2. Shri. Baboo Ram
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Transcript of 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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S. No. Name/Location No of
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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S. No. Name/Location No of
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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S. No. Name/Location No of
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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S. No. Name/Location No of
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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S. No. Name/Location No of
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