Combine From Ofoct

KARNATAKA POWER CORPORATION LTD
RAICHUR THERMAL POWER STATION UNITS 1 & 2 (2X210MW)

DETAILED PROJECT REPORT FOR RENOVATION & MODERNIZATION

RAICHUR THERMAL POWER STATION
COMPREHENSIVE DETAILED PROJECT REPORT FOR

RENOVATION & MODERNIZATION OF
RTPS - UNITS 1 & 2 (2X210MW)
AUGUST 2016
M/S. TUV SUD SOUTH ASIA PVT. LTD

Solitaire, 4th Floor, ITI Road, Aundh,
Pune - 411 007, Maharashtra, India
Table of Contents
Chapter No. Title No. of
Pages
Executive Summary 5
1.0 Introduction 03
2.0 Objective of the Comprehensive DPR 20
3.0 Inputs for preparation of Comprehensive DPR 02
4.0 Review of data 26
5.0 Cost, Schedule & Benefits 15
List of Tables
Table No. Title Chapter Page No.

No.
Table 1 Total estimated cost of R&M works 1 3
Table 2 Cost Benefit Analysis and Break Even 1 4
Period
Table 2.1 Brief Details of the Existing Units at
RTPS
Table 2.2 Operational Details of Units 1 & 2 2 5
Table 2.3 Power generated by Units 1 and 2 2 6
Table 2.4 PAF, % 2 7
Table 2.5 PLF, % 2 8
Table 2.6 APC, % 2 9
Table 2.7 Incidents of Unit Trips & Major cause of 2 10
Trip
Table 2.8 Unit Outages, Hours 2 12
Table 2.9 HFO Consumption, KL/year 2 13
Table 2.10 LDO Consumption, KL/year 2 14
(No Tables in Chapter 3)
Table 4.1 Brief Details of Boilers 1&2 of Units 1&2 4 1
Table 4.2 Scope of R&M works for Boilers 1 and 2 4 6
Table 4.3 Design Data for ESP 4 10
Table 4.4 Data of Coal for ESP Refurbishment 4 11
Table 4.5 Brief Details Turbine Unit 1 4 11
Table 4.6 Brief Details Turbine Unit 2 4 12
Table 4.7 Brief Details Generator Unit 1 4 13
Table 4.8 Brief Details Generator Unit 2 4 14
Table 4.9 Details of HT Motors Proposed For 4 19
Replacement
Table 4.10 Details of HT Switch Gear Proposed For 4 20
Replacement
Table 5.1 Cost for R&M Works (Phase 1) 5 2
Table 5.2 Estimated cost for R&M Works (Phase 2) 5 5
Table 5.3 Total Estimated cost for R&M Works 5 6
(Phase 1& 2)
Table 5.4 Phasing of Expenses 5 10
Table 5.5 Cost Benefit Analysis and Break Even 5 11
Period
List of Annexure
Annexure No. Title No. of Pages
01 RLA &CAS Study of Boilers 1 and Boiler 2 15
02 Condition Assessment of Turbine Generators 1 05
and 2
Bibliography
Appendix No. Title No. of Pages

01 CII – Detailed Energy Audit 129
02 BHEL – Condition Assessment 62
Study-Boiler-1
03 BHEL – Residual Life Assessment (RLA) 437
Study-Boiler-2
04 EESL – Baseline Energy Audit – Volume-1 309 & 187
&2
05 Performance Parameters of Units 1 & 2 MPR-2010 to 2013,
TAR for Units 1 &
2 each – 2010 to
2014
06 Photos of Residual Life Assessment (RLA) 11
Study
07 Assessment of Soundness of Chimney – 1 39
08 Assessment of Soundness of Chimney – 2 39
09 Assessment of Soundness of Cooling 79
Tower – 1
10 Assessment of Soundness of Cooling 79
Tower – 2
11 Assessment of Ash slurry Disposal system 20
for Unit 1 & 2
12 Gravimetric feeder Comparison and Cost In Excel format
Estimation
Legend
Abbreviation Expansion
DPR Detailed Project Report
R&M Renovation & Modernization
KPCL Karnataka Power Corporation Ltd.
RTPS Raichur Thermal Power Station
LE Life Extension
RLAS Residual Life Assessment Study
CAS Condition Assessment Study
PLF Plant Load Factor
RH Re-heater
ST Station Transformer
ICT Interconnection Transformer
MU Million Units
GCV Gross Calorific Value
Kcal Kilo calories
kg Kilograms
Kcal / kg Kilo Calories per Kilogram
% Percent.
PAF Plant Availability Factor
APC Auxiliary Power Consumption
KL Kilo Liters
EES Energy Efficiency Study
HPT High Pressure Turbine
C&I Control and Instrumentation
BFP Boiler Feed Pumps
HFO Heavy Furnace Oil
LDO Light Diesel Oil
CEA Central Electricity Authority
HP High Pressure
APH Air Preheater
EA Energy Audit
GOI Government of India
BHEL Bharat Heavy Electricals Ltd.
BTG Boiler, Turbo Generator
IBR Indian Boiler Regulations
OEM Original Equipment Manufacturer.
O&M Operation and Maintenance
RPSH Radiant Platen Superheater
LTSH Low Temperature Superheater
RDSH Reheater desuperheater
TMCR Turbine Maximum Continuous Rating
BMCR Boiler Maximum Continuous Rating
ESP Electro Static precipitator
HT High Tension
HP High Pressure
Mg/Ncum Milligrams per Normal cubic meter
TG Turbo Generator set
H2 Hydrogen
CO2 Carbon Di oxide
AC Alternating current
LP Low pressure
IP Intermediate Pressure
DM Demineralized
SS Stainless Steel
ID Induced Draft
A/C Air conditioning
DG Diesel Generator
LT Low Tension
ATRS Automatic Turbine Running system
CPRI Central Power Research Institute
FD Forced Draft
PA Primary Air
PRDS Pressure Reducing and Desuperheating station
MPR Monthly Performance Report
TAR Trip Analysis Report
CRH Cold Reheat
CEP Condensate Extraction Pump
CWP Circulating water pump
BOP Balance of Plant
SCADA Supervisory control and Data Acquisition
E&C Erection and Commissioning

CAPEX Capital Expenditure
NDT Non Destructive Testing
ml Mille Liter
EXECUTIVE SUMMARY
1. Power plants which are more than 25 years old are not operating at the design
capacity and efficiency. The existing generation capacity can be maximized by suitable
R&M works of existing plants which is one of the most cost effective options for
increasing the power availability due to short gestation period and lower investment
requirement.
2. RTPS is a coal fired power station located in the Raichur District of the state of
Karnataka, operated & maintained by KPCL. Units 1 & 2 of RTPS were commissioned
in 1985 &1986 respectively. These units have run more than two lakh hours each and
have generated 37849 Mu and 37637 Mu respectively till 28.2.2015.
3. KPCL/RTPS have carried out RLA, CA and EA using the services of various agencies
such as BHEL and CPRI on the Boilers, TG units and auxiliaries of Unit 1 and 2. Based
on these studies, KPCL invited proposals for Consultancy Services for preparation of a
Comprehensive Detailed Project Report (DPR) for R&M Works to improve the
availability and residual life of these units. The Comprehensive DPR was also required
to cover the issue of whether to carry out R&M of Units 1 and 2 or go for a new higher
capacity unit as replacement for these Units. Various environmental issues such as
taking up R&M on the existing ESP’s of Units 1 and 2 in case of decision to go with
R&M of Units 1 and 2 were also to be addressed in the report. M/s. TUV SUD South
Asia Pvt. Ltd was the successful bidder for the above job.
4. Analysis of the various operating parameters of these units shows that the generation
levels of both units are well below the expected generation from similar plants. Trips
due to failures of components and equipment is frequent leading to increased down
time, low availability and plant load factors. HFO, LDO and auxiliary power
consumption is high. Hence it is necessary to look into all the deficiencies in the
various equipment, system design features, account for the inferior grade of coal
presently being supplied to the plant and take a holistic approach in deciding the R&M
for Units 1 and 2.
5. RLA study of Units 1&2 boilers was carried out by OEM BHEL during the year 2005 &
2010 respectively. RLA study of Unit-1 turbine was carried out during 2006 and that
of Unit-2 turbine was carried out during 2010. CA of Unit 1 Boiler was carried by BHEL
in July 2009. Baseline Energy Audit has been conducted by CPRI during the year
2011. All the above studies form the basis of this Comprehensive DPR. CA on ESP of
Unit 2 has been carried out by BHE in August 2011.
6. Ministry of Power, GOI guidelines allows R&M works for power stations where BHEL
are the OEM’s for the Boiler and TG (BTG) sets may be awarded to BHEL through
negotiations. The R& M works may be implemented in two Phases as follows:
Phase 1: R&M works pertaining to BTG, BOP and Electrical including retrofitting
of ESP for which M/s BHEL / OEM.
Phase 2: R&M works pertaining to fire alarm system & DM plant, ash handling
plant, replacement of feeders, certain works in 220 KV switch yard,
auxiliary transformers of Unit 2, new DG sets, SCADA for switch yard
and other miscellaneous works like lighting etc. are required and may
be taken up on tender basis.
7. M/s KPCL has discussed with M/s BHEL and consolidated all the works which need to
be taken up in Phase 1 and obtained the cost. For the Phase 2 works the cost including
supply, E&C, taxes etc. is estimated by M/s TUV- SUD. The total cost for Phase 1 and
Phase 2 works is as given in Table 1.
Table 1- Total Estimated cost for R&M Works (Phase 1& 2)
S.No Area/Work Rs Lakhs
1 Under execution + Phase 1 68775.20
2 Phase 2 9319.10
Total 78094.30
IDC 18115.00
Gross Total 96215.00
8. The schedule for completion of R&M works under Phase 1 & 2 is estimated as 48
months from the date of contract finalization by KPCL on BHEL,

9. Replacing existing old units by a higher capacity new unit is an alternative to R&M.
However going in for a new larger capacity set will pose the following difficulties:
 The cost for R&M works is around Rs 1.8 crores/MW as against Rs 6-7
crores/MW for a new unit.
 New Power Purchase Agreement has to be executed.
 Obtaining fresh statutory clearances e.g. environmental clearance, etc.
 Longer implementation and loss in power availability to grid.
 Major problems in dismantling/removal of existing structures, equipment and
machinery and preparation of site for erection of new unit.
 Coal conveyers feeding Units 1&2 also feed Unit 3. For a new Unit his
arrangement has to be modified affecting operation of Unit 3. Coal conveyor
feeding Units 4 to 8 may also need shifting.
 Higher capacity unit needs power evacuation at 400KV needing changes to
existing 220KV switch yard affecting the evacuation from Unit 3 also.
10. Cost benefit analysis of R&M and break even period are given in the Table 2
Table 2 - Cost Benefit Analysis and Break Even Period
Unit 1 Unit2
Sl. After After
Description Unit Existing Existing
No. R&M R&M
1 Station Heat Rate Kcal/Kwh 2615 2463 2716 2463
2 Plant Load Factor % 64.37% 80.00% 63.79% 80.00%

3 Aux. Power Cons % 10.84 9 10.87 9
4 Cost of Coal per Unit Rs. / Kwh 2.68 2.52 2.78 2.52
5 Cost of Oil per year Rs. Crore 17.99 13.06 17.83 13.06
6 Cost of fuel/year Rs. Crore 334.96 384.09 344.07 384.09
Cost of fuel per unit

7 Rs/Kwh 2.83 2.61 2.93 2.61
generated
8 Fixed Charges Rs/Unit 0.8067 1.0098 0.8067 1.0098
Revenue generated
9 per annum Rs. Crore 85.17 133.87 84.37 133.87
considering only
fixed charges
Net Benefit per

10 Rs. Crore 49 49
annum
Benefit per unit
after R&M
11 Rs. / kwh 0.033 0.034
considering fixed
charges
Total Benefit
12 ( Fixed charges + Rs. / kwh 0.253 0.354
fuel charges)
11. R&M works is expected to extend the life of the units by about 15 years provided the plant
and equipment are operated and maintained as per recommendation.
12. KPCL/RTPS may go for internal funding partly and balance fund the may take from
International funding banks like World Bank / Asian Development Bank / KfW Development
Bank or Power Finance Corporation Ltd, India. It may be partly by equity and the rest by
Debt from banks or international funding agencies. The ratio of equity to debt for such
project work will generally be in the ratio of Equity to Debt as 20:80. Interest rates will vary
based on the source of fund and funding agency.
13. Time line for Phase III scope of works for Unit I & II R&M:
S.No Area/Work Time Required for

