2. shri. baboo ram

7/29/2019 2. Shri. Baboo Ram

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By: Baboo Ram

Ex. Executive Director BHEL Power Sector


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PRESENTATION NAME


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Pre-commissioning means preparation for

commissioning.

commissioning of various equipments and systems arepre-commissioning for commissioning of the power

plant. It is a pre-requisite for commissioning.


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Commissioning means to put the equipment into operation asenvisaged.

For a thermal power plant commissioning means to set up andoptimise all its equipments and systems to get output, efficiency,auxiliary power consumption and emission on sustained basisas envisaged to drive the benefit.

For super critical and ultra supercritical plant commissioningwould mean higher efficiency of the plant with lower emission

level and lower auxiliary power consumption(as compared tosub critical plants ) on sustained basis in order to drive thebenefit of elevated steam parameters.


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Out put

Heat Rate ( Efficiency )

Auxiliary power consumption

Emission level

Sustained generation


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Material

Infrastructure

Expertise


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ANNEX-1


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36 units UMPP 27960MW

32units SCPP 21540MW


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Lower pressure drop means lower

feed-pump power and lower.through-life energy consumption

Other advantages include better

turn-down, simpler construction and

improved availability.

FURNACE WALL DESIGNThe furnace walls are exposed to the greatest heat flux of all heat absorbing surface. This is

because of the intense radiant heat from the fireball.For any given furnace size, the spiral wall unitin which the tube is wrapped around the

unit has fever tubes then vertical wall unit.

SPIRAL & VERTICAL WATER WALL CONFIGURATION

Optimized Rifled Tube


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Nozzle box 12Crcast steel

HP internal

casing

12Crcast steel

Main steam

stop valves12Crcast steel

MainsteamInlet shortpipe

9Cr-1Mosteel

Combined reheat

steam valves12Crcast steel

Reheat steaminlet short pipes

9Cr-1Mosteel

No.1 IP

internal casing12Crcast steel

HP IP

Main steam inlet

flange elbow9Cr-1Mosteel

Cooling structure withmain steam leading pipe

Overlay coatingProtection of No.s 1,2journal thrust bearing

Rotor cooling for IP section(Protection of aged bending)

Control valves 12Crcast steel

H-IP Combined Type 600 C / 600C to 620 C

Steam Temperature

HIP Rotor 12Cr steel


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660MW Steam turbine : Cross section View


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Water-wall Cracking

Higher metal temperatures and the use of low alloy steel.

Thermal fatigue cracking is caused by the combined

action of elevated metal temperatures and thermal

cycling.

Growth of internal tube deposits, high heat flux,

deterioration of fluid-side cooling or external fireside

coatings.

Slagging and shedding, Soot blowing, water cleaning orother factors may cause thermal cycling


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Negative Flow Characteristic

A high mass flux design.

If the furnace heat flux distribution

is non-uniform due to slagging.

A FLOW RESPONSE CALCULATED FOR VARIOUS HEAT

ABSORPTIONS FOR A BOILER WALL CIRCUIT WITH A HIGHMASS FLUX

INCREASE IN HEAT ABSORPTION IS A

REDUCTION IN TUBE FLOW


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Slagging

Due to Spiral tube configuration.

Inclination of the tubes is thought to increase the

propensity of slag and clinker.

The higher fireside metal temperatures of

supercritical boilers may also contribute toincreased slagging.

Slagging refers to deposition of solid layers on theboiler tube, formed by sintering. Slagging is quite hard

to remove and also (although it is sintered material) the

slagging material is usually still a good insulator.


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Welding of Special Materials

Welding of dis-similar pieces i.e. two pieces fabricated

out of different materials is a difficult process.

The difficulty increases when the metals, out of which

the pieces to be welded are fabricated, are newly

developed and not conventional.


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Tube Spacing to Handle Indian Coal

Indian coal has high ash content and

lower calorific value as compared to

coals available in other countries such as

Australia and South Africa.

The designs of supercritical boilersdeveloped by foreign manufacturers are

based on the superior type of coals.

The tubing has to ensure that steam

parameters required for the supercritical

steam cycle are maintained and have tobe adopted to suit Indian coals.


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Height of Structure

Convenient and economical height of the

boiler structure.

The height of the boiler governed, however,

by design considerations.

