NASL

PEER REVIEW OF COAL FIRED THERMAL POWER

STATIONS & BEST PRACTICES IN POWER GENERATION
Hosted by
Ministry of Power Govt. of India & NTPC Limited
February 2008 INDIA

RENOVATION & MODERNISATION OF THERMAL POWER PLANTS

PRESENTATION BY
NTPC-ALSTOM POWER SERVICES PRIVATE LIMITED

by
K. V. Ramachandra Setty
AGM Business Development
1
 NASL

¾ NASL – Introduction

¾ NASL Promoters’ strengths

¾ Retrofit Solutions

¾ Role of CDM

¾ R&M/Retrofit solution – case Studies

2
NTPC-ALSTOM Power Services Private Ltd. NASL
NASL
NTPC
50% 50%

Largest Power Utility in the Original Equipment Designer (OED) &

country with over 27 GW installed Manufacturer (OEM) with over 647 GW
capacity installations world wide.
• Engineering Complete R&D back up and
• Quality Assurance Service Provider with global reach,
• Project Management • Engineering & manufacturing
• O&M-Rich Experience • Research & Development
• Performance Optimization & • IPPs / EPC
Turn around • O&M Services and R&M Services

Brief History ) Established in September 1999

) Exclusive JV for R&M business in India & SAARC region
) Strategic alliance to meet requirement of R&M in India.

3
Our range of services for power plant NASL

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.

4
Our range of services for power plant (2) NASL
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

5
Turnkey R&M Plant Integrator Capability NASL
Coal Power Plant Electrical & BOP
Control system Steam Turbine

Generator
Boiler

Coal & Ash handling

Electrostatic Precipitator
Condensing & Feed heating plant
Flue Gas

6
Retrofits - Executed / under execution
NASL
Output capacity enhancement ¾ Torrent AEC Sabarmati ‘D’ station
(MW) of machine. 1x110 MW unit uprating to 120 MW.

Improved Boiler Efficiency ¾ NTPC Talcher (1x110 MW) APH retrofit

and High efficiency heat ¾ NTPC Tanda (4x110 MW) Boiler renovation
transfer surfaces.

Turbine module Retrofit ¾ Koradi 1x120 MW LP Turbine module

Output / Heat Rate retrofit eliminating Baumann stage.
Improvement. ¾ Bathinda 110 MW High Pressure (HP)
Turbine module retrofit for Heat rate
improvement

7
Retrofits - Executed/under execution NASL
Turnkey R&M Plant/Island ¾ PSEB GNDTP Bathinda 2x110 MW units
¾ MPPGCL Amarkantak 2x120 MW units
TG & Auxiliaries

Restoration works ¾ JSEB Patratu 1x110 MW+ 1x50 MW

I&C Retrofits ¾ NTPC Talcher (3x60 MW)
(DAS/DCS/DDCMIS/FSSS) ¾ NTPC Singrauli (3x200 MW)
¾ PSEB Bathinda (2x110 MW)*
¾ Torrent AEC Sabarmati (1x110 MW)*
¾ JSEB Patratu (2x50 MW)*
¾ NTPC Tanda (4x110 MW)

Emission Controls ¾ Tanda 4x110 MW ESP retrofit (EPIC II)

¾ Badarpur 210 MW ESP Contrllers
Retrofit (EPIC-I to EPIC-II)
Miscellaneous Works ¾ Ranchi 33 KV substation works
¾ GRASIM Nagda MS Piping works
8
 NASL

¾ NASL – Introduction

¾ NASL Promoters’ strengths

¾ Retrofit Solutions

¾ Role of CDM

¾ R&M / Retrofit solution – case Studies

9
NTPC – Operational Performance NASL
Capacity Utilization Turn Around Ability
Unchahar Plant PLF

93 89.91 91.2 120

88.7 88.79
95.6
100

90 86.54 87.51 87.54 90.09

86.2
80
89.4

%
60

87 84.38 40

83.6 84.41
18.0
20

84 80.4 81.8 81.1

0
Tak e n ove r in 1992 2006-07

81 T alcher Plant PLF

78 76.8
100 88.81

74.3 73.6 80

75 72.7
72.2 60

%
40

72 69 69.9 20
18.7

6967.3
0
Tak e n ove r in 1995 2006-07

66 Tanda Plant PLF

63 100 91.14

60
80

1999- 2000- 2001- 2002- 2003- 2004- 2005- 2006-07

60
%

2000 2001 2002 2003 2004 2005 2006

40
14.9
20

All India PLF NTPC PLF NTPC AvF Tak e n ove r in 2000 2006-07

10
ALSTOM - Technology Range on Boiler NASL
Technology : ESPs
Technology : MILLS
Technology : BOILERS FLAKT, LURGI
CE, EVT, STEIN, B&W CE BOWL, STEIN TUBE & BOWL,
Technology : APH
B&W BALL , EVT BEATER WHEEL
API ROTARY APH