Completion
1 Civil works for Chimney 12 months
2 Civil works of Cooling tower 6 months
3 Ash bund works 24 months
4 Construction of Barrage across river at Girijapur 20 months
5 Replacement of HT Switchgears and breakers in APH

1&2
6 Replacement of HT Switchgears and breakers in RWPH
7 Generator Protection system and Replacement of HT
Switchgears and breakers in Station Bus A&B
8 Replacement of HT breakers in Unit II

INTRODUCTION
1.1 There has been substantial increase in thermal power generation capacity addition in
each of the successive Five Year Plans of India; yet there exists a gap between
demand and supply of power. The new installations are highly capital intensive, and
have long gestation period.
1.2 Power plants which are more than 25 years old are not operating at the design
capacity and efficiency. Hence the existing generation capacity can be maximized by
suitable Renovation and Modernization (R&M) and such R&M works of existing plants
is one of the most cost effective options for increasing the power availability due to
short gestation period and lower investment requirement. The R&M projects supported
by World Bank focus on heat rate improvement in addition to life extension, capacity
augmentation, reduction in auxiliary power consumption, improved availability,
reliability, and reduced emissions thus improving the greenhouse effect.
1.3 Many thermal power stations in the country were designed for good quality coals.
However in actual practice the coal available for most plants is of inferior quality
compared to the design coal. The design unit heat rate/efficiency was also based on
the technologies prevailing at that time. These plants now require higher amount of
coal for producing steam for the rated capacity of power generation. Thus, the capacity
of the raw coal feeding system, pulverisers, primary air fan system, ash handling
system etc., for these power stations may have to be augmented during R&M to
generate steam at the rated capacity of the boiler, provided the furnace size is
adequate to burn required quantity of coal with inferior quality.

1.4 For over four decades, the Karnataka Power Corporation Ltd (KPCL) has been a prime
mover behind power sector in the state. KPCL today has an installed capacity of 6498
MW in thermal, hydro, solar and wind with 2325 MW in the pipeline. The 1720 MW
Raichur Thermal power Station located in Raichur District is accredited with ISO
14001-2004 certification for its environmental measures. From an industry vantage
point, KPCL has raised the bar on the quality of deliverables and is working constantly
at lowering cost per MW- a commendable Cost-Value equation that has become a
bench mark on the national grid.
1.5 The leverage point of KPCL initiatives are its resource management strengths- right
across planning, design, finance and project engineering towards achieving maximum
generation from various sources.
In order to bridge the gap between demand and supply, especially in the context of
limited financial resources available, it has become imperative to look for other options
which are not as capital intensive as new capacity addition and which could be
implemented in a comparatively shorter time frame. In this regard, optimum utilization
of existing installed capacity in the country to maximize the generation through
Renovation & Modernization (R&M) of existing power plants is considered to be the
most cost effective option.
1.6 RTPS is a coal fired power station located in the Raichur District of the state of
Karnataka. It is operated by KPCL and was the first thermal power plant to be set up in
the State. The power station was commissioned during various periods from 1985 and
it accounts for a major part of the total electricity generated in Karnataka. The current
installed capacity of the station is 1720 MW. The station has 7 units each of capacity
210 MW and one Unit of capacity 250 MW.
1.7 Unit 1 of RTPS was commissioned in 1985 and Unit 2 was commissioned in 1986.
These units have served over 29 years, running for more than two lakh hours and have
generated 37849.797 Mu and 37637.364 Mu respectively till 28.2.2015. Hence it is

high time to take up R&M works for enhancement of life of these old units. Frequent
failure of boiler tubes, turbine, excessive leakage in air pre-heaters, electrical flash
overs, reduced reliability of equipment, frequent tripping of units, higher specific fuel
consumption, etc. are the driving factors for considering R& M and LE of these Units.
1.8 KPCL/RTPS have carried out RLA & CA using the services of various agencies such
as BHEL and CPRI on the boilers, TG units and auxiliaries of Unit 1 and 2.
Based on these studies, KPCL invited proposals for Consultancy Services for
preparation of a Comprehensive DPR for R&M Works to improve the availability and
residual life of RTPS, Units 1 & 2 (2X210 MW).
The Comprehensive DPR was also required to cover the issue of whether to carry out
R&M of Units 1 and 2 or go for a new higher capacity unit as replacement for these
Units. Various environmental issues such as taking up R&M on the existing ESP’s of
Units 1 and 2 in case of decision to go with R&M of Units 1 and 2 were also to be
addressed in the report.
M/s. TUV SUD South Asia Pvt Ltd was the successful bidder for the above job.
An order was issued by KPCL to M/s. TUV SUD South Asia Pvt Ltd, KPCL
PO No.CE(O&M)/RTPS/U1&2/R&M/DPR/JO-235M/1141 dated 04th August 2014 for
preparation of the Comprehensive DPR for R&M works for these two units.
KPCL had carried out number of survey and had discussion with OEM for various
packages and also asked for quotation for various system / equipment. Based on above
KPCL received quote for above.
In May 2016 KPCL asked TUV-SUD for proposal for comprehensive DPR. TUV- SUD
submitted their proposal in June 2016.
Based on above KPCL placed Work order No. CE (O&M)/RTPS/U1&2/ R&M
/DPR/JO-235M/114 to M/s. TUV SUD South Asia Pvt. Ltd.
Under this order TUV – SUD have to undertake the followings scope of works:
To include in part of R&M works - Phase II
1. R&M works of Ash handling system including modification work of ash slurry
disposal system, to suit the head requirement due to augmentation of Ash pond
No.2 – stage-1.
2. R&M works of cooling tower including civil works if any.
3. Any other civil works to be taken up along with the R&M of BTG, which
necessitates shutdown of units.
To include following works as part of R&M works - to be taken up as Phase -3 works (which
can be taken up without shutdown of units):
1. Augmentation of Ash Pond -2 stage-1 civil works.
2. Construction of barrage across river at Girijapur.
3. Retrofitting of Volumetric feeders.
4. Augmentation of Ash Pond
5. Cooling Tower & associated civil works
6. Civil works of BTG
7. Retrofitting ESP
8. Electrical package:
a. Replacement of Cables for Transformers.
b. Balance HT Switchgear to include station Bus A&B, AHP 1&2, Raw water
pump house.
2.0 OBJECTIVE OF THE COMPREHENSIVE

DPR, DETAILS OF RTPS UNITS 1&2 AND
REQUIREMENT OF R&M
2.1 OBJECTIVES OF Comprehensive DPR
The main objectives of this Comprehensive DPR are as follows:
 To study and recommend ways and means for enhancing the life of Units 1&2 with
a view to maximize the generation from these units with optimal utilization of
available resources. The effort to enhance the life of the equipment and improve
efficiency of the plant would involve replacement of existing worn out/ aged and
obsolete equipment/ component in operation with those with more efficient and
latest designs incorporating the state of the art technologies and improved
metallurgy. These Units were originally designed for a coal of GCV of 4700 Kcal/
Kg. This has deteriorated over the last 3 decades resulting in lower PLF compared
to rated value and the ash generation quantity has increased substantially over the
rated value leading to under capacity of the ash handling systems. The loss in PLF
can be partly compensated by improving the efficiency of boiler which may require
replacement of some portions of pressure parts like Platen Coils, RH coils,
economizer coils etc. Ash handling plant capacity augmentation can be done by
replacing the old ash pumps and pipe work.
 More stringent environmental regulations which have come into force in the last 3
decades since the installation of these units call for refurbishment of the existing
pollution control systems to meet the present day standards and also address the
safety of the men, material, machinery and the health of flora & fauna.
 Aging and deterioration in the condition of the units has resulted in more trips,
increased maintenance during annual overhauls, higher auxiliary power
consumption and higher oil consumption due to more number of start-ups and
part load operations. The result of all these factors is higher operating and
generation cost.
 Hence the study has to Identify the areas in Unit’s 1 and 2 which need renovation,
replacement and modernization with a view to improve the availability, generation,
efficiency and life of these units based on various studies already carried out by
KPCL/RTPS.
 Address various environmental issues such as taking up R&M on the existing
ESP’s of Units 1 and 2 with a view to reduce the final emission levels from the
boiler flue gases.
 Whether to or go for a completely new higher capacity unit as replacement for
these Units as an alternative to carry out R&M of Units 1 and 2 considering
economic viability.
Based on the scope of services / scope ,TUV –SUD have to cover the followings
To include in part of R&M works - Phase II
4. R&M works of Ash handling system including modification work of ash slurry
disposal system, to suit the head requirement due to augmentation of Ash pond
No.2 – stage-1.
5. R&M works of cooling tower including civil works if any.
6. Any other civil works to be taken up along with the R&M of BTG, which
necessitates shutdown of units.
To include following works as part of R&M works - to be taken up as Phase -3 works (which
can be taken up without shutdown of units):
9. Augmentation of Ash Pond -2 stage-1 civil works.
10. Construction of barrage across river at Girijapur.
11. Retrofitting of Volumetric feeders.
12. Augmentation of Ash Pond
13. Cooling Tower & associated civil works
14. Civil works of BTG
15. Retrofitting ESP
16. Electrical package:
c. Replacement of Cables for Transformers.
d. Balance HT Switchgear to include station Bus A&B, AHP 1&2, Raw water
pump house.
2.2 Following areas of Units 1&2 are covered by this Comprehensive DPR for carrying out R&M
studies:
 Boilers
 Bowl mills
 Turbine Generators and their auxiliaries
 Ash handling plant
 Water Systems including DM Plant
 Fuel oil system
 Outdoor switch yard
 LT&HT Motors, switch gears and cabling.
 C&I
 ESP’s
 Ash slurry disposal and Ash pond
 Cooling Tower including associated Civil work
 Chimney associated civil work
 Volumetric Feeders
2.3 EXISTING PROJECT DETAILS
 RTPS is situated on the bank of river Krishna about 18 Kms north of Raichur town,
Karnataka state. The coordinates are 16°21′18″N & 77°20′31″E and the altitude is
350 M above MSL.
 RTPS is easily approachable by road and rail. The Raichur-Hyderabad Highway
passes adjacent to the project site. The nearest Railway station to RTPS is Krishna
Railway Station on SC Railway. The power station is also equipped with a railway
siding called RTPS Railway siding to which full wagon loads can be booked.
However to reach the site one has to detrain at Raichur Railway Station on the SC
Railway which is about 18 Km away from the site.
 The average climatic conditions at the site are as follows:

 Ambient Air Temperature: Maximum - 45 degree C.
Minimum - 06 degree C.
 Design Temperature for all Electrical Equipment - 50 degree C.
 Relative Humidity :
Maximum - 85%
Minimum - 20%
 Average - 65%
 Rainfall - June to September - 720 mm
 Wind Velocity :
Average - 29 Km/hr.
Maximum - 100 Km/hr.
 Prevailing wind direction - NE, SW, SE & W
 Brief details of the units in operation in the plant are given in the following
Table 2-1
Table 2.1 Brief Details of the Existing Units at RTPS
Stage Unit Commissioning Project cost in Power Evacuation

Date Crores
I 1 29.03.1985 736.56 220 KV lines:
a. Lingsugur
2 02.03.1986 1,2&3,
b. Raichur 1&2,
II 3 30.03.1991 290.09 c. Sedam 1&2,
d. Shahpur1&2.
III 4 29.09.1994 736.29 400 KV lines :

IV 5 31.01.1999 1335.96#
a. Mehabubnagar
6 22.07.1999
b. Munirabad,
V 7 10.12.2002 577.35 c. BTPS,
VI 8 09.04.2010 1062.55 d. Gooty 1&2.
# including lease cum sale amount of Rupees 474.97 crores

