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An Overview Of DVC Power Plants In Recent Years

Durgapur Thermal Power Station

Introduction Durgapur Thermal Power Station (DTPS) with present installed capacity of 350 MW comprises U #3 of 140 MW and U #4 of 210 MW thermal units. U #3 provided with M/s ABL Make Boiler & M/s GE, USA Make T.G was commissioned in Dec. 1966 and U #4 of M/s BHEL Make Boiler & T.G commissioned in Sept. 1982. It may be noted that U #1 & #2 of DTPS were decommissioned in Oct.1985 due to severe fire damage. Performance

PLF Pattern of DTPS

60 PLF (%) 40 20 0

Unit #3
50.64 36.78 5.45 56.49 56 11

Unit #4
46.48 34.10 56.61 52.73 42 54

48.14 35.18 36.15 54.23 47 97
00-01 01-02 02-03 03-04 04-05

00-01 01-02 02-03 03-04 04 05

Unit #3 00-01: Total forced outage was 1210.92 hrs out of which outage due to tube leakage was 909.36 hrs. 01-02: Poor availability due to forced outage of 645 hrs. (606 hrs. for Boiler tube leakage) and 2678 hrs. for RLA/refurbishment & Capital O/H (from 10.12.01 to 02.06.02). 02-03: Poor availability due to RLA/Refurbishment & Capital O/H and forced outage from 26.07.02 to 30.04.03 caused by Generator Rotor Earth Fault 03-04: Total outage was 1935 hrs mainly due to Rotor E/F and Boiler Tube Leakage.

04-05: Total outage was 1849 hrs mainly due to Boiler Tube Leakage and O/H from 01.12.04 to 26.12.04. From the above details it is evident that the performance of the Unit was poor during the years 01-02 & 02-03 due to RLA/Refurbishment & Capital O/H and Generator Rotor E/F. In other periods outage was mainly due to Boiler Tube leakage. In general the Unit is presently capable of generating at 56% PLF. For further improvement, R&M/LU action has been taken up so that it can generate at about 70% PLF. Unit #4 00-01: Total outage was 2535 hrs. - tube leakage for 831 hrs, planned outage 474 hrs for renewal of Boiler steaming license, Fire hazards in burner floor 254 hrs and CM & CHP problems due to poor quality of Coal supply 159 hrs. 01-02: Total outage 4830 hrs. mainly due to Capital O/H (01.07.01 to 30.11.01) - 3650 hrs, Boiler tube leakage 565 hrs. and 2678 hrs. for RLA/Refurbishment & Capital O/H (from 10.12.01 to 02.06.02). 02-03: Total outage was 1953 hrs out of which 759 hrs for hooking up Addl. ESP. 03-04: Total outage was 2120 hrs mainly due to Boiler Tube leakage 920 hrs., Condenser tube & Generator H2 cooler gas lkg.- 441 hrs. 04-05: Total outage was 3551 hrs mainly due to Boiler Tube Leakage 1011 hrs, Annual O/H (20.06.04-23.07.04) & Gen Seal Oil Sys. trouble - (30.07.04 18.08.04). Unit #4 is running at an average PLF of 50%. Different actions on Short- term, Medium- term & Long- term basis, as recommended by NTPC-DVC Peer group, have been taken to improve the performance. Also RLA & Capital O/H of this unit has been scheduled in 05-06.

Mejia Thermal Power Station

Introduction It consists of four 210 MW unit of BHEL make, COD Dec.97, Mar.99, Sep.99 and Feb.05. Further to this, Erection of 2x250 MW is in progress and likely to be commissioned by Mar.07

PLF Pattern of MTPS

100 80 PLF (%) 60 40 20 0 00-01 01-02 02-03 03-04 04-05 Unit #1 Unit #2 Unit #3 Unit #4 Station 42.72 23.20 66.21 48.68 86.94 39.84 54.33 60.61 87.31 69.69 64.16 65.67 54.66 82.27 86.00 74.00 48.91 47.73 60.49 72.75 80.60 00-01 01-02 02-03 03-04 04-05

Performance The station performance is gradually improving and presently operating at above 80% PLF.

