
Cost
Total cost
% O&M
cost of Total cost
O&M Cost per MW
Fixed assets
at beginning of year
% O&M
cost of fixed
assets
1998-99
240 22 160 13.76
0.092 396 5.58
1999-00
240 21 168 12.57
0.088 413 5.10
2000-01
240 18 181 9.97 0.075 425 4.243
2001-02
240 18 243 7.40 0.075 430 4.186
2002-03
240 20 302 6.62 0.083 479 4.175
Rs in Crores
Gen. Dept., GEB,HO,Vadodara 38
O&M expenses for Dhuvaran TPS
Year Capacity
in MW
O&m
Cost
Total cost
% O&M
cost of Total cost
O&M Cost per MW
Fixed assets
at beginning of year
% O&M
cost of fixed
assets
1998-99
588 45 324 6.88 0.042 191 13.18
1999-00
588 25 350 7.16 0.042 191 13.13
2000-01
588 25 365 6.88 0.042 198 12.73
2001-02
561 28 387 7.23 0.050 207 13.53
2002-03
561 29 566 5.18 0.052 221 13.28
Rs in Crores
Gen. Dept., GEB,HO,Vadodara 39
O&M expenses for Utran Gas based TPS
Year Capacity
in MW
O&m
Cost
Total cost
% O&M
cost of Total cost
O&M Cost per MW
Fixed assets
at beginning of year
% O&M
cost of fixed
assets
1998-99
174 17 79 21.23
0.09 246 4.54
1999-00
174 15 88 16.64
0.08 249 5.87
2000-01
174 11 70 15.98
0.06 258 4.32
2001-02
174 12 125 9.60 0.07 258 4.65
Rs in Crores
Gen. Dept., GEB,HO,Vadodara 40
Meritorious Awards received by GEB & GSECL Power Stations
SR. YEAR REMARKS
NO.
1 1993 GANDHINAGAR 5.54 Incentive Award For Saving In Specific Fuel Oil SIKKA 2.95 Incentive Award For Saving In Specific Fuel Oil
2 1993-94 KLTPS 1.05 Meritorious Productivity Reward For Generation3 1994-95 DHUVARAN 5.58 Meritorious Productivity Reward For Generation
GANDHINAGAR 10.95 Meritorious Productivity Reward For GenerationSIKKA 3.35 Meritorious Productivity Reward For Generation
4 1994 GANDHINAGAR 7.63 Incentive Award For Saving In Specific Fuel Oil 5 1995 GANDHINAGAR 6.10 Incentive Award For Saving In Specific Fuel Oil
ConsumptionSIKKA 4.90 Incentive Award For Saving In Specific Fuel OilConsumption6 1995-96 GANDHINAGAR 9.18 Meritorious Productivity Reward For Generation & BronzeMedal & Shield
UKAI 7.28 Meritorious Productivity Reward For GenerationDHUVARAN 5.76 Meritorious Productivity Reward For GenerationUTRAN (GAS) 2.65 Meritorious Productivity Reward For Generation & ShieldKLTPS 0.52 Meritorious Productivity Reward For Generation
NAME OFTHERMAL POWER STATION
AMOUNT OFREWARD INLACS
Gen. Dept., GEB,HO,Vadodara 41
Meritorious Awards received by GEB & GSECL Power Stations
SR. YEAR REMARKS
NO.
7 1996 SIKKA 7.53 Incentive Award For Saving In Specific Fuel OilConsumptionWANAKBORI 6.02 Incentive Award For Saving In Auxiliary Power Consumption
8 1996-97 SIKKA 4.28 Meritorious Productivity Reward For Generation & BronzeMedal & Shield
DHUVARAN 6.89 Meritorious Productivity Reward For Generation9 1997 UKAI 4.82 Incentive Award For Saving In Specific Fuel Oil
ConsumptionWANAKBORI 5.738 Incentive Award For Saving In Specific Fuel OilConsumption10 1997-98 WANAKBORI 10.4 Meritorious Productivity Reward For Generation & Shield
11 1998 UKAI 6.21 Incentive Award For Reduction In Secondary Fuel OilConsumption
WANAKBORI 5.72 Incentive Award For Reduction In Secondary Fuel OilConsumption
WANAKBORI 4.97 Incentive Award For Reduction In Auxiliary PowerConsumptionKLTPS 3.08 Incentive Award For Reduction In Auxiliary PowerConsumption12 1998-99 UTRAN(GAS) 1.79 Meritorious Productivity Reward For Generation & BronzeMedal & Shield
WANAKBORI 9.37 Meritorious Productivity Reward For Generation & Shield
KLTPS 0.84 Meritorious Productivity Reward For Generation
NAME OFTHERMAL POWER STATION
AMOUNT OFREWARD INLACS
Gen. Dept., GEB,HO,Vadodara 42
13 1999 WANAKBORI 6.57 Incentive Award For Reduction In Secondary Fuel Oil Consumption
SIKKA 6.62 Incentive Award For Reduction In Secondary Fuel Oil Consumption
WANAKBORI 6.57 Incentive Award For Reduction In Auxiliary Power Consumption
14 2000 UKAI 7.51 Incentive Award For Reduction In Secondary Fuel Oil Consumption
GTPS-5 7.51 Incentive Award For Reduction In Secondary Fuel Oil Consumption
WANAKBORI 6.43 Incentive Award For Reduction In Secondary Fuel Oil Consumption
WANAKBORI 6.01 Incentive Award For Reduction In Auxiliary Power Consumption
SIKKA 3.8 Incentive Award For Reduction In Auxiliary Power Consumption
15 1999-2000 UTRAN(GAS) 3.02 Meritorious Productivity Reward For Generation, Gold Medal &Sheild
WANAKBORI 13.02 Meritorious Productivity Reward For Generation & Shield
REMARKSNAME OFTHERMAL POWER STATION
AMOUNT OFREWARD INLACS
SR.No. YEAR
Meritorious Awards received by GEB & GSECL Power Stations
Gen. Dept., GEB,HO,Vadodara 43
Gen. Dept., GEB,HO,Vadodara 44
O&M expenses for KLTPS
Year Capacity
in MW
O&m
Cost
Total cost
% O&M
cost of Total cost
O&M Cost per MW
Fixed assets
at beginning of year
% O&M
cost of fixed
assets
1998-99
215 32 80 39.98
0.15 753 4.24
1999-00
215 28 69 40.80
0.13 753 3.73
2000-01
215 25 84 29.46
0.11 815 3.04
2001-02
215 24 255 9.41 0.11 815 2.94
2002-03
215 30 256 11.72
0.14 904 3.32
Rs in Crores