 RTPS uses coal for generation of electricity. Its daily requirement of coal is about
24,000 metric tons, delivered from Western Coalfields Ltd. and Mahanadi
Coalfields Ltd. RTPS generates about 2.73 million tons of total ash annually of
which fly ash is about 80% and the balance is bottom ash. Bottom ash which is in
the form of clinker is ground in clinker grinders mixed with water and pumped to the
ash bund. Fly-ash which is separated out from the flue gases in the ESP’s is
disposed off by converting it into wet slurry and dumping it in designated ash
ponds. A part of the fly ash is sold to cement manufacturing industries and other
small scale industries for manufacture of bricks and pavement tiles. The plant's
water requirement is met by pumping raw water from the Krishna River.
 The run of mine coal is pulverized and fired into the boilers that convert water into
high pressure steam. This steam generated is used to drive the turbines coupled to
electric generators which generate electricity. The plant can produce 42 MU per
day when it is functioning at full capacity.
 The power generated is evacuated through 220kV and 400kVpower lines from the
respective switchyards in the plant to the state grid. The 400kV yard is also
interconnected to 220kV yard by two ICT’s each of capacity 315MVA. Erection &
Commissioning of ICT-3 of 500MVA capacity is under progress. Start-up power for
this station is taken from 220kV system by ST-1 for units 1 & 2, ST-2 for Units 3&4,
ST-3 for Units 5&6 and ST-4 for Units 7&8 with interlinking switchgear amongst
them.
 The height of this chimney of Unit I & II is 130m as reported. The Chimney Shell is
made up of RCC with 0.5m thickness at the bottom. Internal and external
circumference of the bottom Shell portion is 27m and 30m respectively.
 Natural Draft Cooling Tower is an important part of Unit –I & II of the entire project
and as reported was constructed by March 1985. The height of this cooling tower is
almost 130m.
2.4 PERFORMANCE PARAMETERS OF UNITS 1 & 2
2.4.1 These Units have been in service for almost three decades since their commissioning.
Operational details of these units are given in following Table 2-2:
Table 2.2: Operational Details of Units 1 & 2
DESCRIPTION UNIT-1 UNIT-2

Date of synchronization 29.03.1985 02.03.1986
Total running hours from the date of inception 2,01,378.14 2,03,570.04
(up to 28.2.2015), Hours
Total Power generation from the date of 37,849.797 37,637.364
inception (up to 28.2.2015), MU
Total number of trips from the date of inception 717 688
(up to 28.2.2015)
2.4.2 The units were originally designed for a coal of a GCV of 4700 Kcal/ Kg. The
coal properties have deteriorated over the last 3 decades resulting in lower
PLF compared to rated value and the ash generation quantity has increased
substantially over the rated value leading to under capacity of the ash
handling systems. Aging and deterioration in the condition of the units has
resulted in more trips, increased maintenance during annual overhauls,
higher auxiliary power consumption and higher oil consumption due to more
number of start-ups and part load operations. The result of all these factors is
higher operating and generation cost. Thus R&M of these units is necessary
for restoring the health of these units.
2.4.3 Data on various performance parameters of these units including trips etc.
furnished by RTPS is enclosed in Appendix 5 and are briefly discussed in the
following paragraphs.
2.4.4 Power generated by Units 1 and 2 during the last six years: is indicated
in tabular and graphic form in the following Table 2-3 and in Figure 1
respectively.
Rated Actual Actual

Year Generation, Generation Generation
capacity Unit-1 Unit-2
2009-10 1839.6 1187.60 1452.79
2010-11 1839.6 1034.72 850.25
2011-12 1839.6 1353.45 1165.95
2012-13 1839.6 1171.53 986.55
2013-14 1839.6 1079.82 1244.13
2014-15 till 28.2.2015 1839.6 1172.22 1229.838
Table 2.3 – Generation, MU/Year
Fig-1: Annual Generation in MU
1500 1452.79
Unit-1 Unit-2
1400 1353.45
1300
1187.6 1244.13
1200 1229.838
1165.95
1171.53 1172.22
1100
1034.72
1000 1079.82
986.55
900
850.25
800
Figure – 1
2.4.5 PAF during last Six years in tabular and graphic form is given in the
following Table 2-4 and in Figure 2 respectively.
Table 2.4 – PAF, %

Year Unit-1 Unit-2
2009-10 82.24 88.66

2010-11
2.4.6 76.32 59.63
2011-12
2.4.7 84.98 78.77
2012-13 88.24 67.13
2.4.8
2013-14 69.23 88.71
2.4.9
2014-15 (Feb) 78.22 85.55
Fig-2: PAF , %
88.66 Unit-1 Unit-2
88.71
90 88.24
84.98 85.55
82.24 78.77
80 76.32
78.22
70 67.13
59.63
69.23
60
50
U…
2009-10
2010-11
2011-12 U…
2012-13
2013-14
2014-15 (Feb)
2.4.6 PLF During last Six years in tabular and graphic form is given in the following Table 2-5 and
in Figure 3 respectively.
Table 2.5 - PLF, %

Year Unit 1 Unit 2
2009-10 64.56 78.97
2010-11 56.25 46.22
2011-12 73.37 63.21
2012-13 63.68 53.63
2013-14 58.70 67.63
2014-15 till 28-2-15 69.64 73.06
Fig-3:PLF (%)
Unit-1 Unit-2
78.97
80
73.37
67.63 73.06
70 64.56 63.21
63.68 69.64
60 56.25 53.63
58.7
46.22
50
40
U…
2009-10
2010-11
2011-12 U…
2012-13
2013-14
2014-15(feb)
2.4.10 Station APC: during last Six years in tabular and graphic form is given in the
following Table 2-6 and in Figure 4 respectively.
Table 2.6 – APC, %
Year APC
2009-10 8.78
2010-11 9.67
2011-12 9.42
2012-13 9.79
2013-14 10.18
2014-15(Feb) 9.12
10.18
10.5
9.79
9.67
10
9.42
9.12
9.5
8.78
8.5
2009-10 2010-11 2011-12 2012-13 2013-14 2014-15(Feb) Station
Fig-4: APC (%)
2.4.7 Number of Trips during Last Six Years along with major reasons thereof is
tabulated in Table 2-7 below
Table-2.7: Incidents of Unit Trips & Major cause of Trip
Unit-1 Unit-2
No. Major cause of Trip No. Major cause of Trip
Year
of of
trips trips
Bottom ash seal trough BTF 3 times, Elect. Fault in
2009-1 leakage, reverse power one of the unit buses,
9 23
0
relay operation, etc.
Turbine axial shift, Coal shortage, BTF, Flame
bunker choking due to 42 failures (15 times)
2010-1
29
1 wet coal, No load
demand
BTF 2 times, Flame Non availability of mills,
2011-1
22 18
2 failures BAH leakage,
HPT vibration, Wet coal, BTF 9 times, Flame failure
2012-1
21 29
3 BTF
Turbine capital No load demand, PA-2A
2013-1
34 24
4 overhaul, DG supply motor cable fault, BTF (Re
failure, Flame failures heater), ID & Mill motor

(6 times) failure.
Boiler related trips Flame failure- 7 times,
including tube BTF-2 times, GT-4 trips,
2014-1
5 till 20 leakages-5 times, GT 24
28-2-15 related trips-3, BFP
trips-3 times.
The number of trips is diagrammatically shown in Figure 5 below
Fig-5: No. of trips Unit-1 Unit-2

45
42
40
35 34
29 29
30
25 22 24
23 24
21
20
20 18
15
10 9
0
2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 (Feb)
2.4.8 Unit outages During Last Six Years: Outages in a utility power station
can be a planned outage or a forced outage due to plant and equipment
failures. The outages both planned and forced for units 1 and 2 are listed in
Table 2-8 below.
Table-2.8: Unit Outages, Hours

Unit-1 Unit-2
Year Planned Forced Total Planned Forced Total
outage outage outage outage outage outage
2009-10 1097 458 1555 0 993 993
2010-11 530 1543 2074 2158 1377 3536
2011-12 722 597 1319 494 1371 1865
2012-13 383 996 1380 1172 1707 2879
474 2695 541 447 989

2013-14 2221
2014-15 till
650 1745 541
28-2-15
1095 616 1157
The outages of Unit 1 and Unit 2 are diagrammatically shown in Figures 6

and 7 respectively.
Fig-6: Unit-1 Outages in Hours

3000 Planned outage Forced outage Total outage in Hrs.
2695
2500
2074 2221
2000
1555 1543
1500 1097 1745
1319 1380
1000 996
722
458 1095
500 530 597
474 650
383
0
2009-10
2010-11
2011-12
2012-13
2013-14
2014-15
(Feb)
Fig-7:Unit-2 Outage Details Vs Year

Planned outage Forced outage Total outage in Hrs.
4000
3536
3500
3000 2879
2500
2158
2000 1865
1707
1500 1377 1371

993 1172 1157
989
1000 993
541 616
500 494 541
447
0
0
2009-10 2010-11 2011-12 2012-13 2013-14 2014-15(Feb)
2.4.9 HFO Consumption during Last Six Years is tabulated in following Table
2-9 and diagrammatically shown in Figure 8.
Table 2.9 HFO Consumption, KL/year
Year Unit-1 Unit-2

2009-10 1764 3097
2010-11 5926 4609
2011-12 2864 5206
2012-13 9404 7115
2013-14 3866 5842
2014-15
till 28-2-15 3244 3802
Unit-1 Unit-2
10000 9404
9000
8000
7115
7000
5926 5842
6000
5206
5000 4609
3866 3802
4000
3097 3244
2864
3000
1764
2000
1000
0
2009-10 2010-11 2011-12 2012-13 2013-14 2014-15(Feb)
Fig–8 Annual HFO Consumption (KL)
2.4.10 LDO Consumption during Last Five Years: is tabulated in

Table 2-10 and diagrammatically shown in Figure 9.
Table 2-10: LDO Consumption, KL/year
Year Unit-1 Unit-2
2009-10 44.41 83.39
2010-11 200.88 164.18
2011-12 52.62 182.61
2012-13 &2013-14 LDO not procured

LDO Consumption, KL/year
Unit-1 Unit-2
250
200.88
200 182.61
164.18
150
83.39
100
52.62
44.41
50
0
2009-10 2010-11 2011-12
2.5 ANALYSIS OF PERFORMANCE PARAMETERS & NEED FOR R&M

 A review of the generation data in the last six years shows that the maximum
generation of Unit 1 was about 73.5% in 2011-12 which has reduced during the
subsequent years and even in the current year 2014-15 it is not expected to cross
70%. In the case Unit 2 the highest generation was about 79% in 2009-2010 which has
dropped in the subsequent years and the figure is expected to be about 73% in the
current year 2014-15.
 It is understood that dip in generation during 2010-11 was due to frequent trips, 2383
hours of outage of Unit-1 and 3536 hours of outage of Unit-2. During this period, some
of the need based R&M works such as replacement of bends, DMW joints for PLSH
and Final SH coils and CW pumps for Unit-1, replacement of HPT module, Boiler C&I
etc., were carried out for Unit-2.
 Carrying out these need based R&M works resulted in reduction of outage hours of
units 1&2 during 2011-12 due to which generation had improved.
 Dip in generation of Unit-2 during 2012-13 was due to 29 trips (9 trips due to Boiler
Tube Leakage) resulting in 2855 hours of outage. During 2013, need based R&M
works like replacement of RH coils, Boiler and Station C&I etc., were carried out for
Unit-1 with planned outage of 2221 hours.
 Generator Transformer-1 failure has occurred during Feb’2015.
AF
AF has been low due to following reasons
Unit 1: During 2010-11, the axial shift problem in Turbine rotor, coal shortage, bunker
choking due to wet coal, No load demand and during 2013-14, Need based R&M (capital
OH) of Turbine and GT failure during Feb’15, Frequent flame failure trips has resulted in
less availability of the unit.
Unit 2: During 2010 to 2013, most of the time the unit availability was less than 70%. This
was mainly due to frequent flame failure in boiler (15 times), Boiler tube failures (BTF: 13
times), electrical fault in unit bus, Bottom ash hopper leakage, coal shortage,
non-availability of mills, etc.
 PLF
PLF of units 1 and 2 is around 60% during last six years except for unit-1 during 2009-10
and for unit-2 during 2011-12.The major causes are - lesser availability of critical
equipment, poor performance of rotating equipment,
non-availability of mills, coal feeding problems, ash evacuation problems, more stringent
emission norms coming into force, turbine related problems, electrical and instrumentation
faults, poor performances of condensate/ feed water heaters, condenser, etc. This is in
addition to the problems like, coal shortage, poor quality coal, bunker/ feeder choking,
occasional low load demand etc.
 APC
APC of the Units has been on the rise due to following reasons:
 Increase in frequency of start up’s and shut down of units,

 Part load operation of the units leading to running of major
equipment/motors out of their efficient/design operation zone (forced
deviation from optimum performance),
 Running more standby equipment due to non-reliability of equipment.
 Usage of constant speed/ non-energy efficient/ oversized motors which
were provided in the original design.
 Inferior grade coal necessitating running of more equipment such as
coal crushers, mills feeders etc.
 Keeping the main CW pump running for auxiliary cooling water supply
during annual overhaul as smaller pumps are not available to meet this
requirement.
 Leakage and consequent air ingress in boiler and auxiliary system,
connecting ducts,
 Poor efficiency of BFPs due to reduced discharge pressure and flow at
pump outlet (efficiency 57.11 -57.42% as against the design value of 79% -
as per CPRI energy audit report 2011).
 Other issues related to poor system design and poor condition of
equipment.
 High & HFO consumption
It is understood that 45% of total station HFO consumption is by units 1&2 during
2009-10. HFO consumption increases with increase in number of trips. During
2010-11, HFO consumption of unit 1 & 2 rose to 5926KL and 4609 KL respectively.
This is equivalent to specific oil consumption of 5.92ml/KWH and 5.61ml/KWH against
desired value of less than 2 ml/KWH. During 2012-13 & 2013-14, HFO is used for
start-up of the units also. Hence, Specific Oil consumption during 2012-13 has risen to
8.03ml/KWH for unit-1 and 7.21ml/KWH for unit-2. These values are very high.
 The above analysis of the various operating parameters of Units 1 and 2 shows that
the generation levels of both units are well below the expected generation from similar
plants. The trips due to failures of components and equipment is frequent leading to
increased down time and consequent low availability and plant load factors. The
consumption of HFO and LDO is high due to frequent trips and repeated start-ups. The
auxiliary power consumption is high due to operation of old inefficient equipment,
operation of additional equipment as safety standby, operation of oversized equipment
such as condenser cooling water pumps for supply of only auxiliary cooling water,
use of poor efficiency old drives and motors etc.
 The need based R&M works being carried out at present are having only a temporary
effect and is not the ultimate solution to improve the generation, reduce the operating
cost and generation cost of these units.