B&W, UK
via Ex-ABL FLAKT
STEIN EVT
CE , API LURGI
APBIL Facilities at
ALSTOM Power Shahabad,
Durgapur,
India Calcutta

TECHNOLOGY RANGE
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
11
ALSTOM -Turbo machines Group NASL
Industrial footprint

Elblag, PL
¾Steam turbines Beijing, CN
Mannheim, DE ¾Foundry & Turbine Shop ¾Steam Turbine & Generator Joint Venture
¾Steam turbines
(600MW): ALSTOM Beizhong Power (ABP)
¾Gas & Steam turbine assembly
Richmond, USA
¾Steam Turbines

Bexbach, DE
¾Blading Shop
Wuhan, CN
Wroclaw, PL
Morelia, MX ¾TMG: Engineering
Generators
¾Generator & Turbines ¾Sourcing
¾Generator Shop
Shop

Rugby, UK
¾Steam Turbines

¾Delhi,
IN
¾Gas& steam turbines
Key:
¾NASL

Levallois, FR
Manufacturing site ¾Steam Turbines Infosys, Bangalore, IN
¾External
Belfort, FR
Joint Venture ¾Generators Birr, CH
¾Generator & Turbine Shop Generators
¾Rotor Shop
Engineering &
Sourcing site Baden, CH Head Office
¾Gas & steam turbines
R&D & Engineering
Purchase Services
site

12
ALSTOM Turbo-machines Portfolio NASL
¾ Low emission Gas Turbines with wide
operating flexibility from 50 MW to 281
MW

¾ High efficiency, modularized Steam Turbines

for the entire range from 100 to 1800 MW

¾ Market leader for Retrofitting Steam Turbines with

over 50% market share – many on 3rd party units

¾ Largest air cooled Turbo-Generators in the market

(up to 400 MW) providing lower operating cost
¾ H2/water cooled Generators up to 1800 MW

Technology Competence in ALL Turbomachines

13
ALSTOM - Energy & Environment Systems NASL

Utility Environmental Control Energy Recovery

Boilers Systems & Plant

Heat Recovery Steam

Generators (HRSGs) for any
Clean Efficient and A complete range of large gas turbine in combined-
Reliable Combustion proven air pollution cycle applications
Systems for New control solutions
Boilers & Retrofit for all market niches In the field of Energy Recovery
Systems: air preheaters and
gas-to-gas heat exchangers,
transfer line exchangers,… 14
ALSTOM – Turbine Retrofit technology range NASL

Manufacturers Diagnostic and Modernization Retrofit Service

Feasibility Study packages packages packages
Units

30 MW LMZ, PLZAM 9 9 9 9

E S
SERVICTION M
ZA
50 MW LMZ, PLZAM 9 9 9 9 MODERNI
RETROFIT R
LMZ, ChTGZ,
100 MW 9 9 9 9
PLZAM Offer Packages List

PLZAM, AEI,
120 MW BHEL, ChTGZ 9 9 9 9

160 MW ChTGZ 9 9
9 9

LMZ, PLZAM,
200 MW BHEL, HARBIN 9 9
9 9

250 MW UTMZ 9 9 9 9

300 MW LMZ, ChTGZ 9 9 9 9

360 MW BBC, PLZAM 9 9 9 9

ABB ALSTOM POWER
500 MW LMZ 9 9 9 9

15
ALSTOM - historical background on Turbine NASL
Evolution of the Steam Turbine Retrofit Business
1900 1925 1950 1975 1990 1995 2000 Locations
1945
Zamech
1837 F. Schichau Elblag, PL
Elbing Elblag
STAL Svenska, Turbin
AB Ljungstrom

