GENERATION

RENOVATION &
MODERNISATION
R. K. Jain
Director (Technical)

NTPC Limited

India Electricity 2006

11th May, 2006

INDIAN POWER SECTOR

Present Status:
Per capita consumption about 600 units per annum
Installed Capacity 1,24,287 MW (April, 2006)
Indias 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 inefficient and
have poor availability

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 capacity addition
augmentation.

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
1.PC fired
2.Fluidized bed combustion-Reduces Sox, NOx
Emissions
3.Indirect 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-ArtTechnology.
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.

Fuel consumption

Rehabilitation

per kWh

Rehabilitation
w/o efficiency
improvement
Rehabilitation
with efficiency
improvement

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

S.No.
S.No.

PARTICULARS

i)
i)

iii)

iv)

Number of thermal power stations

Number of thermal power stations

ii)
ii)

PARTICULARS

iii)

13

Number of thermal units

Number of thermal units

Estimated Cost

Estimated Cost

13

57

57

Rs.977 crores

iv)
Total
Capacity involved
Total Capacity
involved
14270 MW

Rs.977 crores

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 Plan

POWER PLANT R&M OBJECTIVES

availability
improvement

efficiency upgrading

environmental
control updating

increased electrical
output

reduced fuel
consumption

emissions within
new norms

life extension

improved reliability

RESULTS
increased power
output

reduced power
generation cost

plus
CDM BENEFITS

operation free
of restrictions

Challenges in R&M

Limited
Agencies
for
implementation in the country.

R&M

Prohibitive cost of New Technologies

impediment for introduction on wider
scale.
Unfavorable cost benefit analysis.
R&M activity to be linked
planned shut down.

with

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

NTPCs 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.

NTPCs 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.

Governments 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.

Governments 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) / Recommissioning / Residual Life Assessment (RLA)
Funds being provided by PFC / REC

APDP-R&M

Highlights of Achievement
Proj.

PLF
bef.

PLF
aft.

% imp.
in PLF

SOC
bef.

SOC
aft.

% imp. APC
in SOC bef.

APC
aft.

% imp.
in APC

CTPS
3x140
MW

23.97

72.66

203.13

28.60

0.80

97.20

22.30

11.43

48.75

DTPS
1x140
MW

36.78

65.41

77.84

5.28

1.88

64.40

12.59

9.88

21.52

GTPS
2x210
MW

45.00

84.00

93.19

3.00

0.70

76.67

12.40

10.23

17.50

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