 Hence it is necessary to look into all the deficiencies in the various equipment,
system design features, and account for the inferior grade of coal presently being
supplied to the plant and take a holistic approach in deciding the R&M for
Units 1 and 2.
2.5 CEA GUIDELINES FOR R&M
 To improve the performance parameters viz. PLF, PAF, APC etc., of Units 1 and 2
R&M works are envisaged. The R&M work is required for Unit 1&2 BTG package
because most of the equipment is subjected to fatigue stresses and creep due to high
temperatures. Equipment such as turbine rotor and casings, HP piping, boiler headers,
boiler drum, main steam piping and valves, feed discharge lines etc. are designed for a
fatigue life of about 25-30 years of operation. However, many equipment/components
may encounter premature metallurgical failure due to various operational stresses like
frequent temperature and pressure excursions, full load tripping, frequent starts and
stops etc.
 CEA guidelines issued in the year 2009 mandates that the following studies be
conducted on the major plant and equipment through agencies of repute to determine
the extent of R&M to be carried out.
 RLA involving non-destructive and destructive test to assess the

remaining life of the various critical components of the plant, facilitating
steps to be taken for life extension by a further period of about 15-20
years by appropriate repairs and replacements.
 CS involving inspection of pressure parts and non-pressure parts of
boiler, fans, APH etc. It explains existing condition of various equipment
and systems of boiler along with recommendation for reliable, safe,
efficient and continual operation of boiler.
 Carry out a baseline Energy Audit which is basically a technique used to
establish through measurement patterns of energy use, identifying how
and where losses are occurring and suggest measures for
improvement in energy efficiency together with economic implications.
 RLA of unit 1&2 boilers was carried out by OEM BHEL during the year 2005 & 2010
respectively. RLA study of Unit-1 turbine was carried out during 2006 and that of Unit-2
turbine was carried out during 2010. CA of Unit 1 Boiler was carried out by BHEL in
July 2006. Baseline Energy Audit has been conducted by CPRI during the year 2011.
Some photographs showing condition of certain components needing replacement
and R&M are enclosed at Appendix 6.
2.6 OTHER GOVERNMENT AND STATUTORY GUIDELINES

 Ministry of Power, GOI, have given guidelines for awarding R&M works to BHEL vide
letter date 8.1.2004. It is stated that power stations where BHEL has supplied the main
plant, e.g. BTG sets, the R&M works may be awarded through negotiations to BHEL. It
is also stated that utilities may stipulate only performance related guarantees such as
plant capacities, heat rates, boiler efficiency and stabilized operations for 1-2 years.
 As per IBR 1950, utility boilers used for generation of power or process steam has to
undergo RLAS as a statutory requirement after 1, 00,000 running hours or 25 Years of
operation for safe and reliable further operation of boilers. IBR-391A table 1 & 2 covers
the type of tests to be carried out on each component of boiler pressure parts. The
non-destructive tests are useful in assessing the present condition of the individual
component and calculating their remaining life especially where sampling is not
feasible for components like drum, headers, critical piping, control valves etc.
Destructive tests are used for accurate mechanical & metallurgical properties for
assessing the life of tubes only.

3.0 INPUTS FOR PREPARATION OF COMPREHENSIVE
DPR
3.1 The Comprehensive DPR for R&M works is to be prepared based on the CAS, RLAS
and EA which were carried out by KPCL/RTPS at various points of time.
3.2 The following documents and reports prepared by various agencies received from
KPCL forms the basis of this Comprehensive DPR:
 EA study made by CII in May 2007. This report is enclosed as Appendix 1
 CAS carried out by BHEL on Boiler 1 of Unit 1 in July 2009. This report is enclosed
as Appendix 2.
 Summary of the RLAS carried out by BHEL on Boiler 2 of Unit 2 in August
2010.This report is enclosed as Appendix 3.
 Summary of CAS carried out by BHEL on Turbine 1 of Unit 1 in March 2006.
 Summary of CAS carried out by BHEL on Turbine 2 of Unit 2 in December 2010.
 Summary of the RLAS carried out by BHEL on Generator 1 of Unit 1 in September
2013.
 Summary of the RLAS carried out by BHEL on Generator 2 of Unit 2 in October
2010.
 EA prepared by CPRI, Bangalore in September 2011.This report is enclosed as
Appendix 4.
 Summary of CAS prepared by BHEL on ESP of Boiler 2 in August 2011.
 Brief Report prepared by the office of Chief Engineer Thermal Designs giving data
on plant performance and scope of work and cost for R&M works as discussed with
BHEL.
 Performance parameters and data on trips as furnished by RTPS during the last
few years. This is enclosed as Appendix 5.
 Some photographs taken during the various RLAS conducted on major equipment.
These are enclosed as Appendix 6.
 Summary of Assessment of Soundness of Chimney-I by Structwel Designers and

Consultants Pvt. Ltd. In 2013.
 Summary of Assessment of Soundness of Chimney-II by Structwel Designers and

Consultants Pvt. Ltd. In 2013.
 Detailed report with some pictures of Assessment of Soundness of Cooling

Tower-I by Structwel Designers and Consultants Pvt. Ltd. In 2013.
 Detailed report with some pictures of Assessment of Soundness of Cooling

Tower-II by Structwel Designers and Consultants Pvt. Ltd. In 2013.
 Summary of Modification of Ash Slurry Disposal System due to augmentation of

Ash Pond.
 Summary of brief report for the retrofitting of volumetric feeders with the existing
volumetric feeders.
3.3 TUV SUD also visited RTPS site between 29th October and 31st October 2014 and
had discussions with RTPS engineers and O&M groups regarding the current status
and working condition of various equipment and auxiliaries. A second round of
meetings was held at RTPS site between RTPS and TUV SUD on 23rd and 24th
February 2015 to obtain data/details which could not be fully gathered during the first
meeting. The information collected during the above discussions has also been used
as input for this Comprehensive DPR.
Discussions were also held with KPCL at Bangalore on the 1st and 2nd of June 2015.
Details discussed and collected during this meeting have also been used as required
in preparation of this Comprehensive DPR.

4.0 REVIEW OF VARIOUS REPORTS& NEED OF R&M

REVIEW OF RLA & Energy Audit Reports
The information furnished in the various CA, RLA and Energy Audit reports have been
reviewed in detail along with the data/details collected during TUV-SUD site visits and discussions
with RTPS engineers at the plant and the data provided in the brief report prepared by M/s KPCL,
the findings are presented in the following paragraphs. .
4.1 Boilers & Auxiliaries
4.1.1 Brief design details of the boilers and auxiliaries are furnished in Table 4-1
Table 4.1 - Brief Details of Boilers 1&2 of Units 1&2
Make BHEL
Type Tangential fired, balanced draft,
natural circulation, radiant reheat, dry
bottom, pulverized coal fired with bowl
mills.
Fuel type Indian bituminous coal
Design fuel analysis FC 38%, VM, 26%, M 8%, Ash 28%,
HGI 44%, HHV 4700 Kcal/kg
Steam Generation capacity 670 TPH
Superheated steam pressure Unit 1 - 150 Kg/cm2
Unit 2 – 150-155 Kg/cm2

Steam temperature at boiler outlet 540 Deg C
Year of commissioning Unit 1 – 1985
Unit 2 – 1986
Furnace type Welded water cooled wall
Super heater stages 3 stages
Attemperator type Spray
Reheater type Platen
Economizer type Bare tube
Airpreheater type &No’s Regenerative, 2
4.1.2 The Steam Generators are radiant reheat, natural circulation, single drum, semi-outdoor
type units, designed for firing coal as the principal fuel.
The complete furnace section is of welded wall type, arranged as a gas and pressure- tight
envelope. The extended side wall section (where the re heaters are located) is also
covered with water-cooled section. The circulation system is complete with the necessary
down comers, supply and riser piping.
The superheated steam system has mainly three sections. The low temperature super
heater section (arranged in the second-pass of the Unit) the RPSH (arranged at the outlet
section of the furnace) and the final super heater (arranged after the Reheater).
Desuperheater have been provided in between the LTSH and the platen super heaters (in
the connection links L&R) for controlling the superheated steam temperature over control
load range. The complete second pass of the boiler (up to the economizer) has been
covered with steam-cooled super heater wall sections.
The complete reheater has been arranged in one section in the horizontal pass of the
Boiler in between the RPSH and the final super heater section. Two numbers RDSH have
also been provided in the cold reheat steam piping at the inlet of the reheater for
emergency use.
The location and selection of the super heater and the reheater sections have been so
chosen that the rated temperatures of superheat and reheat are anticipated to be achieved
between 60% TMCR and 100% BMCR load of Boiler.
The boiler includes a bare tube economizer made of seamless steel tubes arranged in
between the LTSH section and the regenerative APH.
The complete integral piping, valves and fittings are provided
The Boiler has two numbers regenerative APH of tri-sector type, as the last stage of heat
recovery. The tri-sector APH have separate sections for heating the primary air required for
pulverizes and secondary air with the flue gas.
The fuel preparation section has primarily six numbers bowl mills arranged for pressurized
operation. Each mill is provided with a raw-coal volumetric feeder. The pulverized fuel
from the mill is taken through pulverized fuel piping to the four corners of the furnace.
Each mill serves one fuel nozzle elevation. The burner wind box section is located in the
four corners of the furnace and arranged for tilting tangential firing.
The complete boiler is of the top-supported type and is provided with the required structural
supporting steel work, galleries and staircases.
The Boiler has two cold primary air fans to supply the primary air and two numbers forced
draught fans for supplying the required total combustion air. The boiler is equipped with two
number of ID fans, arranged after the dust collecting system. The complete air and gas
ducting as required is also provided.
ESP’s are located after the air heater to collect the fly-ash from the flue gas.
The boiler has necessary lining and insulation along with fixing material to limit the outside
surface temperature to the required level.
The complete integral piping, valves and fittings, all air and gas ducting with dampers/
gates and necessary refractory materials are also provided.
The CA of Boiler 1 of Unit 1 was done by BHEL in 2009. Summary of the findings and
recommendation of the agency is enclosed at Annexure 1. The CA report of BHEL is
enclosed at Appendix 2.
RLAS on Boiler 2 of Unit 2 was done by BHEL in August 2010. Summary of the RLAS and
recommendation of the agency is also enclosed at Annexure 1. The RLAS report of BHEL
is enclosed at Appendix 3.
4.1.3 The following are major recommendations of CA carried out by BHEL on Unit-1 Boiler 1
during 2009:
 Dissimilar Metal Weld (DMW) joints of PSH-coils and Final SH-coils to be
replaced.
 R.H coils to be replaced.
 ECO-coils & LTSH coils to be replaced.
 Drain & vents valves to be replaced.
 Ducts are punctured & Expansion joints heavily rusted & needs replacement.
 Coal pipes to be replaced.
 Air Pre-Heater components severely eroded & needs replacement.
 FD fans to be replaced
 PA & ID fans shaft to be replaced
4.1.4 The following are major recommendations of RLA studies made on Unit-2 Boiler
2 by BHEL during 2010:
 The damaged spray nozzles (LHS) in CRH line are to be replaced in the next
earliest opportunity.
 Eroded screen tube bends to be replaced.
 RH Coils to be replaced because discoloration & over heating signs in coils.
 Creep pores observed in MS line, HRH Line, SH spray lines hence
re-inspection after 3 years of continued operation.
4.1.5 Based on the findings of the various RLA and CA reports, discussions with RTPS
engineers and the discussions which RTPS have had with BHEL regarding the Scope of
R&M works for Boilers 1 and 2, the following are the major works to be taken up for R&M in
Boilers 1 and 2
a) APH: Air-preheater leakage in RHS is 53.45% for Boiler 1 and 51.15% for Boiler 2.
Corresponding figure for LHS are 44% for Boiler 1 and 45.10 for Boiler 2 as against
design value of 13.11%. Leakages result in higher loading of ID fan and reduction
of performance of boiler. Hence the APH of both Boilers 1 and 2 need replacement.
Replacement of APH will reduce APH outlet flue gas temperature from present
1460C (Design value being 1370C).
Action has been taken by RTPS separately for Unit 1&2, for replacement of the
existing APH by a double seal arrangement, drive mechanism with three input gear
box having two AC motors and one air motor.
b) RH, LTSH, PLSH and Economiser coils: The root cause of deterioration of RH coils
is overheating/ starvation of tubes during start-up& drastic load variations, blockage
of tubes due to phosphate deposition/ foreign material entrapment etc. In LTSH and
economiser zones, boiler tube failure occurs mainly due to fly ash erosion and cold
end corrosion. The factors influencing fly ash erosion are velocity of flue gas, mineral
content such as alfa quartz in coal, change in direction of flue gas, misalignment of
tube assembly, and temperature of flue gas. It is opined that tube banks replacement
is the need of the hour to minimize these tube bank failures. Hence these coils need
replacement in both boilers.
c) Ducts and Dampers: Originally supplied ducts, dampers, gates and expansion joints
are still in service. All the expansion joints are in heavily rusted condition. Hot air
ducts are found in rusted/punctured condition. Flue gas inlet damper of APH is found
in fully eroded condition. Hence, it is proposed to replace the entire hot and flue gas
ducting system along with dampers, gates, flow measuring elements and expansion
joints for gas leak proof and air leak/ingress proof operation of boiler. This has to be
done for both boilers.
d) All HT Motors of Units 1 and 2 are old and have been rewound a number of times.
These motors need replacement.