Bokaro Thermal Power Station

This station consists of two Stages BTPS A & BTPS B. Bokaro A Thermal Power Station Introduction Bokaro A Thermal Power Station (BTPS A) with an installed capacity of 247.5 MW comprises of three (3) nos. 57.5 MW and one (1) nos. 75 MW thermal units. The first three units (U #1, #2 & #3) of M/s GE, USA make Turbine and M/s CE, USA make Boiler were commissioned in 1953 and the other units (U #4) of MAN, West Germany make was commissioned in 1960. Later these were derated (3x45 MW + 1x40 MW) 175 MW. Performance Unit #1, #2 & #3 These Units were commissioned in the year 1953 with an installed capacity of 57.5 MW each, later derated to 45 MW each. These were not provided with Electro Static Precipitator (ESP). As such due to non-fulfillment of Pollution Norms, Unit #1, #2 & #3 were put under shut down from 30th March, 17th July and 13th July 2000 respectively. Central Pollution Control Board made it mandatory to equip these Units with ESPs before putting them back to service. Prior to closer these Units were generating at an average PLF of around 32% during 98-99 till July 2000. Subsequently RLA based R&M program has been under taken for U #1, #2 & #3 by engaging M/s BHEL and GEPSIL with NTPC as consultant for R&M. Now these Units has been scheduled to operate from June 06 after comprehensive O/H and commissioning of ESP. There after R&M program will be under taken. Unit #4 Original capacity of 75 MW was commissioned in 1960. Since its inception the unit had inherent trouble due to which continuous rated output could never be achieved. In view of its unreliability and persistence problems CEA derated its capacity to 55 MW in 1983-84 and then to 40 MW in January 1990. The unit went out of commission in February 1989 due to failure of 23rd stage blade of LP Turbine. Since then it could not be brought back to bar. Performance of the Unit till February, 1989 is 28.34% (PLF) and average PLF of last five years preceding February, 1989 is 8.05%. Subsequently in line with the guide lines of MOP, GOI meeting, write-off action has been initiated by requesting CEA to make a joint assessment with NTPC for final recommendation. In view of the prolonged shut down of the Units of BTPS A the manpower has been reduced to minimum level as required for safety measure and operation of Switch Yard. Bokaro B Thermal Power Station Introduction Installed capacity Bokaro B Thermal Power Station (BTPS B) is 3x210 MW (630 MW) with BHEL make T.G. and ABL make Boiler. These were put in commercial operation in Mar.87, Dec.91 and Apr.94.


PLF Pattern of BTPS'B'

70 60 50 PLF (%) 40 30 20 10 0 00-01 01-02 02-03 03-04 04-05 Unit #1 Average PLF of this unit was around 45%, major problem being frequent Boiler tube lkg. In 04-05, it had undergone Cap. O/H including replacement of Platen SH header (07.07.04 to 31.10.04). Presently it is performing at above 60% PLF. Unit #2 It is also performing at an average PLF of 45%. Major problem is low availability due to frequent tube leakages. In 04-05, its Platen SH header has been changed. Moreover, Annual O/H will be taken up in 05-06. It is expected that performance will improved to above 60% by end of 2005. Unit #3 Unit #3 was under O/H from 01-04-03 to 07.05.03. Other cause of poor availability was Boiler tube leakage. Replacement of Platen SH header will be taken up during Annual O/H scheduled in Jan-Feb.06. Performance is likely to improve from 06-07. Moreover, for further improvement, action has been taken in phases as per recommendation of Peer Group. Unit #1 48.78 50.82 45.89 44.66 30.56 Unit #2 38.29 28.12 56.94 44.51 48.19 Unit #3 30.35 43.43 64.58 57.39 55.39 Station 39.14 40.79 55.80 48.85 44.71 00-01 01-02 02-03 03-04 04-05

