ntpc alstom power
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NASLPEER REVIEW OF COAL FIRED THERMAL POWER PEER REVIEW OF COAL FIRED THERMAL POWER
STATIONS & BEST PRACTICES IN POWER GENERATIONSTATIONS & BEST PRACTICES IN POWER GENERATIONHosted byHosted by
Ministry of Power Govt. of India & NTPC LimitedMinistry of Power Govt. of India & NTPC LimitedFebruary 2008 INDIAFebruary 2008 INDIA
RENOVATION & MODERNISATION OF THERMAL POWER PLANTSRENOVATION & MODERNISATION OF THERMAL POWER PLANTSPRESENTATION BYPRESENTATION BY
NTPCNTPC--ALSTOM POWER SERVICES PRIVATE LIMITEDALSTOM POWER SERVICES PRIVATE LIMITED
bybyK. V. Ramachandra SettyK. V. Ramachandra SettyAGM Business Development AGM Business Development
2
NASL
NASL – Introduction
NASL Promoters’ strengths
Retrofit Solutions
Role of CDM
R&M/Retrofit solution – case Studies
3
NASL
NTPCNASLNASL
50% 50%
NTPC-ALSTOM Power Services Private Ltd.
Original Equipment Designer (OED) & Manufacturer (OEM) with over 647 GW installations world wide. Complete R&D back up and Service Provider with global reach, • Engineering & manufacturing• Research & Development• IPPs / EPC• O&M Services and R&M Services
Largest Power Utility in the country with over 27 GW installed capacity• Engineering• Quality Assurance• Project Management• O&M-Rich Experience• Performance Optimization &
Turn around
Brief History Established in September 1999Exclusive JV for R&M business in India & SAARC region Strategic alliance to meet requirement of R&M in India.
4
NASLOur range of services for power plant
Turnkey solutions• R&M of power plants to originally designed performance
• Re powering, Up grading beyond original design capacity
• Up grading to meet Environmental norms
• Lease, Rehabilitate,Operate, and Transfer projects (LROT)
Solutions for power plant packages• R&M of power plants islands –
Boiler,Turbines,Generators, C&I, Environmental systems,BOP etc.
• Retrofit of major power plant components.
5
NASLOur range of services for power plant (2)
Services• Technical audit of power plants• Residual life assessment and plant life extension studies• Performance improvement and upgrading studies• Functional & performance tests of major equipment• Setting of plant management studies
Operations and Maintenance• R&M related O &M for agreed duration.• Development & implementation of O&M solutions• Training of O&M personals• Inspection & capital over hauling with repair / replacement
6
NASLTurnkey R&M Plant Integrator Capability
Boiler
Steam Turbine
Generator
Condensing & Feed heating plant
Control system
Electrical & BOP
Coal & Ash handling
Electrostatic Precipitator
Coal Power Plant
Flue Gas
7
NASLRetrofits - Executed / under execution
Output capacity enhancement (MW) of machine.
Torrent AEC Sabarmati ‘D’ station 1x110 MW unit uprating to 120 MW.
Improved Boiler Efficiency and High efficiency heat transfer surfaces.
NTPC Talcher (1x110 MW) APH retrofitNTPC Tanda (4x110 MW) Boiler renovation
Turbine module Retrofit Output / Heat Rate Improvement.