e) HP drains and Vent valves: HP drain valves in boiler &turbine area need replacement
due to passing and obsolesce in both Units.BFP recirculation valve in Unit 2 is
passing and needs replacement.
4.1.6 KPCL/RTPS have discussed with BHEL the R&M to be carried out on Boilers 1 and 2and
details of the work to be carried out on Boiler 1 and 2 are briefly summarized in following
Table
Table 4.2 – Scope of R&M works for Boilers 1 and 2
Scope Of R&M
sss S.No. Description
Unit 1 Unit 2
1. LTSH coils To be Replaced To be Replaced
2. Economizer coils To be Replaced To be Replaced
Platen SH & Final SH To be Replaced Total replacement of PSH and
3. coil-DMW joint spool SH Coils.
pieces
4. SH DESH To be Replaced To be Replaced
5. WW Burner panel
To be Replaced To be Replaced
6. RH DESH To be Replaced To be Replaced
To be Replaced. To be Replaced including
Including existing existing electrical valves with

7. SH - DESH station
electrical valves with pneumatic control valves and
pneumatic control valves block valves.
and block valves.
8. RH - DESH station To be replaced To be replaced

Soot blower piping with To be replaced To be replaced
9. SB control station and
TDV’s
Safety valves at Drum To be replaced To be replaced

10
and SH outlet
Flue gas ducting (Eco To be replaced To be replaced
outlet to ESP Inlet) with
11. Exp Joints,
dampers/gates and
supports.
Hot air ducting with To be replaced To be replaced
expansion joints,
12.
dampers/ gates and
supports
ID system Ducting with To be replaced To be replaced
Exp Joints,
13. dampers/gates and
supports –(ESP Outlet to
Chimney inlet)
Primary air ducting from To be replaced To be replaced
Bus duct to mills including

14.
Expansion joints, gates
and supports
Flow elements in PA & SA To be replaced To be replaced

15.
ducting
PF pipes with couplings, To be replaced To be replaced

16.
supports, hangers, orifice
and selected bends
Burner wind box To be replaced To be replaced
assembly along with

17.
flange connection to the
ducting.
Refractory, Lining and To be replaced To be replaced

18.
insulation
Boiler integral piping, To be replaced To be replaced

19.
valves & fittings
Drains and Vents along To be replaced To be replaced

20.
with valves
RH, SH startup vent valve To be replaced To be replaced

21.
with piping.
APH blowers with Valves To be replaced To be replaced

22.
& fittings
Critical piping-hanger and To be replaced To be replaced

23.
other components
24. Boiler C&I To be replaced To be replaced
To be replaced. Details To be replaced. Details as

25. Pulverizes
as given below given below.
26. Air heaters To be replaced To be replaced
27. Fans : PA, FD and ID To be replaced To be replaced
Ducting, Gates and To be replaced To be replaced

28.
Dampers
Retrofit and Retrofit and augmentation as

29. ESP retrofit
augmentation as given given below
below
Feed water line piping To be replaced To be replaced
30. inside Boiler Drum to be
replaced.
Three complete sets of pumps and 6 nos RC valves

31 Boiler feed pumps
common for both units
32 Volumetric Feeders To be replaced To be replaced
For BOP R&M to be carried out for Unit 1 & 2 as per Extended Comprehensive DPR
Repair shall be carried out Repair shall be carried out

for: for:
Corrosion affected Corrosion affected concrete
concrete areas areas
Honey Combing, weak Honey Combing, weak

concrete areas of Shell concrete areas of Shell and
and supporting structures supporting structures
33 Cooling Towers
Cracks at subsequent Cracks at subsequent
concrete pours / cold joints concrete pours / cold joints
Provision of Sacrificial Provision of Sacrificial

Anodes Anodes
Top R.C.C. platform and Top R.C.C. platform and

steel railing shall be steel railing shall be carried
carried out out
Replacing with higher Replacing with higher
efficiency five vane efficiency five vane impeller
impeller retaining with retaining with same motor
same motor and New and New Pump with New
Pump with New Motor is Motor is considered to be
considered to be the better the better option due to
34 Ash handling option due to economical, economical, compatible
compatible and and interchangeable of
interchangeable of pumps. pumps. Whereas option -2
Whereas option -2 calls for calls for different pump
different pump manufacturers and leads to
manufacturers and leads problem in spares
to problem in spares management
management
Repair shall be carried out Repair shall be carried out
for: for:
35 Chimney
Corrosion affected Corrosion affected concrete
concrete areas areas
Honey Combing, weak Honey Combing, weak

concrete areas of Shell concrete areas of Shell and
and supporting structures supporting structures
Cracks at subsequent Cracks at subsequent

concrete pours / cold joints concrete pours / cold joints
Monkey Ladder Monkey Ladder
Top R.C.C. platform and Top R.C.C. platform and

steel railing shall be steel railing shall be carried
carried out out
4.1.7 Bowl Mills Units 1 & 2
There are 12 bowl mills, 6 each for each boiler, BHEL make, Type XRP 803. The
following replacements/renewal is required in the mills:
 Bearing less spring assembly for 6 mills
 Modified scraper assembly for all mills
 Mill bottom for 3 mills
 Separator body top for 3 mills
 Mill motor couplings of all mills
 Gear box bearing temperature RTD for all mills
All the above replacements are included in the R&M works proposed by BHEL.
In addition 12 no. new feeders are to be installed in the coal feed lines. These will be taken
up in Phase 2 of R&M works.
4.1.8 ESP’s of Units 1&2:
ESPs provided for Units 1&2 are in operation for more than 29 years since commissioning
of these units in 1985/86. The existing ESPs are designed for emission at ESP outlet of
150mg/Ncum based on the coal quality such as ash content and GCV specified at the time
of procurement of the boilers. Over the years the quality of coal supplied to the power
station has deteriorated both in terms of its GCV as well as ash content. This has resulted
in higher fly ash loads to be handled by the ESP’s. Further, because of deterioration due to
continuous operation/ageing the performance of ESPs has deteriorated and the

emission levels are higher than the design values. Pollution control board has now made
norms more stringent and accordingly the emissions at ESP outlet has to be maintained
below 50mg/Nm3. Hence for better performance, the present ESPs of Units 1&2 need to be
refurbished and augmented. In view of the above it is intended to take up retrofitting of
ESPs with modified design to reduce the emission levels to 50mg/Nm 3 along with
proposed R&M works of boilers of Units1&2. It is preferable to entrust the work to BHEL
who are the original ESP suppliers. Accordingly RTPS has discussed and finalized the
details of ESP refurbishment with BHEL.
The existing ESP’s casing will be modified to accommodate taller electrodes of latest
design after dismantling the complete internals, retaining the existing support structures,
hoppers & casing. Providing of additional series fields at inlet and outlet as per available
site conditions, rerouting of existing ash handling pipelines and any other equipment if
installed in this area, available front for civil works etc. is also considered.
It is proposed to change the internals of existing ESPs with new design. Existing six field
internals are replaced with five field new improved design internals by increasing casing
height to 14m, bigger field with 750mm wide collecting electrode, 400mm pitch design and
latest design tumbling hammer type rapping mechanism. Also existing ESP casing will be
extended horizontally to have one series field each at inlet and outlet. Thus ESP will have
seven fields in series. Due to fouling in existing intermediate storage hopper at ESP inlet
side between Units 1&2, one field at inlet side Unit-1(D pass) and one field at Unit-2(A pass)
is not feasible and hence not provided. Therefore there will be 27 Electrical fields for one
Unit. The existing internals will be dismantled.
Two Nos. existing LT main switch board feeding power to auxiliary control panels will be
modified. One set of PC based precipitator integrated operating system (IOS) to enable
UCB operator to access the ESP controls for control monitoring and data acquisition
functions will be provided.
After refurbishment, the supplier shall guarantee a precipitator outlet emission of
50mg/Nm3 with all fields in service corresponding to the precipitator collection efficiency of
99.904% considering the gas temperature and dust concentration at ESP inlet as shown
in Table-4.3.
Table 4.3 - Design Data for ESP
Parameter Existing New Remarks
design, proposed
Design
Gas Flow Rate, Nm3/sec 347 408 Flow increase by 17.6%.
Gas temp at ESP inlet 140 150 Temperature increase by10
deg.C
Dust Concentration at 30.5 71 Dust concentration increase
TESP inlet (g/Nm3) by 133%
h
Emission at ESP Outlet 150 50 Emission reduction by 66%.
e
mg/Nm3
above data for refurbishment of ESP’s is based on the analysis of coal as indicated in
following Table 4-4:
Table 4.4 - Data of Coal for ESP Refurbishment
S.No Parameter Unit Air Dried basis As fired basis for
for worst coal worst coal
1 Total Moisture % 13.2 -
2 Ash % 46.8 -
3 Volatile Matter % 24.12 -
4 GCV Kcal/Kg 3351 3095
Augmentation of existing ash handling system for modified ESPs /Ash handling system for
extended fields will be done by the R&M contractor.
4.2 Turbine- Generator sets
4.2.1 Turbine Unit No 1