The height of the (Chimney) is governed by

environmental considerations.


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Transportation of Major Equipment

Imported equipment unloading facilities

at port and project site.

Load bearing capacity of bridgesinvolved (rail or road).

Limited heavy equipment carriers

Needs to develop approach road to the

project site.


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Skilled Manpower

Shortage of enough experience and skill

available for the erection and commissioning

of a 660 MW/ 800 MW.


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INDIAN AMBIENT CONDITIONS AND INDIAN

COALS

OPERATION & MAINTENANCE ISSUES

G coal is available for thermal power plants.The quality of coal available from domestic sources compares very unfavorably with the quality of coals

imported from other countries such as Australia, Indonesia or South Africa.

Problems associated with Indian coal are:

Indian coal typically has higher moisture content. This can lead to lower boiler efficiencies than withimported coal.

Low volatile matter in Indian coal leads to high-un-burnt carbon loses. Low boiler efficiency due to low CV and high ash content in Indian coals High ash and coal handling costs and milling power lead to high auxiliary power consumption High ash and high silica in the coal leads to higher erosion. Though lower flue gas velocities and

provision of shielding plates can reduce erosion, it leads to higher capital costs for the boiler.

Indian ambient condition

High ambient temperature leads to higher cooling water temperature reducing the achievable

condenser vacuum to a maximum of 0.13 bars. This in turn leads to higher steam consumption and a poorer turbine heat rate.

High relative humidity leads to more losses in cooling tower


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AVAILABILITY OF CONTRACTOR FORMAINTENANCE

OPERATION & MAINTENANCE ISSUES

Specific skills for maintenance.

Important to provide extensive training to the plant personnel

using similar facilities abroad and also using training simulators.


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Chemical Cleaning Oil flushing

Steam blowing

Restoration of system

Barring gear

Vacuum system check

Commissioning of gland sealing system

Commissioning of HP/LP bypass system

Steam dumping


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Control gear setting

Checking of turbine and generator protection

Rolling and synchronizing

Loading and trial run

Performance guarantee test


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OBJECTIVE

The objective of this procedure is to chemically clean and passivate the

internal surfaces of the steam generating portion (water touched

surfaces) and heating surfaces (Economizer) using specified chemicalsemploying a single step process. This will render the above mentioned

surfaces free of mill scale, and other deposits and form uniform &

smooth protective layer of magnetite. With this protective layer, the

generating surfaces are rendered passive to generate adequate

negative potential under the operating pH to resist corrosion.


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Iron concentration in three consecutive samples show equilibrium status.

When the iron concentration in the cleaning solution is constant, it indicates

that all the oxides have been dissolved. However, a minimum EDTA(Ethelene

Diamine Tetra Acid ) contact period of 6 hours from the time of attaining the

required temperature (110 deg. C) shall be allowed.

Completion of pickling process once the EDTA strength and iron concentrationlevel out and reach equilibrium.

The system shall be allowed to cool with the ID & FD fans in operation. Open

the drum air vents when the pressure reaches to 1 kg / sq.cm.

When the temperature comes down to 95 deg. C, the system shall be drainedcompletely in hot condition to the effluent pit by opening all the drain valves .


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The drum surface shall be visually inspected for uniform

smooth coating of protective layer.

The low point header will be inspected and loose debris ifany, will be removed


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Hot DM water flushings shall be drained into plant normal drain.

The organic spent EDTA chemical solution after the cleaning process is

drained into a pit. The pH of the effluent will be in the range of 8.5 to

9.0 and hence no treatment for pH adjustment is required as it wouldmeet the pH requirement for disposal.

Compressed air shall be used to destroy the residual Hydrazine &

organics and the effluent shall be disposed after aeration for 10 days.

(The organic chemical is completely bio-degradable).


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Lubricating oil system

Seal oil system

Jacking oil system

Governing oil/ control fluid system


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To clean and remove any foreign material from theoil system


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Completion of oil piping

Installation of temporary piping after proper cleaning

Cleaning of main oil tank and bearing pedestal

Oil throttles in the bearing supply lines must be removed and dummy

provided

Duplex filter element in oil supply line to thrust bearing should be removed

initially however it may be installed during final stage of flushing

Flushing devices are installed in the bearing pedestal to bypass the

bearings

MOP must be removed and flushing device installed


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Jacking oil system is isolated and it should be flushed

separately.