Koradi 1x120 MW LP Turbine module retrofit eliminating Baumann stage.Bathinda 110 MW High Pressure (HP)Turbine module retrofit for Heat rateimprovement
8
NASLRetrofits - Executed/under execution
Turnkey R&M Plant/Island
Restoration works
PSEB GNDTP Bathinda 2x110 MW unitsMPPGCL Amarkantak 2x120 MW units TG & Auxiliaries
JSEB Patratu 1x110 MW+ 1x50 MW
I&C Retrofits (DAS/DCS/DDCMIS/FSSS)
NTPC Talcher (3x60 MW)NTPC Singrauli (3x200 MW)PSEB Bathinda (2x110 MW)*Torrent AEC Sabarmati (1x110 MW)*JSEB Patratu (2x50 MW)*NTPC Tanda (4x110 MW)
Emission Controls Tanda 4x110 MW ESP retrofit (EPIC II)Badarpur 210 MW ESP ContrllersRetrofit (EPIC-I to EPIC-II)
Miscellaneous Works Ranchi 33 KV substation worksGRASIM Nagda MS Piping works
9
NASL
NASL – Introduction
NASL Promoters’ strengths
Retrofit Solutions
Role of CDM
R&M / Retrofit solution – case Studies
10
NASLNTPC – Operational Performance
Turn Around AbilityCapacity UtilizationUnchahar Plant PLF
18.0
95.6
0
20
40
60
80
100
120
Taken over in 1992 2006-07
%
Talcher Plant PLF
18.7
88.81
0
20
40
60
80
100
Taken over in 1995 2006-07
%
Tanda Plant PLF
14.9
91.14
0
20
40
60
80
100
Taken over in 2000 2006-07
%
67.3
80.484.38
69
81.8
86.2
69.9
81.1
86.54
72.2
83.6
88.7
72.7
84.41
88.79
74.3
87.51
91.2
73.6
87.5489.91
76.8
89.490.09
60
63
66
69
72
75
78
81
84
87
90
93
1999-2000
2000-2001
2001-2002
2002-2003
2003-2004
2004-2005
2005-2006
2006-07
All India PLF NTPC PLF NTPC AvF
11
NASLALSTOM - Technology Range on Boiler
Combustion Engg.[ CE ] & Air Preheater Inc.[ API ] USA are both ALSTOM group Companies, with complete range of Upgrades for Boilers, Bowl Mills & Ljungstrom Rotary Air Preheaters on OEM / OED basis
TECHNOLOGY RANGE TECHNOLOGY RANGE
CE , APICE , API
B&W, UKB&W, UKvia Exvia Ex--ABLABL
LURGILURGIEVT EVT STEIN STEIN
FLAKT FLAKT
APBILAPBILALSTOM PowerALSTOM Power
IndiaIndia
Technology : BOILERSCE, EVT, STEIN, B&W CE BOWL, STEIN TUBE & BOWL,
B&W BALL , EVT BEATER WHEEL
Technology : MILLSTechnology : ESPsFLAKT, LURGI
Technology : APHAPI ROTARY APH
Facilities at Shahabad,Durgapur,Calcutta
12
NASLALSTOM ALSTOM --Turbo machines GroupTurbo machines GroupIndustrial footprintIndustrial footprint
Key:
Manufacturing site
Joint Venture
Engineering & Sourcing site
R&D & EngineeringPurchase Servicessite
Mannheim, DESteam turbinesGas & Steam turbine assembly
Bexbach, DEBlading Shop
Richmond, USASteam Turbines
Morelia, MXGenerator & Turbines
Shop
Rugby, UKSteam Turbines
Levallois, FRSteam Turbines
Belfort, FRGeneratorsGenerator & Turbine Shop
Elblag, PLSteam turbinesFoundry & Turbine Shop
Wroclaw, PL GeneratorsGenerator Shop
Birr, CHGeneratorsRotor Shop
Baden, CH Head OfficeGas & steam turbines
Beijing, CNSteam Turbine & Generator Joint Venture
(600MW): ALSTOM Beizhong Power (ABP)
Wuhan, CNTMG: EngineeringSourcing
Delhi, INGas & steam turbinesNASL
Infosys, Bangalore, INExternal
13
NASLALSTOM Turbo-machines Portfolio
Low emission Gas Turbines with wide operating flexibility from 50 MW to 281 MW
High efficiency, modularized Steam Turbines for the entire range from 100 to 1800 MW
