NTPC Refurbishment and R&M in - C. Subramaniam AGM (OS-R&M) NTPC Ltd. EOC, Noida-24
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Refurbishment and R&M
in
NTPC
C. Subramaniam
AGM (OS-R&M)
NTPC Ltd. EOC, Noida-24
Disclaimer: Some of the statements are forward looking, and are not
necessarily the views of the management.
NTPC- Today
THE LARGEST POWER GENERATION COMPANY IN
INDIA, WITH COMPREHENSIVE IN-HOUSE
CAPABILITIES IN BUILDING AND OPERATING POWER
PROJECTS
CURRENT OPERATING CAPACITY – 29,394 MW
(INCLUDING JV). 16,680 MW UNDER CONSTRUCTION.
18 COAL BASED AND 8 GAS BASED POWER PLANTS
Business 4 HYDRO PROJECTS UNDER CONSTRUCTION,,
DEVELOPING COAL MINES FOR CAPTIVE USE,
EXPLORING OIL / GAS BLOCKS IN CONSORTIUM
WITH PARTNERS
SUBSIDIARIES (5 NOS.) & JV COMPANIES (10 NOS.)
FORMED FOR TAKING UP GENERATION, POWER
TRADING, DISTRIBUTION BUSINESS AND FOR
SETTING UP OF SMALL HYDRO PLANTS (
NTPC- Today
GOVERNMENT OWNS 89.5%
OWNERSHIP FIIS OWN 4.90 % AND REST 5.60 % OWNED BY
DOMESTIC INSTITUTIONS & PUBLIC
ONE OF THE FIVE LARGEST INDIAN COMPANIES WITH
A MARKET CAP OF MORE THAN RS 1,80,000 CRORE
SIZE NET WORTH OF RS 48,000 CRORE +
TOTAL ASSETS OF RS 80,000 CRORE +
RANKED # 1 INDEPENDENT POWER PRODUCER IN ASIA
IN 2007 ( BY PLATTS, A DIVISION OF MCGRAW-HILL
COMPANIES)
STATURE THE FOURTH LARGEST GENERATING COMPANY IN
ASIA
411TH LARGEST COMPANY IN THE WORLD (FORBES
RANKING – 2007)- JUMPS UP BY 83 POSITIONS FROM
THE 494TH RANK IN 2006.
Spread across all major States
No of Capacity
KOLDAM
KOLDAM plants MW
(800 LOHARINAG
LOHARINAG PALA PALA
(800 MW)
MW)
DADRI
(600
(600 MW)MW)
RUPSIABAGAR
RUPSIABAGAR KHASIABARA
KHASIABARA
NTPC Owned
DADRI (260MW)
(817 (260MW)
(817 MW)
FARIDABAD
FARIDABAD
MW)
LATA TAPOVAN
LATA TAPOVAN
(162
(162 MW)
MW)
Coal 15 23395
(430
(430 MW)
MW)BTPS
BTPS
(705
(705 MW)
NCTPP
MW) (840
TAPOVAN
NCTPP TAPOVAN VISHNUGAD
MW) (520
(840 MW) (520 MW)
MW)
VISHNUGAD
Gas/Liquid fuel 7 3955
TANDA
TANDA
ANTA
ANTA UNCHAHAR
UNCHAHAR
(440
(440 MW)
MW)
RAMMAM III
Total 22 27350
(413
(413 MW)
MW) (840
(840 MW)
MW) KAHALGAON RAMMAM III
KAHALGAON
(90
(90 MW)
AURAIYA
AURAIYA
(652
(652 MW)
MW)
(840
(840 MW)
MW) MW)
Owned by JVs
SINGRAULI
SINGRAULI RIHAND
(2,000
(2,000 MW)
RIHAND
MW) (2,000
(2,000 MW)
MW) BARH
BARH
Coal & Gas 4 2044
FARAKKA
FARAKKA
GANDHAR
GANDHAR
VINDHYACHAL
VINDHYACHAL
(2,260
(2,260 MW)
MW)
(1,600
(1,600 MW)
MW)
Total 26 29394
(648
(648 MW)
MW)
KORBA
KORBA
(2,100
(2,100 MW)
MW) TALCHER
TALCHER KANIHA
(3,000
(3,000 MW)
MW)
KANIHA
Regional Spread of Generating Facilities
KAWAS
KAWAS SIPAT
SIPAT
(645
(645 MW)
MW)
TALCHER
TALCHER Thermal
(460
(460 MW)
MW)
Thermal
Region Coal Gas Total
RAMAGUNDAM
RAMAGUNDAM
(2,600 SIMHADRI
SIMHADRI
Northern 7035 2312 9347
(2,600 MW)
MW)
(1,000
(1,000 MW)
MW) THERMAL POWER STATION
Western 5860 1293 7153
HYDRO POWER PROJECTS
GAS POWER STATIONS Southern 3600 350 3950
ONGOING PROJECTS
Eastern 6900 - 6900
JVs 564 1480 2044
KAYAMKULAM
KAYAMKULAM
(350
(350 MW)
MW) Total 23959 5435 29394
R&M Potential in NTPC
• Average age of NTPC Coal Units is 121,233 Hrs &
that of Gas Units is 99,166 Hrs.
• The first series of 200 MW Units installed at
Singrauli, Korba, Ramagundam are nearing
200,000 Hrs and are reaching ‘end of life’ and are
due for Major R&M.
• Most of the 200/210 MW Units in India have higher
running hours.
• The first series of 500 MW Units at NTPC stations
are nearing 150,000 Hrs. of operation.
• There is considerable potential for Life extension,
Capacity and Efficiency improvement through
R&M.