Chandrapura Thermal Power Station

Introduction Chandrapura Thermal Power Station (CTPS) with an installed capacity of 780 MW comprises of three (3) nos. 140 MW (derated from 140 MW to 130 MW w.e.f. 01.12.1993) and three (3) nos. 120 MW thermal units. The first three units (U #1, #2 & #3) of M/s GE, USA make were commissioned between 1964 and 1966 and the other three (3) nos. units (U #4, #5 & #6) with M/s BHEL make Turbine and M/s ACC Babcock Limited (ABL) make Boilers were commissioned between 1974 and 1979. Considering derated capacity of U #1, #2 & #3 present capacity of CTPS is 750 MW (3x130 MW + 3x120 MW). Performance

PLF Pattern of CTPS

70 60 50 40 30 20 10 0
00-01 01-02 U#1,2 Unit #1 Unit #2 Unit #3 Unit #4 Unit #5 Unit #6 Station &3 2.95 0.00 0.00 33.07 35.22 33.93 57.99 36.75 0.64 0.00 3.45 0.00 29.36 16.40 9.34 0.00 1.20 1.71 0.55 0.00 0.00 22.29 21.23 23.82 36.06 17.15 27.76 19.84 34.22 28.83 55.43 02-03 03-04 04-05

PLF (%)

00-01 27.65 01-02 50.18 02-03 46.53

03-04 42.88 36.35 23.44 04-05 48.31 62.38 55.62

The performance of CTPS Units #4, #5 & #6 has been very poor since inception. Unit #4 The main reason for poor performance of U #4 was the failure of TurboGenerator (high vibration of TG Bearing No. #3) on 3rd June, 01.After O/H of TG and its auxiliaries Unit was synchronized on 23.04.03. Unit suffered forced outage on 29.05.03 due to a devastating fire that broke out in 3.3 KV Cable gallery. Prior to fire incidence during the operating period in Apr.-May03 unit average load was 42.96 MW (PLF 35.8%). Also, during operation continuous oil support was unavoidable due to inherent problem of ABL Boiler right from its commissioning. Since then unit remained under shut down. Unit #5 Unit operation was found to be uneconomical due to very high specific oil consumption, poor performance of cooling tower, coal mills and frequent boiler tube leakage. (PLF: 01-02, 29.36%, 02-03, 16.4% & in 03-04, 9.34%). Unit was last in operation on

23.11.03 and gone under S/D due to Boiler tube leakage and Generator Seal leakage. Later unit was kept available but not brought back to bar as per management decision because of uneconomic generation of the unit since very beginning owing to high SOC. Unit #6 Since commissioning the unit could not be operated at rated capacity. Unit suffered forced outage in July 95 due to bursting of 3.3 KV Switch gear resulting in severe damage of all switch gears along with Bus bars, internal wiring, Protection relays and other accessories. After complete rehabilitation work, unit couldnt be stabilized and kept in continuous service in spite of repeated efforts mainly due to high turbine (IP Rotor vertical) eccentricity, high vibration in TG Bearing #3 & #5, erratic performance of coal mills, BFPs etc. Unit was last de-synchronized on 06.06.02 due to boiler tube leakage along with above problem. In view of prolonged S/D of the Unit #4, #5 & #6 and uncertainty about their restoration and rehabilitation, the manpower, earlier engaged for O&M of above three units, had subsequently be reduced to bare minimum skeleton level as required for operation of safety measures. For economical operation and improvement of station generation several action has been initiated. DVC has given stress to run U #1, #2 & #3 at present. Performance of these three units has shown gradual improvement (Annual PLF considering these three units was 27.76 %, 34.22 % & 55.43% during 02-03, 03-04 & 04-05 respectively). SOC has been subsequently brought down from 16.435 ml/kWh in 03-04 to 2.61 ml/kWh in 04-05 which is close to National average for such old units. A comprehensive R&M program will be taken up during 06-07 for these Units for Life Extension and Uprating the capacity. Also it has been decided in the recent meeting with M/s. BHEL, Bhopal and NTPC to carry out Thermal Performance Test (TPT) of Unit # 6 after extensive overhauling of Boiler with its accessories, TG and auxiliaries etc. as per the scope of work of NTPC, based on which decision for revival of U #4, #5 & #6 will be taken.