Market leader for Retrofitting Steam Turbines with over 50% market share – many on 3rd party units
Largest air cooled Turbo-Generators in the market (up to 400 MW) providing lower operating costH2/water cooled Generators up to 1800 MW
Technology Competence in ALL Turbomachines
14
NASLALSTOM - Energy & Environment Systems
UtilityBoilers
Environmental Control Systems
Energy Recovery& Plant
A complete range ofproven air pollutioncontrol solutionsfor all market niches
Heat Recovery Steam Generators (HRSGs) for any large gas turbine in combined-cycle applications
In the field of Energy Recovery Systems: air preheaters and gas-to-gas heat exchangers, transfer line exchangers,…
Clean Efficient and Reliable Combustion Systems for New Boilers & Retrofit
15
NASLALSTOM – Turbine Retrofit technology range
Manufacturers Diagnostic andFeasibility Study
Modernizationpackages
Retrofitpackages
Servicepackages
Units
30 MW
500 MW
360 MW
300 MW
250 MW
200 MW
160 MW
120 MW
100 MW
50 MWSERVICE S
MODERNIZATION M
RETROFIT R
ABB ALSTOM POWER
Offer Packages List
LMZ, PLZAM
LMZ
BBC, PLZAM
LMZ, ChTGZ
UTMZ
LMZ, PLZAM, BHEL, HARBIN
ChTGZ
PLZAM, AEI, BHEL, ChTGZ
LMZ, ChTGZ, PLZAM
LMZ, PLZAM
16
NASLALSTOM -- historical background on Turbinehistorical background on Turbine
TNO, TP2, TP6, TC25, 13UP28.5, 13P32.5, 13UP55/65, TK50, 11P60, 9UK75,11P68, 9K66, 13UC105, 13UP110, 13UK125, 18UK135, 13K215, 18K348, 18K370
Locations
Elblag
Baden
Paris
Mhm.
Rugby
Steam Turbine Retrofit Business Evolution of the
1970
1900 1925 1950 1975 1990 1995 2000
1883
1893
1891
1885
1879
1896
1898
BBC AGSchweiz, CH
British Thompson-Houston
MAN
ASEA
1916
BBC/CEMFrance
1901
MetropolitanVickers
EnglishElectric
1919
Rateau
1919
1904
AEI
1959
GEC
ALSTHOM1976
ASEASTAL-LAVAL
1987
ALSTOM
ALSTOM
1998
2000
MANEnergie
1970
GETT
GECALSTHOMEnergieGmbH
1999
ABBALSTOMPower
1963
1989
GECALSTH
OM
CompagnieElectromecanique
(CEM) Paris
AlsaciennedeConstruction
Mecanique(SACM)
BBCGroup
BBCAG
ASEA
ZamechElblag, PL
1945
1837 F. SchichauElbing
BBC AGMannheim, DE ABB
STAL Svenska, TurbinAB Ljungstrom
1990
17
NASLALSTOM Power – Turbine Retrofit references
Retrofit of 200MW turbines
LP IP HP
46 8 17
DIAGNOSTICS D
SERVICE S
MODERNIZATION M
RETROFIT R
Turbine type: 500 MW360 MW300 MW250 MW200 MW160 MW100/120 MW50/60 MW
OEM:- LMZ- Zamech- CHTGZ- Skoda- BHEL
18
NASLALSTOM retrofit references*
0
100
200
300
400
500
600
700
800
Retrofit Reference List
Third partyOwn fleet
Third party 72 38 20 157 287Own fleet 169 3 54 202 428
HP HP/IP IP LP Total
* As on June 30, 2007
19
NASL
NASL – Introduction
NASL Promoters’ strengths
Retrofit Solutions
Role of CDM
R&M / Retrofit solution – case Studies
20
NASLIssues of older Steam Power Plants
equipment exposed to thermal stresses and life extension
lost availability, especially due to failures in boiler & turbine area
performance deterioration vis-à-vis original design
new technologies of better performance established in the interim.
new environmental norms emission limits not achievable by existing plant
full spectrum of spare parts likelyto be unavailable on existing plant.