• Investments in Major R&M ranges from 1.2 to 1.6
Crs/MW.
• R&M has good CDM potential
R&M in NTPC till date • One of the major contributors for Sustenance of the high performance levels of NTPC’s Units in spite of ageing of Units has been the specific R&M interventions when the Units complete 100,000 hours of operation. • First cycle of R&M, mainly catering to site specific problems, to address, ageing, obsolescence and the changing environmental standards are being executed. • In some of the take-over plants like Talcher & Tanda - major retrofit of Boiler, ESP, Control and Instruments, etc. carried out.
The Challenges Ahead
How to
avail CDM
Benefits??
Competition From Probable New
New Generation Environmental
of Plants (Cost of Regulations
Generation) like NOx/SOx
Fuel Security Compliance with
(Gas / Naptha) Kyoto Protocol /
G8 Resolution
NTPC 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 output Competitive power operation free of
generation cost restrictions
plus
CDM BENEFITSR&M Business Plan DESTINATION Competitive cost of generation in NTPC’s 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.
Target
Competitive COG in NTPC’s
ageing fleet and achievement
of targeted performance level
2nd intervention: 200,000 /
100,000 hrs of operation for
coal/gas : Life Extension,
obsolescence, Technology
Upgradation to bring it close
to contemporary Units
environmental regulations
1st intervention: 100,000 hrs
of operation: Address ageing,
technological obsolescence,
environmental regulationsTotal R&M Solutions
• Components • Benefits
Boiler + ESP Efficiency
Improvement
Turbines & Reliability
Generators Design Audit Increase
Reduction of
Electrical Updating Start up Times
Spares
Modernization Availability
Instrumentation & Compliance to
Control environmental
Replacement
standards
Cooling Water Cyclic load
Systems operation
Extended life
Ash Handling time
Coal HandlingDevelopment of R&M Solutions
Protection of Reduced Reduced Life
environment APC O&M Cost Extension
Solutions
R&M
Address Efficiency Uprating & Zero forced
Obsolescence Increase Technology outage by
Upgrades design
CDMR&M Action Plan
Units
completing Address ageing, technological obsolescence,
100,000 environmental regulations
Hrs Coal
TARGET
Achieve targeted
performance level in a
Safe, Reliable & Efficient
Units
manner, in NTPC’s ageing Address Life Extension, obsolescence, Technology
completing
fleet through cost- Upgradation to bring it close to contemporary Units
200,000 /
effective, planned and time environmental regulations
100,000
bound R&M on a ‘Project
Hrs Coal/Gas
Mode’.
Gap Analysis &
Development of Efficiency imp by Cost – Development of in- Development Development
Technology Road Effective High End house expertise: of Standard of strategies to
Map for R&M Solutions: •Twinning with RLA Specs enhance
Capacity Building •Enhancement of Process international for: competition
For developing parameters •Agencies. •Turbine In R&M tenders:
High End •Use of State of the Art •Augmentation of •Boiler Review Specs
Solutions Turbine Blading R&M Groups •Generator based on feed
•Literature Survey •Cold-End Upgradation •Recruitment of •GT back from
•Internet scan •Re-powering equipment international
•Interaction with •Topping Cycle specialists. Utilities &
international Vendors.
Utilities & VendorsSALIENT POINTS OF NEW BUSINESS PROCESS FOR R&M R&M to be carried out on a Project Mode in line with New Builds. Development of Eight Year Rolling Plan (EYROP) for RLA & R&M. Identification of Unit Target Shutdown dates (UNTAD) for RLA & R&M. Key R&M Milestones (KRMS) to be identified for R&M Alignment of all Departments to the UNTAD. Scheduling & Monitoring of R&M by CMG. Identification of Target And Objectives Plans (TOPS) to achieve the competitive cost of generation. Development of High End Technological Solutions For R&M to meet TOPS.
High End Technological Solutions Advanced Supercritical Retrofit: Vertical Tube Supercritical PosiflowTM boiler technology is ideal for retrofitting to existing sub-critical boilers. Such a retrofit, combined with modification of the steam turbine, steam pipe-work and some of the balance-of- plant can raise the plant cycle efficiency up to 43-46% with commensurate carbon dioxide reductions. Biomass Co-firing . Circulating fluidized bed firing .
Sub-critical vrs. Supercritical Not a great deal of difference
Performance and Emissions
• Typical Efficiency increase for upgrade of a modern
sub-critical Natural Circulation boiler to supercritical is
~17% (from 38% to 45% : net, LHV)
• Headline Emissions Savings,
Tonnes/Year (%age reduction)
CO2 673k (17)
Fuel 290k (17)
NOx 1.7k (17)
SO2 3.7k (17)
Dust 400 (50)
• Savings may be substantially greater depending on
actual Preconversion efficiencyPossible Areas of Cooperation • Development of State of art NDE tools and techniques in RLA and condition assessment. • Process mapping from concept to implementation of R&M schemes. • Front End Engineering & Design (FEED) Study for 200/500 MW Units for up rating process parameters on the lines of Turow. • Development of Service providers /Suitable partners for RLA and R&M.
Summary ¾R&M should focus on ‘cost-effective technology upgrades’ instead of in-kind replacements. ¾R&M to be planned in advance before major deterioration or breakdown of unit ¾Target Objectives of R&M to be clearly identified upfront ¾R&M should be taken up on a ‘Project Mode’ with clearly identified dates akin to ‘New Builds’. ¾Urgent need to enhance manufacturing capacity to handle load of R&M / Creation of new manufacturing base
R&M SUCCESS STORIES IN NTPC
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