GENERATION

RENOVATION &
MODERNISATION
 INDIAN POWER SECTOR
•Present Status:
– Per capita consumption about 600 units per annum
– Installed Capacity 1,24,287 MW (April, 2006)

•India’s Projected Growth is 7-8 % of GDP – Projected power

requirement by year 2012:
– Per capita consumption 1000 units per annum
– Installed capacity over 2,00,000 MW

•Projected power requirement by year 2032:

– Per capita consumption about 3000 units per annum
– Installed capacity about 6,00,000 to 7,00,000 MW

However government of India is targeting double digit growth

rate (10%) and hence projections are likely to get revised
upwards. The above necessitates :
• Sustainable Large Capacity Addition Program at higher
efficiency
• Upgrading fleet of Old Power Stations which are
 R&M and Re-powering
•India has large number of old plants which
are inefficient and running below design
capacity
•Operating pressure and temperature of these
old plants are lower and there is no reheating
in some of the units
•Fuel available at present is different from
what plant were designed for
•Some of the equipments have degraded
•Re-powering of these plant can quickly
increase the power generation at relatively
lower cost to consumer
•Re-powering can increase the cycle
efficiency and hence reduce emission of
greenhouse gases and pollutants
 R&M and Re-powering
•R&M will involve up gradation of milling system, APH,
ESP, firing system etc and refurbishment of turbine,
condenser, pressure parts, fans etc.
•Re-powering may involve following changes in plant
design :
• Adoption of higher steam parameters
• Introduction of topping cycle, old turbine may be
retained in bottoming cycle.
• Bottoming turbine cycle efficiency improvement
by adoption 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
 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
[Link] fired
[Link] bed combustion-Reduces Sox, NOx
Emissions
[Link] 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 & AUXILIARIES

Replacement/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.
 Technological Options

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.
 Technological Options

Gas Turbine
Inlet Air Cooling system.
Online Compressor Washing System
Dry Low NOx Burners.
Improved metallurgy for improved life of Hot
Gas Path Components
Improved efficiency
Thermal Barrier Coatings of Blades & Vanes.
Improved major inspection intervals.
Multi Fuel Firing
 Technological Options

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

Increased power output resulting from efficiency increase is

free of fuel cost, free of operational cost and free of emissions.

Rehabilitation Rehabilitation
Fuel consumption w/o efficiency
improvement
per kWh
Rehabilitation
with efficiency
improvement

0 20 40 years
 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 Government of India way back in 1984
when PHASE-I R&M Programme for 34 thermal
power stations in the country was launched by
the Central Electricity Authority as a Centrally
Sponsored Scheme

•The Government of India has now accorded

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

 R&M PROGRAMME DURING 10TH
PLAN
[Link]. PARTICULARS

[Link]. PARTICULARS

i) Number of thermal power stations 13

i) Number of thermal power stations 13

ii) Number of thermal units 57

ii) Number of thermal units 57

iii) Estimated Cost Rs.977 crores

iii) Estimated Cost Rs.977 crores

iv) iv) Total

Total Capacity Capacity involved
involved 14270 MW 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

No of units for R&M in 10th Plan

Plan No of units for R&M in 11th Plan

45 30
40
25
35
30 20

No of units
No of units

25 43 29
15
20
15 10
10
10 5
5 4
0 2
0 0
110 MW and 200 & 210 MW 500MW 110 MW and 200 & 210 MW 500MW
Below Below
Unit size Unit size

Total M W for R&M in 10th Plan Total M W for R&M in 11th Plan

360 1000 0
5000
110 MW and Below 110 MW and Below
200 & 210 MW 200 & 210 MW
500MW 500MW
8910
6090
 POWER PLANT R&M OBJECTIVES

availability environmental
efficiency upgrading life extension
improvement control updating

increased electrical reduced fuel emissions within

improved reliability
output consumption new norms

RESULTS

increased power reduced power operation free of

output generation cost restrictions

plus
CDM BENEFITS
 Challenges in R&M

•Limited Agencies for R&M

implementation in the country.