Fuel/Emission per kWh net
0 20-25 50years
Increase due to- ageing/ fouling of boiler,
turbine, heat exchangers- erosion & corrosion of boiler
ducts, piping, fans, LP blades- higher auxiliary consumption
retrofit by original technology
retrofit by original technology
performance upgrading by new
technology
Retrofitting
Fuel Consumption and Emission
20 - 50% efficiency improvement potential by midlife rehabilitation
21
NASLNational Perspective Plan for R&M/LE
CEA has formulated a National Perspective Plan up to 2010-11 for Renovation & Modernisation (R&M) and Life Extension (LE) of thermal units of various Thermal Power Stations to be implemented during IX, X & XI Plans. Life extension of thermal units is to extend the economical life by another 15-20 years and to recapture/up-rate the capacities by implementing comprehensive R&M Plans
IX Plan X Plan XI Plan
LE R&M
7 29
127
17305
850
25
1,685
1,560
LE R&M LE R&M
No. of thermal power stations
No. of thermal units
Total Capacity involved (MW)
Estimated cost (in Rs. Crores)
12181332
106 34
10,413
57
14,270
9,200 977
6,000
6,000
31
7,090
751
Source : From CEA website
22
NASLLife Extension 200/210 MW units – X/XI th PlanProject Utility Size (MW) OED/OEM (TG) OED/OEM (Blr)
Badarpur unit 4,5 NTPC 210 LMZ/BHEL CE/BHEL
Obra Units 9 to13 UPRVUNL 200 LMZ/BHEL CE/BHEL
Ropar Unit 1,2 PSEB 210 Siemens/BHEL CE/BHEL
Kota Unit 3,4 RRVUNL 210 Siemens/BHEL CE/BHEL
Anpara Units 1,2,3 UPPRVUNL 210 LMZ/BHEL CE/BHEL
Satpura Unit 6,7 MPPGCL 200/210 LMZ/BHEL CE/BHEL
Korba (West) Unit 1,2 CSEB 210 Siemens/BHEL CE/Alstom
Ukai Unit 3,4,5 GEB 210 LMZ/BHEL CE/BHEL
Wanakbori Unit 1,2,3 GEB 210 LMZ/BHEL CE/BHEL
Bandel Unit 5 WBPDCL 210 LMZ/BHEL CE/BHEL
Durgapur Unit 4 DVC 210 LMZ/BHEL CE/BHEL
Nasik Unit 5 Mahagenco 210 LMZ/BHEL CE/BHEL
Koradi Unit 6,7 Mahagenco 210 LMZ/BHEL CE/BHEL
Chandrapur Unit 1,2 Mahagenco 210 LMZ/BHEL AVB
Bhusawal Unit 3 Mahagenco 210 LMZ/BHEL CE/BHEL
23
NASLNTPC units in operation for > 20 years
Project Unit Size (MW)
Capacity (MW)
OED/OEM (TG)
OED/OEM (Blr)
4260
Singrauli Unit 1-5 200 1000 LMZ/BHEL CE/BHEL
Ramagundam Unit 1-3 200 600 Ansaldo Ansaldo
Vindhyachal Unit 1-6 210 1260 USSR USSR
Singrauli Unit 6,7 500 1000 Siemens/BHEL CE/BHEL
Korba Unit 4,5,6 500 1500 Siemens/BHEL CE/BHEL
Ramagundam Unit 4,5,6 500 1500 Siemens/BHEL CE/BHEL
4500
Korba Unit 1-3 200 600 Siemens/BHEL CE/BHEL
24
NASLBoiler Retrofit SolutionsBoiler Retrofit Solutions
Mills & PA Fan
Airpreheater
Economiser
Burners
Reheater
25
NASLALSTOM ALSTOM -- Turbine Train Retrofit SolutionsTurbine Train Retrofit Solutions
Turbine Train Retrofit Solution
LP bladed RotorIP inner casing / blade carrier
Cross section with new rotors, inner casings, stationary blades, blade carries , bearings and steam sealings
IP Bladed Rotor
HP Bladed Rotor
Glands steam sealing system modified