Maithon Gas Turbine Station.

Introduction MGTS consists of three Gas Turbine Units which were supplied and commissioned by GE, USA as a turnkey package dur4ing 89-90. The units were installed to serve as stand by emergency source of power to support on system exigency and black out condition. All three Units are of 30 MW capacity each (nominally rated at 27.5 MW at 500C ambient). Apart from being the instant peaking source with black-start facility, these units have helped and are quite capable of providing uninterrupted power supply in case of exigency. These have acted as peaking source. GT units run on peak cycle (Brayton Cycle) with 3 stags impulse turbine and 17 stage axial compressor mounted on same shaft. It has 630 HP starting diesel engine, 10 nos. annular combustion chamber. Turbine speed 5082 RPM us reduced to 3000 RPM with reducing gear box. 1. Fuel used A. HSD: C.V. 10,300 K.Cal/Kg. B. Naphtha: C.V. 11,300 K.Cal/Kg. Sp. Oil consumption: 0.39-0.43 Lt/KWH.

01. 02. 03. 04. 05.

Serves as standby source of power in case of system exigencies. Provides reactive power to the system for voltage regulation, in case it functions as synchronous condenser. Regarded as quick peaking source as Unit takes 16 Minutes for start up, synchronization and loading. Requires less manpower, cost beneficial and short gestation period. Plant is dependent on costly principal fuel, but it stands justified in choice between costly power and no power, in case of exigencies.


GT No. I & III have been under shut-down due to forced outage since 20.7.99 & 14.5.96 respectively. In order to revive the same, BHEL Gas Turbine Services (BGGTS) were entrusted with the work of major inspection towards overhauling. It was detected that major components in the critical zones including turbine rotor and stator portion have sustained extensive damage, in both the Units. Due to nature and extent of damage in both the units being same, the possibility of cannibalization of either one to revive the other thus stands ruled out. Action has been taken to re-commissioning the Units on Renovation by procuring Spares GT No. II is available for generation. However, it has not been synchronized since 3rd November 03. In general Gas Turbine is being run only on advise of CLD to meet the system demand that too in extreme urgency as the cost of generated power from GT is unacceptably high. To keep the Unit healthy for meeting up the power demand at the time of requirement during extreme emergency condition, it has been decided to run this Unit at full speed no load (FSNL) for one hour at an interval of one month.

Hydro Power Projects

DVC has three Hydel Power Station Maithon (3x20 MW), Panchet (2x40 MW) and Tilaiya (2x2 MW). Location & Installed Capacity of Hydel Power Plants of DVC : (i) Maithon Hydel Power Station River Barakar, Dist. Burdwan, State West Bengal, Installed Capacity : 60 MW ( 3x20 MW Units) Date of Commissioning : U # 1 Oct.57, U # 2 Mar.58, U # 3 Dec.58. (ii) Panchet Hydel Power Station River Damodar, Dist. Dhanbad, State Jharkhand, Installed Capacity : 80 MW ( 2x40 MW Units ) Date of Commissioning : U# 1 Dec.59, U # 2 Mar.91 (iii) Tilaiya Hydel Power Station. River Barakar, Dist. Hazaribagh, State Jharkhand, Installed Capacity : 4 MW ( 2x2 MW Units ) Date of Commissioning : U # 1 - Feb.53, U # 2 Jul.53. Generation of these Plants mainly depends on Rain Fall and scheduled water release for irrigation & flood control purpose. A detailed R&M/ Up rating program has been taken up for Maithon & Panchet Hydel as per R&M scheme shown in the Appendix - F enclosed.