•Prohibitive cost of New Technologies

impediment for introduction on wider
scale.

•Unfavorable cost benefit analysis.

•R&M activity to be linked with

planned shut down.
 CDM Potential in R&M

Offers substantial CDM benefits through

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 own Stations
•R&M is identified as Key Thrust Area as the
many NTPC plants are crossing 1,00,000
operating hours
•R&M of power plants of 10,799 MW capacity
has been undertaken / in progress
•R&M of power plants of 7,642 MW capacity is
under planning
•The cost of R&M may be up to Rs. 1.5 crores
per MW depending on the life and condition of
the plant.
NTPC R&M Project under CDM:
NTPC has taken up Badarpur R&M project
under CDM
PIN is already prepared
 NTPC’s EXPERIENCE SO FAR
NTPC Talcher TPS (4x60+ 2x110 MW)
R&M Scope
•Extensive RLA and R&M of SG and TG
•Retrofitting of existing ESP and addition of new fields
•Replacement of Static Excitation System, Power & Control cables,
replacement/ Retrofit of HT/LT Switchgear ,Augmentation of H2 plant
•Renovation of Cooling Towers
•Augmentation of Ash Handling
•New AWRS
•New Railway Siding inside the plant
•New Coal Handling Plant
•R&M of Switchyard
R&M cost - Rs 1.50 Crs/MW
PLF is around 88% as against 19% during takeover in Jun
1995.
 NTPC’s EXPERIENCE SO FAR
NTPC Tanda TPS (4x110 MW)
R&M Scope
•Extensive RLA and R&M of SG and TG
• ESP Renovation
•Replacement of 6.6 KV & 11 KV Switch gear
•Replacement of LT Switch Gear
•Renovation of Fire Fighting system
•New Stacker Reclaimer
•Additional DM Stream
•New DDCMIS for Units 1&2 and Upgradation of DAS for Unit 4
•Clarification of CW Make up water system & Effluent Treatment plant
R&M cost - Rs 1.17 Crs/MW
PLF is around 85% as against 21% at the time of
takeover in Jan 2000
EXPERIENCE OF TECHNOLOGY UPGRADES
•The 60 MW boilers at Talcher TPS have been redesigned
taking into account the current coal characteristics. Milling
system have been upgraded.

•The 110 MW Units at Kothagudam have been upgraded to

120 MW by PPIL with a Turbine HR less than 2000
Kcal/Kwh.

•110 MW Unit at AECO, Sabarmati has been upgraded to

120 MW by NASL with Turbine HR improvement of
approximately 140 Kcal/Kwh.

•No. of 200/210 MW LMZ Units have been upgraded to 225

MW in other countries with considerable improvement in
Heat rate. These are now being planned in India.
 Government’s Initiatives

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 NTPC
NTPC 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 stations

The 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 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 Achievement
Proj. PLF PLF % imp. SOC SOC % imp. APC APC % imp.
bef. aft. in PLF bef. aft. in SOC bef. aft. in APC

CTPS 23.97 72.66 203.13 28.60 0.80 97.20 22.30 11.43 48.75
3x140
MW

DTPS 36.78 65.41 77.84 5.28 1.88 64.40 12.59 9.88 21.52
1x140
MW

GTPS 45.00 84.00 93.19 3.00 0.70 76.67 12.40 10.23 17.50
2x210
MW
 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

International best practices range from one-to-one

replacements to Mega R&M

In USA and other advanced countries utilities have

largely gone for Mega R&M because of the age of
their units & rapid changes in their business
environment which required them to remain
competitive and efficient

Hence, Mega R&M schemes such as up-gradation

of process parameters, improved balding in
turbines, Re-powering, & even installing machines
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

benefited the stations by way of
•Overcoming Technological obsolescence.
•Low cost capacity addition
•Extending the life of equipment /
components.
•Complying with Statutory and Environmental
Norms
•Sustaining availability and improved
performance
There is huge potential in India for R&M
activities because of large number of old plants
which are inefficient and running below design
capacity
R&M to be planned in advance before major