Outer casings, bearings, pedestal, lube oil / governing oil system retained
HP inner casing
Bearing 2
LP diaphragm / blade carrier
Bearing 3 & 4
Bearing 5
Bearing 1
Turbine supervisory Instruments, Automatic Turbine Run up & Turbine testing system implementation
26
NASL
ALSTOM’sModernisation and Retrofit
Technology for
110/120/200/210 MW Steam Turbines
27
NASL200/210 MW LMZ design Steam Turbine Retrofit
Live steam parameters: Live steam parameters: 113030 ataata / 530/ 530°°CCReheat steam parameters: Reheat steam parameters: 23.13 23.13 ataata / 537/ 537°°CCFeed water temperature: Feed water temperature: 239.95239.95°°CCCooling water temperature: Cooling water temperature: 3333°°CC
Original configuration of 200/210 MW Turbine
28
NASLALSTOM Retrofit packages 200/210MW turbine
HP & IP turbine retrofit including valves and control, oil,
governing systems as well as block of thermal limitation
R01 LP part retrofitR02Condenser retrofitR03
RETROFIT R
29
NASLALSTOM Modernisation packages for 200MW
MODERNIZATION M Oil systemmodernization
Forcedcooling system
Modernizationof governingsystem (EHC)
Modernization of jacking oil
system
Coolingof LP casing
Separateactuator for HP governing valves
M11
M8
M13M01
M02
M03
M04
M14
M21
Holes for endoscopeinspection
Control system modernizationMeasurements:sensor installation,signal transmissionand display
M19M06
Control system modernizationTURBOMAT:Binary control andstart-up automatics
Turbine bypasssystem
M08Modernization
of jacking oil system
Modernizationof LP guidediaphragms
M05M20Modernization
of bearing pedestalanchorage
M17Improved HP
impulseblading system
M08Modernization
of jacking oil system M07
M09HP stop valve
casingmodernization
Electrohydrauliccontrol of LP bypass
Modernizationof IP governing
valvesM12
Improved IPimpulse
blade systemM18
M05Modernization
of gland systemM05Modernization
of gland system
Hydraulic prestressof casing boltsM16
Turbine adaptationfor transfer of heat and process steam
M15
Modernizationof gland system
Modernization of HP governing valvesM10
30
NASL200/210 MW Steam Turbine Retrofit solutions
ALSTOM Solutions for HP/IP of 200/210 MW LMZ design Turbine using Impulse blading technology
31
NASL200/210 MW Steam Turbine Retrofit solutions
ALSTOM Solutions for HP/IP of 200/210 MW LMZ design Turbine using Reaction blading technology
HP - Reaction type IP - Reaction type
32
NASL200/210 MW Steam Turbine Retrofit solutions
ALSTOM LP Turbine retrofit for 200/210 MW LMZ design turbine
33
NASLCondition for Retrofit
200 MW Turbine Efficiencies before & after retrofit
Expected operating conditions
Turbine design existing after retrofit improvement
HP turbine 82% 78% 87 % 5 - 9% (2.7 - 4.9 MW)
IP turbine 91% 89% 92.5% 1.5 - 2.5% (1.5 - 3MW)
LP turbine 78% 65% 88% 10-23% (7-10 MW)
Existing Performance based on normal degradation of turbine.