1883 ASEA ASEA ASEA 1990

STAL-
1916
LAVAL

1893 BBCAG BBC

Mannheim, DE Group Mhm.
ABB

1891 BBCAG BBC

Schweiz
, CH AG 1987
Baden

1901 1999 2000

1885 Compagnie BBC/CEM ABB
Electromecanique France ALSTOM ALSTOM Paris
(CEM) Paris
Power
1959

1896 British Thompson- 1919 AEI

Houston
Metropolitan
Vickers
1970 1989 1998

English GEC GEC

ALSTH ALSTOM Rugby
Electric 1970
OM
1879 Alsaciennede 1919 ALSTHOM
Construction 1976
Mecanique(SACM) 1963
Rateau GEC
ALSTHOM
1904 TNO, TP2, TP6, TC25, 13UP28.5, 13P32.5,Energie
13UP55/65,
TK50, 11P60, 9UK75,
1898 MAN GETT MAN
GmbH
Energie 13UK125, 18UK135, 13K215, 18K348, 18K370
11P68, 9K66, 13UC105, 13UP110,

16
ALSTOM Power – Turbine Retrofit referencesNASL

S D
TIC
DIA
GN
OS
SER
VIC
E S
M
Retrofit of 200MW turbines
TION
O DE RNIZA
M
RETROFIT R

LP IP HP

Turbine type: 46 8 17
500 MW
360 MW
300 MW OEM:
250 MW - LMZ
- Zamech
200 MW
- CHTGZ
160 MW - Skoda
100/120 MW - BHEL
50/60 MW

17
ALSTOM retrofit references* NASL

Retrofit Reference List

800

700

600

500

400
Third party
300
Own fleet
200

100

0
HP HP/IP IP LP Total
Third party 72 38 20 157 287
Own fleet 169 3 54 202 428

* As on June 30, 2007

18
 NASL

¾ NASL – Introduction

¾ NASL Promoters’ strengths

¾ Retrofit Solutions

¾ Role of CDM

¾ R&M / Retrofit solution – case Studies

19
Issues of older Steam Power Plants NASL

¾ equipment exposed to thermal Fuel Consumption and Emission

stresses and life extension
Fuel/Emission Retrofitting
¾ lost availability, especially due to
per kWh net
retrofit by original

failures in boiler & turbine area

Increase due to technology
- ageing/ fouling of boiler,
turbine, heat exchangers
- erosion & corrosion of boiler
¾ performance deterioration vis-à- ducts, piping, fans, LP blades
- higher auxiliary consumption

vis original design

¾ new technologies of better performance
upgrading by new

performance established in the

technology

interim. 0
20-25
years 50

¾ new environmental norms

20 - 50% efficiency improvement
emission limits not achievable by potential by midlife rehabilitation
existing plant
¾ full spectrum of spare parts likely
to be unavailable on existing
plant.

20
National Perspective Plan for R&M/LE NASL
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 LE R&M LE R&M
No. of thermal power stations 7 29 32 13 18 12

No. of thermal units 25 127 106 57 34 31

Total Capacity involved (MW) 1,685 17305 10,413 14,270 6,000 7,090

Estimated cost (in Rs. Crores) 1,560 850 9,200 977 6,000 751

Source : From CEA website

21
Life Extension 200/210 MW units – X/XI th Plan NASL
Project 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
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
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 22
 NTPC units in operation for > 20 years NASL

Project Unit Size Capacity OED/OEM OED/OEM

(MW) (MW) (TG) (Blr)

Singrauli Unit 1-5 200 1000 LMZ/BHEL CE/BHEL

Korba Unit 1-3 200 600 Siemens/BHEL CE/BHEL
Ramagundam Unit 1-3 200 600 Ansaldo Ansaldo
Vindhyachal Unit 1-6 210 1260 USSR USSR

4260

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

23
Boiler Retrofit Solutions NASL

Reheater

Burners

Economiser

Airpreheater

Mills & PA Fan

24
ALSTOM - Turbine Train Retrofit Solutions NASL
Turbine Train Retrofit Solution
IP inner casing / LP bladed Rotor
Bearing 3 & 4
HP Bladed Rotor Bearing 2 blade carrier

Bearing 1

HP inner casing IP Bladed Rotor LP diaphragm /

blade carrier Bearing 5

Cross section with new rotors, inner casings, stationary blades, blade carries , bearings and steam sealings
Glands steam sealing system modified
Outer casings, bearings, pedestal, lube oil / governing oil system retained

Turbine supervisory Instruments, Automatic Turbine Run up & Turbine testing system implementation

25
 NASL

ALSTOM’s
Modernisation and Retrofit
Technology
for
110/120/200/210 MW
Steam Turbines
26
200/210 MW LMZ design Steam Turbine RetrofitNASL