Table 4.5 - Brief Details Turbine Unit 1
Make Kraft Work Union (KWU),
Germany
Type Multi Stage Fully condensing
Rating 210 MW
Superheated steam pressure at turbine inlet 148 Kg/cm2
Superheated steam temperature at turbine 535 Deg C
inlet
Type of condenser Water cooled
Year of commissioning 1985
CA on this turbine was carried out by BHEL in March 2006. The summary of the BHEL
study is given in Annexure 2.
BHEL had not observed any major issues and had recommended running the machine
subject to carrying out the following
a) IP stud (PP) No. 155, which was found to have damaged threads, to be repaired /
replaced.
b) Bearing No. 3 (top and bottom) to be monitored for edge de-bonding which was
noticed in DPT in UT during every overall to ensure safe operation of the unit.
c) The cracked blade numbers 414 (G – 23) and 585 (G-48) of 8th stage (generator
side) of LP rotor to be replaced.
d) A detailed micro structural examination of all the components to be taken up during
next overall to assess the then prevailing material condition for further continuous
operation of the machine.
4.2.2 Turbine Unit No 2
Table 4.6 - Brief Details Turbine Unit 2
Make Kraft Work Union (KWU), Germany
Type Multi Stage Fully condensing
Rating 210 MW
Superheated steam pressure at 148 Kg/cm2
turbine inlet
Superheated steam temperature at 535 Deg C
turbine inlet
Type of condenser Water cooled
CA on this turbine was carried out by BHEL in December 2010.
The summary of the BHEL study is given in Annexure 2.
During NDT examination on TG components, HP stationary blades were found to have
metal debris which might have come from the boiler tubes. RTPS was advised to
replace existing HP rotor and inner casing with the spare one and go for a set of new
spares. Lot of scaling was observed in the condenser tubes during the testing and it
was suggested to remove the scaling fully or replace with new tubes to enhance the
efficiency of the condenser. All the other components subjected to NDT were good for
continued service.
During In-Situ metallographic examination, no significant degradation of
microstructure was observed in the components investigated. Hardness values
measured on various components were also as per the respective material
requirements. As such no immediate action was recommended and all the tested
components were cleared for continued service for another 5 years. Last stage LP
blades on both sides i.e. 2L, 3L and 2R & 3R were advised for replacement at the
earliest as the design life of the components was exhausted.
4.2.3 Generator Unit No 1
Table 4.7 - Brief Details Generator Unit 1
Make THW
Type of cooling Hydrogen cooled and Stator water

cooled
Rating 210 MW
Generation voltage 15.75 KVA
Stator of this generator was replaced in September 2005.
Condition assessment on this generator was carried out by BHEL in
September 2013. BHEL had not observed any major issues and had recommended
running the machine.
For the purpose of this report no major rework is assumed for this generator.
4.2.4 Generator Unit No 2
Table 4.8 - Brief Details Generator Unit 2
Make THW
Type of cooling Hydrogen cooled and Stator water
cooled
Rating 210 MW
Generation voltage 15.75 KVA
Stator of this generator was replaced in August 2003.
Condition assessment on this generator was carried out by BHEL in
October 2010.
Electrical tests conducted on rotor and stator windings showed that the condition of
insulation in both cases is satisfactory. BHEL had not observed any major issues and
had recommended running the machine.
BHEL had suggested that the electrical tests be repeated during the next major
overhaul to rule out any major deterioration in the condition of the insulation.
4.2.5 R&M for TG Units 1 & 2
Based on the recommendations of the various investigations carried out on the TG
sets and based on the discussions with RTPS operating personal the following are the
R&M works necessary for the two TG sets:
Turbine Unit 1
 No replacement or refurbishment in HP, IP and LP turbines. The work suggested in
the CA report has been carried out as part of regular maintenance of the plant.
 LPH-3, HPH-5&6 for Unit 1 have extensive leakages leading to very low feed water
inlet temperature to the economiser. Hence these heaters need complete
replacement to improve the boiler inlet water temperature which will lead to
improvement in the overall thermal efficiency of the boiler.
 Condenser Vacuum drop needs prime attention to improve turbine heat rate. The
performance of condenser deteriorates during summer, resulting in reduction of
generation. Replacement of condenser tube will improve condenser vacuum and
reduce back pressure on the turbine. This in turn will increase efficiency and
reduce the heat rate of the unit. Condenser tube replacement is necessary.
 All major valves, piping and accessories including valves in the LP and HP heater
and by pass lines, turbine drain valves, oil supply unit etc. to be replaced.
 All compensators in the various lines of the turbine to be replaced.
Generator Unit 1
 H2 and Co2 gas systems to be completely replaced along with manifolds etc.
with current state of art system.
 AC seal oil pump and Vacuum pump along with motors, piping, valves and
instruments to be replaced.
 Seal oil system filter to be replaced.
Turbine Unit 2
 No replacement or refurbishment in HP, IP and LP turbines. The work suggested in
the CA report has been carried out as part of regular maintenance of the plant.
 In the case of Unit 2, the performance of all the heaters is very poor. This has
resulted in reduced inlet feed water temperature at economizer (165 0C as against
design value of 2410 C), high flue gas temperature at boiler outlet,high spray
requirement.et, high coal consumption, low boiler load and reduction in creep life of
super heater and re-heater tubes. Hence replacement of all the heaters of Unit 2 is
essential.
 Condenser Vacuum drop needs prime attention to improve turbine heat rate. The
performance of condenser deteriorates during summer, resulting in reduction of
generation. Replacement of condenser tube will improve condenser vacuum and
reduce back pressure on the turbine. This in turn will increase efficiency and
reduce the heat rate of the unit. Condenser tube replacement is necessary.
 All major valves, piping and accessories including valves in the LP and HP heater
and by pass lines, turbine drain valves, oil supply unit etc. to be replaced.
 All compensators in the various lines of the turbine to be replaced.
Generator Unit 2
 H2 and Co2 gas systems to be completely replaced along with manifolds etc.
with current state of art system.
 AC seal oil pump and Vacuum pump along with motors, piping, valves and
instruments to be replaced.
 Seal oil system filter to be replaced.
4.3 Auxiliary Systems
4.3.1 Ash Handling System – Units 1 & 2
Based on discussions with Ash Handling Plant personal at RTPS it is found that there
are problems in the following areas of the existing ash handling system for Units 1 and
2 which need replacement/rectification:

 Boiler bottom ash collection system has heavy leakage and the existing feed
gates, clinker grinders, hydro ejectors and ash piping need extensive
modification with installation of new equipment.
 Economizer and air preheater ash handling system as existing is a wet system
with ash slurry pumps and pipelines. These are giving problems due to severe
erosion and a new pneumatic handling system is proposed.
 Dry ash piping at various locations especially at bends is posing severe erosion
problems. These will have to be replaced by better wear resistant materials.
 The existing compressors for fly ash handling are reciprocating type which
needs lot of maintenance and have lived their useful life. These are proposed
to be replaced by more efficient screw compressors.
 Fly ash storage silo fluidization system needs replacement.
 Instrument air compressors need replacement.
 The boilers are designed to use coal with ash content of 28%. However over
the years there has been an increase in the ash content of the coal and
presently the ash content is as high as 52%. Hence the ash generated has also
increased and the bottom ash slurry pumps have become grossly undersized
and inadequate. All the ash slurry pumps have to be replaced with suitable
higher capacity pumps.
 Additional capacity to be provided in ash slurry sump.
 Ash disposal lines to ash pond needs resizing for the additional ash quantity.
The ash slurry lines and all valves in these lines need replacement.
 All the LP and HP pumps in the ash handling plant are not of adequate capacity
and needs replacement with larger capacity pumps.
 LP, HP and seal water lines need replacement as these are worn out due to
aging.
 Instrument air piping in the complete ash handling plant is worn out due to
aging and has frequent leaks. These lines are to be replaced.

 The fluidizing system in the ash silos of the ESP’s is not working for a long time.
A new system needs to be installed.
 To cater the requirements of wet ash disposal from all the units, Ash Pond I & 2
were constructed. Ash pond I is completely filled and abandoned since 2002.
At present entire quantity of bottom ash and un- lifted portion of fly ash is
disposed off into the ash pond II in slurry form. Owing to the continuous
dumping of the bottom ash & un- lifted portion of the fly ash, the level of the ash
pond-II has reached a stage which is high and alarming.
 Under the present conditions, if the height of the ash bund is increased, the
discharge pressure of the existing slurry pumps is not sufficient to discharge
the slurry effectively. Accordingly ash slurry disposal connected electro
mechanical works are to be modified to suit the system requirement.
 Replacing with higher efficiency five vane impeller retaining with same motor
and New Pump with New Motor is considered to be the better option due to
economical, compatible and interchangeable of pumps. Whereas option -2
calls for different pump manufacturers and leads to problem in spares
management.
4.3.2 Cooling Towers Unit I & II
 Visual Inspection of Cooling Tower - 1 was carried out with thorough exercise
externally as well as internally. Internal inspection was possible since this unit
was under shutdown for annual maintenance during our progress of inspection
works.
 Photographic records were generated by digital camera making the
dispositions of the defects conspicuous and clear on the structure and also
their extents of spread as observed. Photographs show condition of the defects
spread across the structure and helps to analyze and device strategies for
repairs required for the structure.

 Some major distresses observed are exposed reinforcement, corrosion cracks,
leakage; bulging, spalling etc. following discussions provides the details on the
criticalities as observed of structure. Details are explained distinct segment
wise and various parts of the structure and provide clear idea about the
condition of structure. They are;
A) Service Road (Plinth area)

B) Pedestal
C) Circular Columns
D) Shell
E) Top platform and Railings
F) Staircases, Monkey Ladders & Hot Water Inlets
4.3.3 Chimneys of Unit I & II
 Visual Inspection of Chimney - 1 was carried out with thorough exercise
from external faces. The whole structure for its full height was inspected by
direct and close inspections whereas for distant locations binoculars have been
used.
 Photographic records were generated by digital camera making the
dispositions of the defects conspicuous and clearly identified on the structure
and also their extents of spread. Photographs shows condition of the defects
on the chimney structure and help to analyze and device strategies for repairs
required.
 Some major distresses observed are exposed reinforcement, corrosion cracks,
leakage; spalling etc. On platforms these observations are noted quite
conspicuously. Also the junction of cantilevers shows discontinuity or lack of
homogeneity with parent shell structure.
 Following discussions provides the details on the criticalities as observed of the
structure. Details explained are distinct and segment wise by various parts and
provide clear idea about the condition of structure. They are;

A) Shell.
B) Platforms and Railings.
C) Monkey Ladder.
4.3.2 Water Systems including DM water Plant – Units 1 & 2
Based on discussions with RTPS, it is found that there are problems in the various
water systems including the DM water plant. The following need attention in these
systems
 Clarifier 1 - Traction rail on top of the clarifier, platform at the top around the
clarifier tank, bridge including the drive mechanism, flash mixers, flow meters,
agitators in alum tank and some of the valves need replacement.
 River water system – All butterfly valves, along with electrical actuators, rubber
expansion joints, non-return valves etc. to be replaced.
 Condenser cooling water system – All butterfly valves, rubber expansion joints,
flow meters at pump outlet and condenser inlet are to be replaced.
 DM water lines from the DM water plant to the Boilers. These lines are to be
replaced by new SS pipelines and suitable valves.
 Two DM water pumps of required capacity and head with motors and power
supply arrangement to be provided.
 New LP & HP dosing system with pipe work to be provided.
4.3.3 Fuel Oil System – Units 1 & 2
Following items need replacement as these are worn out due to usage for over 29 years:
 Supply and return piping including tracing, insulation and cladding where ever
required.
 Valves in the entire fuel oil system where ever these are found damaged and
unusable.
4.3.4 Other Utilities:
 The entire service water system piping needs replacement as it is heavily
corroded causing frequent leaks.
 Replacement of worn out low pressure cooling water lines to hydrogen coolers.
 Booster pump for supply of water to ID fan cooling system to be considered.
 Retrofitting of centralised A/C system of unit control room as this system is very
old and fails frequently.
4.4 Switch Yard and Electrical Equipment
4.4.1 Outdoor switch yard
Following items in the outdoor 220KV switch yard are very old and of outdated design.
These have frequent failures and spares are not available in many cases. Some of the
transformers have been rewound many times and the internal losses are very high.
 220 KV Circuit breakers for Units 1 & 2
 220 KV isolators of Unit 2 Bays ST1 and ST2
 Station transformer of Units 1 & 2, Capacity 50 MVA
 Auxiliary transformers of Unit 2, 2x16MVA
 DG sets 2x500KVA
4.4.2 LT&HT Motors, Switch gear and Cabling.
The following HT drive motors are in poor working condition and are also of outdated
design. These motors have failed many times and have been rewound on numerous
occasions. Spares such as bearings for these motors are not available. These need to
be replaced by new motors:
Table 4.9 - Details of HT Motors Proposed For Replacement
Sl. No Description of Motor Rating, KW Quantity, No
1 ID Fan Motor 1300 KW 4
2 FD Fan Motor 750 KW 4