34
NASLALSTOM Turbine Retrofit solutions for 120 MW
Power rate : 120 MWPower rate : 120 MWLive steam parameters: 101 kg/s / 125.1 bar / 538°C Reheat steam parameters: 26.1 bar / 538°CFeed water temperature : 227`°CCondenser pressure: 10 kPa
Original 120 MW turbineOriginal 120 MW turbine21 units installed in India (17 BHEL + 4 Poland)21 units installed in India (17 BHEL + 4 Poland)
35
NASLALSTOM Turbine Retrofit solutions for 120 MW
Poor and inefficient profiles of blading in HP and IP PartPoor and inefficient profiles of blading in HP and IP Part
Blading system with Baumann stage and thin stator bladesBlading system with Baumann stage and thin stator blades
No sealing of rotor blades at shroudsNo sealing of rotor blades at shrouds
Stellited inlet edges of the rotor blades of the two last stagesStellited inlet edges of the rotor blades of the two last stages
Bad dynamic conditions due to improper arrangement of bearing coBad dynamic conditions due to improper arrangement of bearing conceptncept
Water gland system in hot area (HP & IP turbine)Water gland system in hot area (HP & IP turbine)
No HP / LP bypass systemNo HP / LP bypass system
Single shell IP casingSingle shell IP casingPoor condenser pressurePoor condenser pressure
Medium losses in the cycle Medium losses in the cycle
Restrictions of turboset operational parametersRestrictions of turboset operational parameters
Disadvantages of original unitDisadvantages of original unit
36
NASLALSTOM Turbine Retrofit solutions for 120 MW
Power output increasePower output increase
Heat rate decreaseHeat rate decrease
Operational flexibility increaseOperational flexibility increase
Extend the time between main overhaulsExtend the time between main overhauls
Turboset durability increaseTurboset durability increase
Turboset availability increaseTurboset availability increase
Elimination of restriction of turboset operational parametersElimination of restriction of turboset operational parameters
Lifetime extensionLifetime extension
Improvement of rotorImprovement of rotor--dynamic behaviourdynamic behaviour
Main purposes for modernisationMain purposes for modernisation
37
NASLALSTOM Turbine Retrofit solutions for 120 MW
HP part retrofit includingprotection system and thermal limitations unit
R01R01 IP part retrofit includingprotection system and thermal limitations unit
R02R02 LP part retrofitND56 - impulseND63 - reactionND31 - reaction
R03R03
Condenser retrofitCB type
R04R04
List of developed packages List of developed packages -- RETROFITRETROFIT
38
NASLALSTOM Turbine Retrofit solutions for 120 MW
M05M05 Modernisation of gland steam system
M04M04 HP & LP By-pass system
M07M07 Control of by-pass system (EHC)
M17M17 Condenser modernisation
M11M11 Modernisation of LP part outlet
M05M05 Modernisation of gland steam systemM05M05 Modernisation of
gland steam system
M08M08 Modernisationof HP part
M01M01 Oil system modernisation
M12M12 Modernisationof LP part inlet
M13M13 Cooling of LP casing
M05M05 Modernisation of gland steam system
M14M14 Holes for endoscope inspection
M16M16 Hydraulicprestress of casing bolts
M18M18 Forced cooling system
Modernisation of control system (EHC)
M03M03
Modernisation of IP part and HP-IP pedestals
M09M09 Modernisation of LP part blading system (impulse)
M10M10
Control systemmodernisation
Binary control andstarting automatics
M06M06
Control systemmodernisation
Measurements: sensorinstallation, signal trans-mission and display
M19M19Adaptation forprocess steam and
heat extractionM15M15
Modernisation ofIP-LP and LP-Gen
couplings for SHK typeM02M02
List of developed packages List of developed packages -- MODERNISATIONMODERNISATION
39
NASLALSTOM Turbine Retrofit solutions for 120 MW