Turning gear nozzle box is removed and replaced with flushing

device.

Suitable oil heating arrangement must be available to raise

the oil temperature to around 75 C.

Oil cooling arrangement should also be there to cool the oil for

giving thermal shocks.

Arrangement for analysis of oil sample should be available.


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Use of cotton waste is prohibited for cleaning the oil system. Markin cloth to

be used.

For checking the direction of rotation of the oil pumps oil must be filled in

the oil tank

Provision must be made for stopping the oil pumps from local as well as

from UCB

Fire fighting arrangement must be available during flushing

Arrangement for cleaning the spilled oil should be available before starting

the oil flushing.

Motor current of the oil pumps specially the auxiliary oil pump should not

exceed the rated value.


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Oil flushing is considered complete when there is no

mechanical impurities and traces of moisture as catched from

oil sample.

Duplex filter remains clean after 24 hours of flushing.

Particle count is also some time used to declare completion

of oil flushing.

Recommendation of turbine supplier should be a guiding

factor.


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After oil flushing the system is restored to original position.

All the temporary piping and flushing devices are removed.

All the orifices/ restrictions are restored.

All instrumentation pressure, temperature ,flow devices etc. are normalized.

Blanks installed during flushing are removed.

Main oil tank is drained , oil tank cleaned and recharged with fresh oil .

Bearing pedestals are cleaned before boxing up

Coolers are normalized


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The function of barring gear is to rotate the shaft at low speed to

remove the temporary bend during start up and after shut down

to prevent hogging.

Barring gear are :

Electric motor operated

Hydro motor operated

Hydraulic barring gear

All turbines have manual barring gear provision


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Alignment of rotor train completed

Rotors coupled

Oil flushing completed

Instrumentation inside the bearing pedestals completed.

Bearing pedestals boxed up

Generator work is completed and generator boxed up.

Exciter is coupled.

Insulation of generator bearing is checked before generator bearingpedestal box up.

Condenser floated and joint between turbine and condenser made.


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Lube oil and seal oil system commissioned

Jacking oil pumps are available

All the turbovisory , local and control room instrumentation are

installed, calibrated and available for monitoring

Interlock and protection for oil tank, oil pump and barring are

tested and available

Dc emergency power as well as DG set are commissioned and are

available

Shaft lift is checked in all the journals and is ok

Direction of rotation of the shaft is checked.


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ESTABLISH THE LUBE OIL SYSTEM ENSURE LUBE OIL TEMPERATURE AFTER OIL COOLER IS >35 C

ENSURE PRESSURE IN ALL BEARING OIL SUPPLY LINE AND FLOW IS SITE

GLASSES

ENSURE PRESSURE IN SEAL OIL SUPPLY LINE AND FLOW IN SITE

GLASSES.

ENSURE DIFFERENTIAL PRESSURE REGULATOR IS FUNCTIONING.

DC SEAL AND DC LUBE OIL PUMPS ARE ON AUTO START MODE AN CASEOF AC FAILURE

SWITCH ON THE SUPPLY TO SUPPLY TO TURBOVISORY.


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START JACKING OIL PUMP AND CHECK THE JACKING OIL PRESSURE

AN ALL THE BEARINGS .

TURN THE SHAFT MANUALLY WITH THE HELP OF MANUAL BARRING

GEAR AND CHECK THE FREENESS OF THE SHAFT

MOTIVE OIL CAN BE ALLOWED TO ENTER BARRING GEAR WHEELCHAMBER BY OPENING THE ELECTRICALLY OPERATED MOTIVE OIL

VALVE

JACKING OIL PUMP IS KEPT RUNNING AS LONG AS SHAFT IS TURNING.


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ANY ABNORMAL IS NOISE IN THE TURBINE GLANDS OR BEARINGS.

RETURN OIL FLOW FROM THE BEARINGS AND TEMPERATURE OF

OIL.

TURBOVISORY READINGS.

GENERATOR SEAL OIL TEMPERATURE AND LINER METAL

TEMPERATURE.

