NTPC Alstom

1

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



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


%

Tanda Plant PLF

14.9

91.14

0

20

40

60

80

100


%

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



Retrofit Solutions

Role of CDM


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


ALSTOM Solutions for HP/IP of 200/210 MW LMZ design Turbine using Reaction blading technology

HP - Reaction type IP - Reaction type

32


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


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


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


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


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


120 MW turbine after full shaft120 MW turbine after full shaft--line retrofitline retrofit

40


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


12 applications- Poland (11 units)- Croatia (Plomin)

120 MW turbine Baumann stage removal120 MW turbine Baumann stage removal

42


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



Retrofit Solutions

Role of CDM


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



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


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


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%

63


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

64


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

65


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

66

NASL

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NTPC Alstom

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