120 MW turbine after full shaft120 MW turbine after full shaft--line retrofitline retrofit
40
NASLALSTOM Turbine Retrofit solutions for 120 MW
blading system with Baumann stageblading system with Baumann stage
thin stator blades with nonthin stator blades with non--aerodynamicaerodynamicprofiles and low efficiencyprofiles and low efficiency
no sealing of rotor blades at shroudsno sealing of rotor blades at shrouds
the stellited inlet edges of the rotorthe stellited inlet edges of the rotorblades of the two last stages are theblades of the two last stages are thesource of damages of condenser pipessource of damages of condenser pipes
Original LP part Original LP part (before LP retrofit)(before LP retrofit)
41
NASLALSTOM Turbine Retrofit solutions for 120 MW
12 applications- Poland (11 units)- Croatia (Plomin)
120 MW turbine Baumann stage removal120 MW turbine Baumann stage removal
42
NASLALSTOM Turbine Retrofit solutions for 120 MW
120 MW turbine LP part retrofit 120 MW turbine LP part retrofit -- KORADI P.P. KORADI P.P. (India)(India)
43
NASL
Electrostatic Precipitator Retrofit Solutions
44
NASLESP Retrofit - Why is it required
CHANGE IN EMISSION NORMS
Past Present Future trends
Emission norms (mg/NM3) 250-300 100-150 50-100
CHANGE IN PROCESS PARAMETERS
Gas volume (velocity, treatment time)
Temperature
Inlet dust load (coal quality)
Moisture
Dust Resistivity (Ash Composition)- Sulphur in Coal, Fe2O3 & Na2O in Fly ash
Grain size (surface area)
45
NASLESP Retrofit – Why is it required
Deterioration in ESP Performance – Major reasons
• Mechanical & Electrical Health
• Flue Gas Flow Distribution between ESP Passes
• Leakages in the system
• Rapping system operation
• Gas Flow Distribution within Precipitation area
• Hopper Gas Screen
• Ash Discharge System
• Outlet GD Screen
• Intelligence of the TR Controller
• ESP Inlet parameters
46
NASLESP Retrofit – Techniques
• Filling up of Dummy Field
• Increase in Collecting Area by- Increase in height- Addition of fields- Addition of new parallel ESP
• Change of Internals of existing field
• State of Art New generation ESP Controllers EPIC-III on Ethernet communication
47
NASLESP Retrofit Solutions
Field addition Height increase and
Field addition
And / OR
Addition of parallel ESP
48
NASLGNDTP Bathinda Units 1&2 (2x110 MW)–Photographs
View of additional field in the ESPs
49
NASLGNDTP Bathinda Units 1&2 (2x110 MW)–Photographs
Site Photos
View of additional field in the ESPs between Chimney & CHP
50
NASL
NASL – Introduction
NASL Promoters’ strengths
Retrofit Solutions
Role of CDM
R&M / Retrofit solution – case Studies
51
NASLRetrofit Projects Result in GHG Emission
Reductions
decreased emissions per kWh
increased Output
reduced kWhcosts
increased capacity
increasedefficiency
increased Reliability
decreasedfuel consumption
Retrofit
NEW ASSET = CERNEW ASSET = CER
A Retrofit Project can be registered as a CDM project
52
NASLCDM Potential for R&M/Up-rate Project
Case study-1: 1x110 MW unitCapacity after R&M = 120 MW
Heat rate before R&M = 2857 kCal/kWh
Heat Rate after R&M = 2450 kCal/kWh
Present PLF = 78.64%
PLF After R&M = 85.0%
CERs for electricity generated equivalent to existing generation
= 99,213 /year
CERs for electricity generated above the present level (Base line: average heat rate of all 110 MW units in the state grid)
= 17,159 /year
Total CERs generated = 116,272 /year
NOTE: 1 CER = 1 MT CO2
53
NASL
NASL – Introduction
NASL Promoters’ strengths
Retrofit Solutions
Role of CDM
R&M/Retrofit solution– Case Studies
54
NASL
STEAM TURBINE RETROFIT BY NASL
TORRENT AEC ‘D’ STATIONUPRATING OF 110 MW UNIT TO 120 MW
55
NASLTorrent AEC Sabarmati - D Station, 110 MW
Project Schedule
Overall (LOA date to commercial operation): 17.0 Months