COSTING DOWN TIME FROM FULL BARRING SPEED TO ZERO


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MAIN STEAM

COLD REHEAT

HOT REHEAT

HP BYPASS

LP BY PASS

AUXILIARY STEAM AND PRDS HEADER

GLAND SEALING

OTHER SMALL BORE LINES


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The objective of steam blowing is to remove scales, loose

material, iron cuttings etc, that might have been entrapped in

Super Heaters, Steam piping, reheaters during manufacture,

storage, erection at site. Failure to remove the debris may

result in damage to turbine blades. Valves etc.


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The steam blowing is done in four stages. Viz Stage 1(1a,1b) Stage 2

(2a & 2b), Stage 3 (3a & 3b) & stage 4. Loop pipes from ESV and IV toturbine are to be taken care for cleanliness before erection and not to

be steam blown.

Steam blowing is carried out by adopting puffing method for stages

1a, 2a 2b,&3a,3b. in which, boiler pressure is raised to 40 Kg/cm2

and released through a quick opening valve and steam blowing done

till the Drum pressure drops from 40 Kg/cm2 to 20 Kg/cm2

Steam blowing for stages 1b & 4 are carried out by continuous

method. Steam blowing by continuous method shall be done at 40-

50% of normal operating pressure of the respective system for period

of 20 to 30 minutes. Blowing repeated after a time gap of 2 Hrs.


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Stage1a: SH, MSL, ESV, temporary line from ESV to EOTV and EOTV to exhaust with

temporary piping will be concluded by observing the indents on the target plate.

Stage1b:SH,MSL,Aux PRDS, Atomizing Steam lines & FO heating/tracing lines.

Stage 2a SH, MSL, ESV, temporary lines from ESV to EOTV, EOTV to CRH line, CRH lines up

to boiler end with temporary exhaust pipe. Tap off lines from CRH for deaerator, , auxiliary

PRDS, HP heater 6a & 6b, gland sealing, etc. shall be remain closed/isolated. Stage 2a end

point will be concluded by observing the indents on the target plate .

Stage 2b : 2a plus HP bypass inter connection, hand operated valve mounted in place of

HP bypass valve and CRH lines up to Boiler end with temporary exhaust piping. In this stage

6 to 8 blows will be given through HP bypass to ensure cleanliness of the limb. Boiler MS

stop valve will be used for stage 2b. EOTV will be kept closed. Manually Operated Isolation

Valves in HP bypass lines will be kept opened fully.

Stage

3a : 2a plus reheater, HRHL, IV and temporary pipe.

CRH line along with attemperator shall be welded with reheater before start of stage 3a. LP

bypass lines shall be blanked during stage 3a. Stage 3a end point will be concluded by

observing the indents on target plates .


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Stage-3b: Stage 3a plus LP Bypass lines.

Stage-4 :

4a) APRDS to Gland seal steam

4b) CRH to turbine extraction line (HPHS &LPHS).

4c) CRH to Extraction 4 to Deaerator

4d) CRH to Deaerator / FST

4e) CRH to HP Heaters.

4f) CRH steam line to Turbine gland sealing line

4g) CRH to APRDS


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BLANKING DEVICES ARE INSTALLED IN TURBINE MAIN TOP AND CONTROL

VALVES AND SIMILARLY IN ESV

TARGET PLATE IS INSTALLED BEFORE THE STEAM EXHAUST.

TEMOPORARY PIPING ARE ERECTED FROM MAIN STOP VALVE TO OUTSIDE

BUILDING

TEMPORARY PIPING ARE ERECTED FROM ESV TO OUT SIDE BUILDING

ARRANGEMENTS ARE MADE TO BLOW COLD REHEAT PIPE LINE TOWARDS

BOILER END

LOOPS ARE ERECTED TO BLOW HP BYPASS AND LP BY PASS

TEMPORARY ARRANGEMENTS ARE MADE TO BLOW GLAND SEALING AND

OTHER SMALL BORE LINES


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The purpose of steam blowing of all critical piping, the steam blowing

valve will be opened at 40 kg/Sq.Cm. and closed at 20 kg/sq.cm drumpressure.

All the steam lines are purged as per various stages and it is a standard

practice to limit number of blows per day to( 8-10) with an interval of 1-1

hours.

Blowing is carried out during the day and system is left cooling during

night

While blowing stage 3a, suitable dummies will be put at LPBP outlet

temporary line. Required flange provisions are made in these temporarylines for installation of dummies.


