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Renovation Modernization

& Up rating of Hydro Power Plants


Presentation

About UJVN Ltd.


UJVN Ltd. is a part of erstwhile UPSEB
After bifurcation of Uttar Pradesh,
Uttarakhand came into existence in year
2000
Due to above bifurcation Uttarakhand Jal
Vidyut Nigam (now known as UJVN Ltd.)
came into existence in Year 2001

Core Business of UJVN Ltd.


UJVN Ltd operates into the following areas:
Generation of Power from Hydro Power Plants
Construction of New Hydro Power Station
(LHP & SHP)

UJVN Ltd. has intended to diversify its business


in the following areas also:
Solar
Gas
Thermal

UJVNL is a wholly owned Corporation of the


Government of Uttarakhand set up for managing
hydro power generation from existing power
stations and development, promotions of new
hydro projects with the purpose of harnessing
potential hydro power resources of the State
UJVNL operates hydropower plants ranging in
capacity from 0.2 MW to 304 MW, totaling up to
1306 MW

PROBLEMS: CONSTRUCTION OF NEW


PROJECTS
Inaccessible Sites
Obtaining techno-economic clearances from
CEA/CWC
Environment & Forest Clearance.
Defence clearance
Land Acquisition & Rehabilitation
Geological Risks
Inter state aspects

Renovation Modernization &


Upgradation
In the present scenario of resource
constraint and to tide over the shortage of
electricity, Renovation, Modernization &
Up rating (RM&U) of the existing/old
hydro electric power projects is considered
as one of the best options, as this is cost
effective and quicker to achieve than
setting up of new green field power
projects.

In order to augment the


hydropower generation and to
improve the availability of existing
hydro
power
projects,
Government of India also placed
emphasis on RM&U of various
existing old power projects in the
country.
Govt. of India constituted a
National Committee in 1987 and a
Standing Committee in 1998.

Reasons for RM&U

No or Minimum clearances required


Less Gestation Period up to 3 to 4 years
Less Risk
Less cost as against equivalent new project
Easy Financing
Technological Advancement
Exploration of Safety Margins and Overload
Margins in the Old design
Life Extension of Existing Facilities

Stages of RMU
Identification of the Project for RMU.
RLA & LE Studies (Residual
Assessment & Life Extension).
Detailed Project Report.
Tendering & Award of work.
Execution

Life

RLA & LE Studies


Systematic way of checking health of
every component of the old hydro power
station is done by Residual Life
Assessment and Life Extension (RLA &
LE) studies. This study helps in assessing
the uprating of the existing facilities of the
plants. RLA studies are helpful in
determining which component of the plant
to retain and which one to discard and
replace.

Technical Parameters of UJVN Ltd


Projects under RM&U
Sl.
No.

Name of Power
Station

Commiss
ioning
Year

River

Insta
lled
Capa
city
(MW)

Type of
Runner

Number
of Unit

1.

Chibro

1975

Tons

240

Francis

2.

Khodri

1984

Tons

120

Francis

3.

Dhakrani

1965

Yamuna

33.75 Kaplan

4.

Dhalipur

1965

Yamuna

51

Kaplan

5.

Kulhal

1975

Yamuna

30

Francis

6.

Tiloth

1984

Bhagirithi

90

Francis

7.

Chilla

1980

Ganga

144

Kaplan

8.

Ramganga

1975

Ramganga

198

Francis

9.

Khatima

1955

Sharda

41.4

Kaplan

10.

Pathri

1955

Ganga

20.4

Kaplan

11.

Mohammapur

1952

Ganga

9.3

Kaplan

Generation Details
Sl.
No.

Name of Power
Station

Average Generation
of last 10 years
(in MU)

Expected
Generation
after RMU
(in MU)

Additional
Generation
(in MU)

1.

Chibro

865

942

77

2.

Khodri

406

444

38

3.

Dhakrani

161

184

23

4.

Dhalipur

240

276

36

5.

Kulhal

145

183

38

6.

Tiloth

446

484

38

7.

Chilla

684

1074

390

8.

Ramganga

283

450

167

9.

Khatima

163

10.

Pathri

95

235
155

72
60

11.

Mohammapur

35

65

30

Total Gain = 970 MU

Financial Details
Sl.
No.

Name of Power Station

Total Project Cost


(in Crore)

Debt
Equity
Ratio

Financial Tie Up

1.

Chibro

185

80:20

KfW

2.

Khodri

170

80:20

KfW

3.

Dhakrani

117

80:20

KfW

4.

Dhalipur

117

80:20

KfW

5.

Kulhal

119

80:20

KfW

6.

Tiloth

127

80:20

KfW

7.

Chilla

337

80:20

CCC

8.

Ramganga

451

70:30

9.

Khatima

126

10.

Pathri

104

70:30
70:30

PFC
PNB

11.