Deliveries: 13.5 MonthsShutdown (bar to bar): 100 Days
Achievements
Parameter Before R&M
Turbine Heat rate - 2477.3 Kcal/kWh
Output - 105 MW
Availability - 90.5% (3 years)
Average PLF > 83.5% (3 years)
Uninterrupted continuous run -
Highest PLF
After R&M
2030 Kcal/kWh
120MW Plus
> 98% ( for last 30 months)
> 90% (for last 30 months)
185 days (Dec’05 to June’06)
101.2% (April-June’06)
56
NASLTorrent Power Sabarmati D Station, 110 MW
Turbine train retrofit
New HP module with inner casing
New IP module with inner casing & blade carrier
New LP module with diaphragm
Outer casings retained
Old bearings rebabitted and retained
Gland sealing system retained with change of pneumatic control valves
Boiler Reheater Modification
Resurfacing of reheater coils
Addition of new coils in the reheater
57
NASLTurbine Retrofit - D Station, 110 MWKey Features of Retrofit
Saving cost by extended re-utilisation of existing equipment
Equipment of proven reliability but without impact on technical performance retained
– outer casing– governor- and stop valves– bearing assemblies– speed governor block and main oil
pump– Generator
Re-machining of existing casings on existing foundation
In-situ machining of Turbine Casing
58
NASLTorrent AEC Sabarmati - D Station, 110 MW
Turbine Train Retrofit Solution
LP bladed RotorIP inner casing / blade carrier
Cross section with new rotors, inner casings, stationary blades, blade carries , bearings and steam sealings
IP Bladed Rotor
HP Bladed Rotor
Glands steam sealing system modified
Outer casings, bearings, pedestal, lube oil / governing oil system retained
HP inner casing
Bearing 2
LP diaphragm / blade carrier
Bearing 3 & 4
Bearing 5
Bearing 1
Turbine supervisory Instruments,
59
NASLTorrent Power Sabarmati D Station, 110 MW
State of art DCS system
New state of art ALSPA 320 DCS
New transmitters, recorders, indicators, cables
New pneumatic control valves and power cylinder
New turbine vibration monitoring system
Introduction of FSSS system with HEA igniters, oil guns, trip valves & flame scanner system
60
NASLTorrent Power Sabarmati D Station, 110 MW
Russian Design before R&M
ALSTOM Design after R&M
61
NASL
PSEB, GNDTP BATHINDA
TURNKEY R&M OF UNITS 1&2 (2x110 MW)
BY NASL
62
NASLPSEB GNDTP Bathinda Unit 1&2 (2x110 MW)
Project Time Schedule – Achieved Unit 2 Unit 1
1. LOA date 27.05.03 27.05.03
2. Unit shut down 09.03.04 10.03.06
3. Unit commissioning 11.07.05 02.02.07
Achievement Unit 2 Unit 1
Trial operation completed 09.01.06 03.05.07
Unit continuously operating 110 MW plus 110 MW plus
Average Plant availability 92 % 99%
Average Plant PLF 88 % 96%
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NASLPSEB GNDTP Bathinda Unit 1&2 (2x110 MW)
Boiler
Conversion to membrane typewater walls
Replacement of all pressure parts
New “THIRD” pass for Airheater
New auxiliaries – ID / FD / PA &Vapour fans
New field addition in ESP
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NASLPSEB GNDTP Bathinda Unit 1&2 (2x110 MW)
Turbine
New reaction type HP turbine with inner casing
LP turbine modified blades for stage 3, 3A & 4, 4 A
LP turbine complete set of diaphragms of improved design for stage 3, 3A & 4, 4A
LP turbine modified gland bodies for front & rear glands
Overhauling of retained IP turbine
New modified gland sealing system & New HP heaters
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NASLPSEB GNDTP Bathinda Unit 1&2 (2x110 MW)
DCS and InstrumentationState of art DCS system
Transmitters, Indicators , recorders
Control valves and power cylinders & Cables
SWAS and gas analyzers
FSSS with oil guns, trip valves, HEA igniters flame scanners
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NASL
Thank YouThank You
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