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All instruments coming in the steam flow are isolated or removed

Temporary pipings are properly supported and insulated

Steam exhaust is led to outside building to a safer place so as not to

cause damage to equipment or person

Steam blowing should be done preferably during day time due to

noise pollution

Sufficient quantity of dm water is stored


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Steam blowing is considered complete when target plate remainsclean (2-3) small dots in three consecutive steam blows after

overnight cooling.

for stages 1, 2a, & 3a Disturbance factor value at selected locations

should be greater than unity.

More than 5 (five) pitting and shall not have any deformed edges.

Besides, there shall be no pitting in the rim zone, i.e., area other than

central zone

Gland steam and other small bore pipings are blown for 1-2 hours and

blowing is terminated on visual operation


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Disturbance Factor = Qb2 x Vb

Q2 MCR x VMCR

Qb - Steam flow during blowing

QMCR - Steam flow at MCR

Vb - Sp. Volume of steam during blowing

VMCR - Sp. Volume of steam at MCR

Qb = Sonic Velocity During blowing x Area x 1

Vb

Where

Qb = St. flow in kg/sec

Sonic Velocity = KP Vb g =M/sec

Area = Sq.MVb = Cu.m/Kg

K = Constant = 1.3

P = Pressure at the exit pipe = Kg/Sq.m

Vb = Sp. Volume =Cu.M/Kg

g = Acceleration due to gravity = M/Sec2


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After steam blowing the system is restored to original position.

All the temporary pipings and temporary supports are removed.

All the orifices/ restrictions are restored.

All instrumentation pressure, temperature ,flow devices etc. arenormalized

Blanking arrangements are removed and valves restored .

Blanks installed during steam blowing for system isolation are

removed and system normalized.


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Remote trip from UCB Manual trip from local

Low vacuum trip

Low vacuum trip -hydraulic

Low lube oil pressure

Axial shift

Over speed striker 1 and 2

Fire protection channel -1

Fire protection channel-2

MOT low level

Low lub oil pressure

Boiler fire out

Main steam temperature low

Generator protection


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Steam dumping is carried out before steam admission toturbine

During steam dumping operation, quality of steam is

improved by turbine supplier

HP/LP by pass system is used for steam dumping

Turbine is kept on barring gear

Full vacuum is raised


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Max flow is stabilized through HP/LP by pass with rated

steam parameter.

Steam dumping is carried out till quality of condensate at

CEP discharge is same as inlet to hot well make up.

After steam dumping hot well, deaerator & Boiler drum are

drained, clean and inspected before recharging.


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GE,s Super Critical/ Ultra Super Critical Steam Turbine.

Recommended procedure for commissioning of large steam turbine by BHEL.

Analysis of Supercritical technology in Indian Environment and Utilizing Indian coal

by Prof: M M Hasan, Mechanical Engineering dept (Jamia Islamiya New Delhi)

STEAM TURBINE DESIGN CONSIDERATIONS FOR SUPERCRITICAL CYCLES,Presented by Bechtel Power Corporation, Frederick.

Bituminous coal fired large SC Power Plants for the European Market presented by

Mr.K. Busekrus(HITACHI) ON 2007

Supercritical technology in Indian presented by NTPC Ltd.


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S. No. Name/Location No ofunits

Capacity(MW)

Utility

1. UMPP, Mundra 5 800 M/S. Tata power Ltd

2. UMPP, Sasan 6 660 M/S. Reliance Power

Ltd

3. UMPP, Krishnapatnam 5 800 M/S. Reliance PowerLtd

4. UMPP, Tilaiya 5 800 M/S. Reliance Power

Ltd

5. UMPP, Orissa 5 800 -

6. UMPP, Chatisgarh 5 800 -

7. UMPP, Tamilnadu 5 800 -


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S. No. Name/Location No ofunits

Capacity(MW)

Utility

1. Hissar 2 660 M/S. HPGCL

2. Jhajjar 2 660 M/S. HPGCL

3. Talvandi Sabo 2 660 M/S. PSEB

4. Mundra, Kutch 2 660 M/S. Adani Power Ltd

5. Meja-IV, Uttar Pradesh 2 660 M/S NTPC Ltd Joint

venture

6. Sipat-I, Bilaspur 3 660 M/S NTPC Ltd

7. New Nabinnagar, Bihar 3 660 M/S NTPC Ltd Jointventure

8. Krishnapatnam 3 800 M/S. APGENCO


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S. No. Name/Location No of

units

Capacity

(MW)

Utility

9. Solapur Thermal Power

Station, Maharashtra

2 660 M/S. NTPC Ltd

10. Barh Super Thermal

Power Station

3 660 M/S. NTPC Ltd.