3 PA Fan Motor 1250 KW 1
4 Mill Motors 340 KW 12
5 Condensate Extraction Pump Motor 500 KW 4
6 Boiler Feed Pump Motor 4000 KW 6
7 Circulating Water Pump Motor 1325 KW 5
The following HT switch gear and relays are of very old design and availability of
spares is difficult and expensive. Hence these need to be replaced
Table 4.10 - Details of HT Switch Gear Proposed For Replacement
Sl.No Description Rating Quantity, Remarks
Amps Nos
1 Breaker 12 / 1240 55 40 no’s in Phase 1
2 Breaker 12 / 3150 16 Balance in Phase 2
3 Relays - 70 40 no’s in Phase 1
Balance in Phase 2
The existing HT cables are paper insulated lead sheathed type which is causing
frequent cable faults and failures. Hence these cables have to be replaced by XLP
cables of required size.
4.5 Control &Instrumentation
It is understood that R&M has been carried out on the C&I systems of the boilers by
BHEL and on the station C&I by Yokogawa. R&M on turbine ATRS has been done by
BHEL.
However the C&I system architecture for all the plant auxiliaries is not current digital
system and there are problems in control in a number areas of the plant such as the
ash handling system, outdoor switch yard etc.
A new DCS system for the main plant of Units 1 and 2 is under implementation and it is
understood that the system is already functional for Unit 1 and for Unit 2 the system will
be fully implemented as soon as they are able to get a plant shut down.
It is desirable to have current state of the art DCS system for the auxiliaries such as
ash handling plant and switchyard which can be taken up in Phase 2.
4.6 Baseline Energy Audit Recommendations by CPRI
CPRI, Bangalore has conducted energy audit of all seven Units and also the various
auxiliary systems in 2011. The audit was carried out to study the possibility of reduction
in the heat rate and auxiliary power consumption of the Units. The main observations
and recommendations of CPRI for improvement in efficiency and reduction in auxiliary
power consumption are indicated below:
 Unit-1&2 are old units capable of efficient performance with operational
optimization, maintenance improvements & small continuous improvements in
R&M.
 Medium term measures include APH baskets up-gradation including geometry
& material. Replacement of baskets and seals reduce the air ingress in flue gas
ducts and reduces the energy consumption of ID fans, FD fans & PA fans.
 To reduce the energy consumption in ESP by replacing internal spares.
 Partial boiler skin insulation replacement.
 Monitoring of passing in high energy drains.
 Charging of PRDS from CRH line during normal operation.
 The overall efficiency of BFP, CEP, ID fan, FD fan & PA fan are on lower side
which needs to be improved.
 Improving the CWP efficiency by overhauling of pumps and motors.
 The auxiliary power used by BFP & CEPs slightly higher than other units.
Suggested to check the passing in recirculation by-pass valve by conducting the
test.
 Replacement of existing 750KW FD fan Motor with 350 KW motor.

5.0 COST, SCHEDULE & BENIFITS

5.1 Scope of R&M
KPCL has envisaged that the R&M works as discussed in Section 4.0 may be
implemented in two Phases as follows:
Phase 1: R&M works pertaining to BTG, BOP and Electrical including retrofitting
of ESP for which scope of work have been discussed and finalized and
offers received from BHEL. Some of these R&M works have already
been taken up due to their urgent requirement.
Phase 2: R&M works pertaining to the following areas will be taken up in
Phase 2 (Requiring Shutdown)
 Fire Alarm system & DM plant.
 Ash handling plant including DCS & modification of Ash slurry
disposal system.
 Following items in the outdoor 220KV switch yard
o Part of Circuit breakers (22 no’s) for Units 1 & 2
o Relays (40 No’s)
o 220 KV isolators of Unit 2 Bays, ST1 and ST2
o Station transformer of Units 1 & 2, Capacity 50 MVA
 Auxiliary transformers of Unit 2, 2x16MVA
 DG sets 2x500KVA
 SCADA for switch yard
 Cooling Tower and associated civil works if any
 Civil works to be taken up along with R&M of BTG
Phase 3: R&M works pertaining to the following areas will be taken up in

Phase 2 (Does not require shutdown)
 Retrofitting of Volumetric feeders

 Augmentation of Ash Pond
 Cooling Tower and Associated civil works
 Civil works of BTG
 Retrofitting ESP
 Electrical Package:-
1. Replacement of cable for Transformers
2. Balance HT switchgears to include station Bus A&B, AHP
1&2, Raw water pump house.
5.2 Cost Estimate for R&M
5.2.1 KPCL has discussed with BHEL and consolidated all the works which need to be taken up
for comprehensive R&M (Phase 1) of Unit 1&2 and ensure that the work is done
simultaneously in one shutdown period. Accordingly, the scope of work pertaining to Boiler
& Auxiliaries, T.G & Auxiliaries, BOP, Electrical and ESP retrofitting has been finalized.
BHEL has submitted their techno-commercial offer covering supply, erection, testing &
commissioning including civil works of BTG package and also for retrofitting of ESP as
detailed below in Table 5-1 for the
Phase 1 work:
Table 5.1 – Cost for R&M Works (Phase 1)
Sl. Description of Equipment
No. Rs lakhs
1 Boiler & Auxiliaries
A Fans 2609.00
B Pressure parts including gates, ducts, valves 6353.40
C P.F. Bends. 350.00
D Mills (Bearing less spring assembly, scraper assembly etc.) 469.07
E Critical piping, valves, hangers and supports. 1563.00
2 Sub Total 1- Boiler and auxiliaries 11344.47
3 T.G & Auxiliaries

A T.G.:-Last 2 stage blades of LP turbine, oil Centrifuge system, all 11994.00
turbine drain valves, Condenser- total tubes replacement, stop &
control valves of LP by pass system, AC seal oil pump, seal oil
vapour extractors.
B Boiler Feed Pumps (Pump Assembly- 3 nos.) & R.C. Valves (6), 943.00
Vent condenser (2 Nos.)
C H. P. Heaters. 1078.00
D HP Bypass valves, Line drains, de-aerator piping 780.00
4 Sub Total 3 – TG and auxiliaries 14795.00
5 BOP, Electrical, E&C, Civil etc.
A BOP CW system( expansion joints & Discharge valves), DM 3111.00
water plant (pipe line to unit 2), LP piping along with valves,
River water system(NRVs & Discharge valves), Fuel oil piping
etc.
B Electrical: H. T. Motors (BFP, CEP, CWP, ID,FD,PA, mill 2494.00
motors), Cables
C E & C of BTG 7456.72
D Civil works of BTG 50.00
6 Subtotal 5 - BOP, Electrical, E&C, Civil etc. 13111.72
7 Grand Total 2+4+6 – BTG & BOP 39251.19
8 ESP Retrofitting (As per extended Comp DPR, to be added in
Phase III?????)
A SUPPLY: ESP (Rs. 4230 lakhs), Ash Handling System of new 5045.00
fields envisaged with recommended spares (Rs. 500 lakhs),
Illumination for the new fields and extended height (Rs. 135
lakhs), service transformer (180 Lakhs).
B E&C 3000.00
C CIVIL 1575.00
9 TOTAL of 8 – ESP Retrofitting 9620.00
Less cost quoted for ESP Service Transformer not considered
10 for replacement (-)180.00
Grand Total of BTG, BOP and Electricals, ESP retrofitting 48691.19
11 supply, erection, testing, commissioning and Civil works
12 Other costs (Taxes, Duties, Insurance and Freight )
A ED at 10.3% on Supply cost of Rs 36609 lakhs 3770.77
B CST at 2% of Supply cost+ ED i.e. Rs 40379.77 lakhs 807.59
Service Tax at 14% on E&C cost + Civil works i.e. Rs 12082 1691.48
C Lakhs
D Freight at 3% of supply cost of Rs 36609 Lakhs 1098.27
E Insurance on supply at @0.80% 292.80
13 Subtotal 10 – Other costs 7660.91
14 Grand Total 56352.10
15 Less cost of 3 no’s BFP R/C valves already placed (-) 131
16 Total cost 14-15 56221.10
Orders already placed and works under execution as part 125.54
17 of R&M + 10% supply and erection
18 Total of Works under execution + Phase 1 (16+17) 68775.20

5.2.2 For the Phase 2 works the estimated cost including supply, E&C, taxes etc. is estimated as
follows based on costs given by original OEM’s and indicated in Table 5.2– Estimated
cost for R&M Works (Phase 2)
1 DG set, Fire Alarm system & DM plant. 2218
2 Ash handling plant including DCS. 3000
3 Switchyard, UAT/ST and switchgear. 1535
4 Replacement of coal feeders 12 nos from volumetric to 1000.1
gravimetric.
5* Replacement of balance HT switch gear breakers and 180
relays – Include Annexure 2 of Sl. No, 4 (Hard copy
provided on 15.06.16)
6 SCADA for switch yard 75
7 Lighting and illumination works 120
8 Hangers on BFP discharge to economizer line and APRDS 20
headers
9 HPT and IPT repair cost 821
10 Bunker gates and feeder gates, feeder inlet pipes, feeder 300
chutes, and centre feed pipes 12 sets
11 LT breakers, AC system,, cable trays, generator protection 50
system etc.
Total 9319.10
5.2.3 For the Phase 3 works the estimated cost including supply, E&C, taxes etc. is estimated as
follows based on costs given by original OEM’s and indicated in Table 5.3– Estimated
cost for R&M Works (Phase 3)

1 Civil works for Chimney 400
2 Civil works of Cooling tower 200
3 Ash bund works 5200
4 Construction of Barrage across river at Girijapur 10000
5 Replacement of HT Switchgears and breakers in APH 100

1&2
6 Replacement of HT Switchgears and breakers in RWPH 80
7 Generator Protection system and Replacement of HT 65
8 Replacement of HT breakers in Unit II 90
9 Replacement of Protection(only in Unit II) and Auxiliary 90+(30+15)