Mohammapur

68

90:10

NABARD

Major Problems encountered in old Power Stations


Most of the Projects have already outlived its normal useful
life (30 to 55 yrs).
Excessive wear & tear of under water parts, resulting
inefficient operation of the power plant and consequently derating of the machine (s).
No mechanism for measurement of flow through turbines.
Old and obsolete Governors.
Old and obsolete Excitation system.
Automation system of the power house is defunct ional. It
takes more time to start / stop the units.
Old and non functional Control & Protection system. Most of
the controls of the Power Station are under manual operation.
Unavailability of spare parts of outdated systems and
equipment.

Pathri HEP
Average annual energy generation
Proposed annual energy generation
after M&U
Expected gain in energy

Project Cost
Project Cost (Including IDC)
Debt Equity ratio
Tariff (Rs/kWH)
First Year Tariff
Tariff after repayment of loan
Levelized Tariff

89.91 MU
155.6MU
65.69 MU

Rs. 70.86 Crore


Rs.105.62 Crore
70:30
Rs 1.4
Rs 0.54
Rs 1.03

Mohammadpur HEP
Average annual energy generation
Proposed annual energy generation after M&U
Expected gain in energy

Project Cost
Project Cost (Including IDC)
Debt Equity ratio
Tariff (Rs/kWH)
First Year Tariff
Tariff after repayment of loan
Levelized Tariff

35 MU
64.92 MU
29.92 MU

Rs. 53.66 Crore


Rs. 64.35 Crore
90:10
Rs 2.03
Rs 0.74
Rs 1.78

Proposed RMU Works


Replacement of turbines and associated
accessories with the provision of new
runner/runner blade of improved design
having higher efficiency.
Provision of new sets of guide vane and
replacement of grease lubricated bearings
by self lubricated bushes.
Replacement of new digital governor
system.

Provision of new static excitation system.


Installation of monitoring system for
turbine and generator.
Replacement of Control, Protection and
Instrumentation System by the state-of- art
technology.
Refurbishment of generator with provision
of new class F insulated rotor windings
,cooling water system, CO2 system and
common auxiliaries .

Phasing of RMU Schemes


In the first phase following two plants have
been taken up for RMU in year 2010 and
execution is under progress:
Pathri (3 X 6.8 MW)
Mohammadpur ( 3 X 3.1 MW)

Methodology for Execution of RM&U


Two different mode has been adopted for RM&U
of Pathri & Mohammadpur Power Stations:
For Pathri Power Station 1 month shutdown of unit
was given to the firm for Reverse Engineering.
Thereafter prolonged shutdown of Ist unit was given
after detailed engineering.
Thus schedule of shutdown of units are as follows:
Unit # 1

Unit # 2
Unit # 3

:
:

1 month for reverse engineering and


12 months thereafter
10 months
10 months

After Reverse Engineering the scope of the


Contract changed and based on this change
the Schedule & Cost of the Project also
changed;
After acceptance of changes the schedule of
shutdown changes as follows:
Unit # 1

Unit # 2
Unit # 3

:
:

1 month for reverse engineering and


18 months thereafter
9 months
9 months

Shutdown of the units is planned only after


availability of supplies at site for the last two
units;

Problems During Execution


Mohammadpur & Pathri Power Station are
under execution. Following issues were
noticed till date:
It has been noticed that the scope of the Project
got exceed due to replacement of the items which
are to be repaired as per scope.
Main reason which has been noticed is non-accessibility
of items during RLA & LE studies, which is the basis for
scope preparation;
Due to these changes in the scope the time schedule
and cost also got affected.

Execution of Mohammadpur
Contract for extensive RM&U of this plant was awarded
on 6th April 2010;
Work started from 6th June 2010;
Total Contractual Period is 36 months;
Time allocated for three unit as per contract was:
Unit # 1
Unit # 2
Unit # 3

:
:
:

18 months
9 months
9 months

Due to change in scope the first unit is commissioned


after 22 months. Efforts are being to compensate this by
reducing the execution time of other units.

Overall Benefit from RMU


After completion of Pathri & Mohammadpur
R&M, UJVNL shall have a addition of about
90 MU.
Life extension of about 30-35 years of the
existing old plants.
Better efficiency of plant & machines;
Better know-how of employees;
Centralized monitoring of all the plants.

One Unit of Mohammadpur Power Station


has been commissioned on 30th April 2012
after extensive RM&U.
Switchyard & Control Room has been
commissioned;
All common works associated with the Units
have been completed;

New unit has generated additional 2.546


MU from May 2012 to August 2012 (7.614
MU) as compared to its generation in
same months of 2009 (5.068MU).

Issues & Challenges


Due to demand supply gap it is very difficult to undertake the RMU
of plants;
Not much of expertise is available in the Indian market for Scope
determination of RMU Project:
It is not possible to engage any manufacture for RLA & LE studies,
since such action shall debar him from participation in tender for
execution.
There is a dearth of good consultancy firm / agency for conducting tests
required in RLA & LE studies.
Owner of the plant does not give the unit for complete dismantling,
which results in wrong assessment of scope.

No standard benchmark for such projects;


Non availability of initial documents of the Projects;
Issues related to copy right of the original manufacturer;
Employees reluctance to accept the change;

Thank You