11. Raghunathpur-II, West

Bengal

2 660 M/S. DVC

12. Gidderbaha Station-1,

Punjab

2 660 M/S. PSEB

13. Shahpur Thermal

Power Company Ltd

2 660 M/S STPCL

14. Jewargi Power

Company of Karnataka

Ltd

2 660 M/S Power Company of

Karnataka Ltd.


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units

Capacity

(MW)

Utility

1. Dhenknal, Orissa 2 660 M/S. Lenco Infratech

2. Pussurar Region,

Raigarh

Chhatisgarh

3 660 M/S. Infrastructure

Leasing & Financial

Service Ltd.

3. Chutru Region of

Jharkhand

3 660 M/S. Infrastructure

Leasing & Financial

Service Ltd.

4. Gondia, Maharashtra 3 660 M/S. Adani Power

Maharashtra Private

Ltd

5. Chandil Region ofJharkhand

3 660 M/S. InfrastructureLeasing & Financial

Service Ltd.

6. Bade Dumarpali,

Raigarh Chhatisgarh

2 660 M/S Ahtena

Chhatisgarh Power

Private Ltd.


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units

Capacity

(MW)

Utility

7. East Godavari, Kakinda 2 660 M/S. Spectrum Power

Generation Ltd

8. Sinnar, Nasik

(Maharashtra)

2 660 M/S. Fama Power

Company Ltd

9. Nagapattinam,

Tamilnadu

2 660 M/S. PEL Power Ltd.

10. Nandgaon pet,

Amravati

(Maharashtra)

4 660 M/S. Sophia Power

Private Ltd.

11. Tamnar Raigarh,

Chhatisgarh

2 660 M/S. Opelina Finance &

Investment Ltd

12. Tamnar Raigarh,

Chhatisgarh

2 660 M/S Jindal Power Ltd


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units

Capacity

(MW)

Utility

13. Lathur, Maharashtra 2 660 M/S. Amravati Thermal

Power Ltd.

14. Machillipatnam, Andhra

Pradesh

2 660 M/S. Thermal

Powertech

Corporation(I) Ltd15. Gopuvanipalem,

Krishna (Andhra

pradesh)

3 660 M/S. Nagarjuna

Construction Company

Ltd.

16. Simar Thermal Power

Plant, Junagarh (Guj.)

2 800 M/S. JSW Energy Ltd.

17. Salaboni Thermal

Power Ltd, Paschim

Midnapore

2 800 M/S. JSW Energy Ltd.

18. Manappad Tuticorin,

Tamilnadu

2 660 M/S Ind-Bharat Power

(Madras) Ltd


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units

Capacity

(MW)

Utility

19. Mundra, Kutch, Gujrat 3 660 M/S. Adani Power Ltd.

20. Sompeta, Dirkakulam

(Andhra Pradesh)

3 660 M/S. Nagarjuna

Construction Company

Ltd.

21. Central India Power,

Phase-II, Maharashtra

3 668 M/S. Central India

Power company Private

Ltd.

22. Tanda Expansion, Uttar

Pradesh

2 660 M/S. NTPC Ltd

23. Katwa, West Bengal 2 660 M/S. WPDCL

24. Bakreshwar Extesion

Project

1 660 M/S. WPDCL


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units

Capacity

(MW)

Utility

25. Koradi Extension

Project Maharashtra

2 660 M/S. Mahagenco

26. East Coast, Andhra

Pradesh

2 660 M/S. East Coast Energy

27. NSL Power, Tamilnadu 2 660 M/S. NSL Power Private

Ltd

28. Marakanam, Tamilnadu 4 800 M/S. NTPC Ltd

29. Darlipali, Orissa 4 800 M/S. NTPC Ltd

30. Lara, Chhatisgarh 5 800 M/S. NTPC Ltd31. Kudgi, Karnataka 3 660 M/S. NTPC Ltd. JV with

M/S. PCKL

2. shri. baboo ram

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