Relay in Unit I & II
=135
5.2.4 The total cost for Phase 1 and Phase 2 works is as given in Table 5-3
Table 5.4-Total Estimated cost for R&M Works (Phase 1& 2)
1 Under execution + Phase 1 (Table 5-1) 68775.20
2 Phase 2 (Table 5-2) 9319.10
Total 78094.30
Say 78100.00
IDC 18115.00
Total 96215.00
5.3 Schedule of Implementation of R&M works
The schedule for completion of R&M works under Phase 1 for both Units 1 and 2 from
the Zero date, which corresponds to the contract finalization date by KPCL on BHEL, is
indicated as 48 months. The schedule has been prepared in such a way that only one
Unit is taken out of service at a time in order to minimize the loss of power supply from
RTPS to the grid.
The schedule shall be broadly as follows corresponding to a Zero date of
1st September 2015. Assuming RTPS can provide the required shut down of Units 1
and 2 as per schedule envisaged it should be feasible to complete the Phase 1 R&M
works by August 2019.
 Engineering: 6 Months from zero date i.e. by end of February 2016.
 Manufacture and supply of boiler parts: 10 Months after completion of engineering
i.e. by December 2016.
 Manufacture and supply of turbine parts: 12 Months after completion of engineering
i.e. by end February 2017.
 Manufacture and supply of ESP parts of first unit: 10 Months after completion of
engineering i.e. by end December 2016.
 Manufacture and supply of ESP parts of second unit: 10 Months, after completion of
engineering i.e. by end April 2017.
 Erection of Unit-1 BTG and ESP one pass (out of four) components and systems
which do not need plant shut down including any new civil works etc. 6 months from
September 2016 to February 2017.
 Shut down of Unit 1 BTG and ESP, 4 months for completion of balance works i.e.
from March 2017 to End June 2017.
 Commissioning and stabilization of Unit 1 BTG with ESP one pass (out of four), 2
months July & August 2017.
 Erection of Unit-2 BTG and ESP one pass (out of four) Component systems which
do not need plant shutdown including new civil works etc., 7 months from October
2017 to April 2018.
 Shut down of Unit 2 BTG & ESP 4 months for completion of balance works i.e. May
2018 to August 2018.
 Commissioning and stabilization of Unit 2 with ESP one pass (out of four),
2 months September & October 2018.
 Erection of Unit-1 ESP 3 passes (out of 4), 6 months from October 2018 to March
2019.
 Shut down of Unit-1 for isolation and normalisation of BTG with ESP
3 passes (out of 4), 45 days from 1st April to mid of May 2019.
 Commissioning and stabilization of unit-1 (after normalization of ESP
3 passes out of 4), one month and end by mid June 2019.
 Unit-2 Erection of ESP balance 3 passes (out 4), 7 months from
December 2018 to May 2019.
 Shut down of Unit-2 for isolation and normalization of ESP balance 3 passes, (out
of4) 45 days from Mid June 2019 to July 2019.
 Commissioning and Stabilization of Unit-2 (after normalization of ESP
3 passes out of 4), one month by August 2019.
The schedule is enclosed as drawing No HIQ-KPCL-TUV-SCH-001.
5.4 New Higher capacity Unit as an Alternative to R&M
Replacing existing old units 1&2 by a higher capacity new unit is an alternative available to
R&M of old units 1&2. During R&M of existing Units, KPCL/RTPS can also look into the
possibility of uprating the existing units. This has to be discussed with the OEM BHEL at
the time of finalization of R&M works. However any major uprating in generation capacity
may not be possible considering the life of these units, type of design which is almost 3
decades old and the restrictions in the capacities of various auxiliary systems.
However R&M of existing Units is a more favorable option due to the following reasons:
 The cost for R&M works as indicated in Table 5.3 above is around
Rs 1.8 crores/MW as against installing a new unit which at current rates will
be Rs 6-7 crores/MW.
 The book value of existing units 1&2 is nullified if we go for new unit.
 New Power Purchase Agreement has to be executed in place of existing
PPA.
 For new unit fresh statutory clearances like environmental clearance,
allocation of water, aviation clearance etc. will have to be obtained.
 The schedule of implementation of a new unit requires longer time frame of
five to six years including getting all statutory clearances. During this period
the grid will lose the entire power available from the existing 2 units
(2x210MW).
 Dismantling/removal of existing structures, equipment and machinery of
Units 1 and 2 and clearing of debris for accommodating the new unit and
preparation of site for erection of new unit is a major job both in terms of
additional cost and time. Existing works like cooling tower, TG building, boiler
and other foundations, chimney etc. of units 1 and 2 are to be dismantled and
new structures are to be erected.
 Erection of new units will need larger space in the existing area where Units 1
and 2 are located. Providing additional space may be difficult as many of the
common utilities like coal conveyers, DM plant, water systems etc. are
situated on one side and Station Transformers, DG plant, CW pipe lines and
220KV switch yard catering to remaining units of RTPS are located on the
other side. Hence this imposes a major constraint in developing a proper
layout for the new unit and locating construction yard for new unit will also be
a problem.
 The coal feeding conveyers feeding the bunkers of Units 1&2 are also
feeding Unit 3 and 4. If a new higher capacity unit is to be installed this
arrangement has to be modified affecting operation of Unit 3. The coal
conveyor feeding Units 4 to 8 may also need shifting to make space for higher
capacity unit.
 At present power generated by Units 1, 2 & 3 are fed to 220KV Bus. In case
higher capacity new unit is considered, power evacuation will have to be at
400KV calling major changes to existing power evacuation 220KV switch
yard which is serving Units 1&2 along with Unit 3. This will affect the
evacuation from Unit 3 also. All lines emanating from 220 KV switch yard
(Lingsugur 3 lines, Shahabad 2 lines, Raichur 2 lines and Sedam 2 lines) and
incoming power to RTPS (ST-1, 2, 3) will need re arrangement and upgrading

to 400 KV which is very costly and time consuming proposition. This will
affect the state grid because of loss of 630 MW generations from the three
units.
 The ash evacuation pipe lines for a distance of about 6 Km from plant to ash
pond will need augmentation.
 Existing road network leading to the different locations of the main plant and
transformer yard has to be redesigned and re-laid and many existing service
and maintenance buildings may have to be relocated to make space for new
higher capacity unit.
 Many other issues and problems may arise which will surface only when the
Comprehensive DPR for the new higher capacity unit is taken up and which
cannot be foreseen at present.
5.5 Capex Requirement
The Phasing of fund requirement to meet the schedule as per Para 5.3 above is given in
the following Table 5.4
Table 5.4 Phasing of Expenses
Half year No 1 2 3 4
Period 1/9/15-28/2/16 1/3/16-31/8/16 1/9/16-28/2/17 1/3/17-31/8/17
Fund Required as 5 15 20 20
% of total
estimated cost
Half year No 5 6 7 8
Period 1/9/17-28/2/18 1/3/18-31/8/18 1/9/18-28/2/19 1/3/19-31/8/19
Fund Required as 15 10 10 5
% of total
estimated cost
5.6 Cost Benefit Analysis:
An analysis of the generation costs before and after R&M and the benefits have been
analyzed and simple break even period calculated. Details are given in the following Table
5-5
Table 5.5 - Cost Benefit Analysis
R&M of 210MW Units of Raichur TPS

Overall Cost-Benefit Analysis
DESCRIPTION Unit Unit-1 Unit-2
After After
A PLANT DATA Existing Existing
R&M R&M
a Rated capacity of T-G set MW 210 210 210 210
b Boiler Capacity T/Hr 670 670 670 670

No. of Units considered
c No. 1 1 1 1
for calculation.
d Total Capacity(=bxc) MW 210 210 210 210
e Unit Gross Heat Rate Kcal/Kwh 2615 2463 2716 2463
f Plant Load Factor % 64.37% 80.00% 63.79% 80.00%

No. of Hrs. per
g Hrs. 8760 8760 8760 8760
annum(24x365)
B GENERATION
Electricity generated Million
h 1184 1472 1173 1472
(=gxcxbxf/1000) Kwh
Aux. Power Consumption % 10.84 9.00 10.87 9.00
Million
i Aux. Power Consumption 128 132 128 132
Kwh
Million
j Net Exported Units(=h-i) 1056 1339 1046 1339
Kwh
C BENEFIT
k CV of Coal Kcal/Kg 3527 3527 3527 3527
Coal Required per Million
l 0.869 1.017 0.895 1.017
annum (=(e/k)xh/1000) Tons
m Cost of Coal / ton Rs./ton 3647 3647 3647 3647
Cost of Coal per year
n Rs. Crore 317 371.037 326.246 371.037
(=lx 10^6 x m/10^7)
Cost of Coal per Unit
o Rs. / Kwh 2.68 2.52 2.78 2.52
(=n/hx10)
p Sp Oil Consumption ml/Kwh 4.28 2.50 4.28 2.50
Oil required per annum

q KL 5068 3679 5022 3679
(=hxp)
r Present rate of Oil Rs./KL 35491 35491 35491 35491
Cost of Oil per year
s Rs. Crore 17.99 13.06 17.83 13.06
(=(qxr)/10^7)
Total cost towards fuel
t Rs. Crore 334.96 384.09 344.07 384.09
(=n+s)
Cost of coal and fuel oil
Rs./Kwh 2.83 2.61 2.93 2.61
per unit generated
Cost of fuel saved per
unit generated after Rs./Kwh 0.22 0.32
R&M
Cost of fuel saved per
Rs. Crores 32.20 47.41
annum
u Fixed Charges Rs. / Kwh 0.8067 1.0098 0.8067 1.0098
Revenue generated per
annum (=uxj/10)
v Rs. Crore 85.17 133.87 84.37 133.87
considering only fixed
charges
Net Benefit per

x Rs. Crore 49 49
annum
Benefit per unit after

Rs./Kwh 0.033 0.034
R&M
Total Benefit after
Rs./Kwh 0.252 0.356
R&M
Note: Assumption for tariff calculation, Tariff Calculations, Fixed charges statement
and Cash flow statement are enclosed as Annexure-3: Financial Calculations. Payback
period is worked out in cash flow statement.
5.7 Estimated Life Extension Due to R&M
As indicated by BHEL who will carry out the R&M works for the BTG package
carrying out the listed R&M works will lead to an extension in life of Units 1 and
2 by 15 years provided the plant and equipment are operated and maintained as
per their recommendation.
5.8 Financial Sources
KPCL/RTPS will be funding the R&M works partly from internal sources (Equity)
and the rest by commercial borrowings (Debt) from banks or international
funding agencies. The ratio of equity to debt for such project work will generally
be in the ratio of Equity to Debt as 20:80. Interest rates will vary based on the
source of fund and funding agency.
5.9 Bench Mark Prices
Maharashtra State Power Generation Corporation Ltd, Maharashtra, had carried
out a study for R&M on Units 1 and 2 of Chandrapur Super Thermal Power
Station, Chandrapur. These units are identical in capacity and specifications to
RTPS Units 1 and 2. The estimated cost for R&M for these units was around Rs
1.5 Crores per MW.
5.10 Time lines for Phase III scope of works for Unit I & II R&M:
S.No Area/Work Time Required for

Completion
1 Civil works for Chimney 12 months
2 Civil works of Cooling tower 6 months
3 Ash bund works 24 months
4 Construction of Barrage across river at Girijapur 20 months
5 Replacement of HT Switchgears and breakers in APH

1&2
6 Replacement of HT Switchgears and breakers in RWPH
7 Generator Protection system and Replacement of HT
8 Replacement of HT breakers in Unit II
5.11 Conclusion
In view of above and with reference to the entire Comprehensive DPR, we are
recommending for R&M of Unit 1 & Unit 2, instead of going for new higher
capacity plant.

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KARNATAKA POWER CORPORATION LTD

RAICHUR THERMAL POWER STATION UNITS 1 & 2 (2X210MW)

KARNATAKA POWER CORPORATION LTD

COMPREHENSIVE DETAILED PROJECT REPORT FOR

M/S. TUV SUD SOUTH ASIA PVT. LTD

Table No. Title Chapter Page No.

Appendix No. Title No. of Pages

E&C Erection and Commissioning

have generated 37849 Mu and 37637 Mu respectively till 28.2.2015.

due to failures of components and equipment is frequent leading to increased down

for Units 1 and 2.

Unit 2 has been carried out by BHE in August 2011.

negotiations. The R& M works may be implemented in two Phases as follows:

of ESP for which M/s BHEL / OEM.

plant, replacement of feeders, certain works in 220 KV switch yard,

auxiliary transformers of Unit 2, new DG sets, SCADA for switch yard

be taken up on tender basis.

Phase 2 works is as given in Table 1.

Table 1- Total Estimated cost for R&M Works (Phase 1& 2)

S.No Area/Work Rs Lakhs

1 Under execution + Phase 1 68775.20

Gross Total 96215.00

months from the date of contract finalization by KPCL on BHEL,

crores/MW for a new unit.

 New Power Purchase Agreement has to be executed.

 Obtaining fresh statutory clearances e.g. environmental clearance, etc.

 Longer implementation and loss in power availability to grid.

 Major problems in dismantling/removal of existing structures, equipment and

machinery and preparation of site for erection of new unit.

arrangement has to be modified affecting operation of Unit 3. Coal conveyor

feeding Units 4 to 8 may also need shifting.

 Higher capacity unit needs power evacuation at 400KV needing changes to

Table 2 - Cost Benefit Analysis and Break Even Period

1 Station Heat Rate Kcal/Kwh 2615 2463 2716 2463

2 Plant Load Factor % 64.37% 80.00% 63.79% 80.00%

6 Cost of fuel/year Rs. Crore 334.96 384.09 344.07 384.09

Cost of fuel per unit

Net Benefit per

and equipment are operated and maintained as per recommendation.

based on the source of fund and funding agency.

S.No Area/Work Time Required for

2 Civil works of Cooling tower 6 months

3 Ash bund works 24 months

4 Construction of Barrage across river at Girijapur 20 months

5 Replacement of HT Switchgears and breakers in APH

7 Generator Protection system and Replacement of HT

Switchgears and breakers in Station Bus A&B

8 Replacement of HT breakers in Unit II

have long gestation period.

augmentation, reduction in auxiliary power consumption, improved availability,

reliability, and reduced emissions thus improving the greenhouse effect.

adequate to burn required quantity of coal with inferior quality.

14001-2004 certification for its environmental measures. From an industry vantage

bench mark on the national grid.

generation from various sources.

implemented in a comparatively shorter time frame. In this regard, optimum utilization

of existing installed capacity in the country to maximize the generation through

Renovation & Modernization (R&M) of existing power plants is considered to be the

most cost effective option.

210 MW and one Unit of capacity 250 MW.

generated 37849.797 Mu and 37637.364 Mu respectively till 28.2.2015. Hence it is

residual life of RTPS, Units 1 & 2 (2X210 MW).

addressed in the report.