Live steam parameters: 130 ata / 530°C

Reheat steam parameters: 23.13 ata / 537°C
Feed water temperature: 239.95°C
Cooling water temperature: 33°C

Original configuration of 200/210 MW Turbine

27
ALSTOM Retrofit packages 200/210MW turbine NASL

RETROFIT R

HP & IP turbine retrofit

R01 including valves and control, oil, R03 Condenser retrofit R02 LP part retrofit
governing systems as well as block
of thermal limitation

28
ALSTOM Modernisation packages for 200MW NASL

MODERNIZATION M M01 Oil system

modernization
Modernization of HP
M10 governing valves M13 Cooling
of LP casing
Control system
Forced Separate Modernization modernization
M02 cooling system M11 actuator for HP M19 of LP guide
governing valves diaphragms M06 TURBOMAT:
Modernization
Binary control and
of governing Modernization of start-up automatics
M03 M8 jacking oil Modernization
system (EHC)
system M08 of jacking oil system Control system
Improved HP modernization
impulse Modernization Measurements:
M17 blading system M12 of IP governing M21 sensor installation,
valves signal transmission
and display
Holes for endoscope
M14 inspection

Hydraulic prestress
M16 of casing bolts

Modernization Modernization
M20 of bearing pedestal M05 of gland system
anchorage
Improved IP Turbine adaptation
Modernization Electrohydraulic M18 impulse M15 for transfer of heat
M08 of jacking oil system M07 blade system and process steam
control of LP bypass
Modernization
Modernization M05 of gland system
Turbine bypass HP stop valve M05
M04 M09 casing of gland system
system modernization

29
200/210 MW Steam Turbine Retrofit solutions NASL
ALSTOM Solutions for HP/IP of 200/210 MW LMZ design Turbine
using Impulse blading technology

30
200/210 MW Steam Turbine Retrofit solutions NASL
ALSTOM Solutions for HP/IP of 200/210 MW LMZ design Turbine
using Reaction blading technology

HP - Reaction type IP - Reaction type

31
200/210 MW Steam Turbine Retrofit solutions NASL
ALSTOM LP Turbine retrofit for 200/210 MW LMZ
design turbine

32
 Condition for Retrofit NASL
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.

33
ALSTOM Turbine Retrofit solutions for 120 MW NASL

Power rate : 120 MW

Live steam parameters: 101 kg/s / 125.1 bar / 538°C
Reheat steam parameters: 26.1 bar / 538°C
Feed water temperature : 227`°C
Condenser pressure: 10 kPa
Original 120 MW turbine
21 units installed in India (17 BHEL + 4 Poland) 34
ALSTOM Turbine Retrofit solutions for 120 MW NASL
Poor and inefficient profiles of blading in HP and IP Part

Blading system with Baumann stage and thin stator blades

No sealing of rotor blades at shrouds

Stellited inlet edges of the rotor blades of the two last stages

Bad dynamic conditions due to improper arrangement of bearing concept

Water gland system in hot area (HP & IP turbine)

No HP / LP bypass system

Poor
Singlecondenser pressure
shell IP casing

Medium losses in the cycle

Restrictions of turboset operational parameters

Disadvantages of original unit

35
ALSTOM Turbine Retrofit solutions for 120 MW NASL

Power output increase

Heat rate decrease

Lifetime extension

Operational flexibility increase

Extend the time between main overhauls

Turboset durability increase

Turboset availability increase

Elimination of restriction of turboset operational parameters

Improvement of rotor-dynamic behaviour

Main purposes for modernisation 36

ALSTOM Turbine Retrofit solutions for 120 MW NASL

R01 HP part retrofit including

R02 IP part retrofit including R03
LP part retrofit
ND56 - impulse
protection system and protection system and ND63 - reaction
thermal limitations unit thermal limitations unit ND31 - reaction

R04 Condenser retrofit

CB type

List of developed packages - RETROFIT 37

ALSTOM Turbine Retrofit solutions for 120 MW NASL
M14 Holes for
M19 Control system
modernisation endoscope inspection
M01 Oil system M12 Modernisation Measurements: sensor M15 Adaptation for
modernisation of LP part inlet installation, signal trans- process steam and
mission and display heat extraction
M03 Modernisation
control system
of
M13 Cooling of LP M16 Hydraulic
(EHC) casing prestress of casing bolts
M08 Modernisation M05 Modernisation of M18 Forced cooling
of HP part gland steam system system
M02 Modernisation of
IP-LP and LP-Gen
couplings for SHK type

M05 Modernisation of M11 Modernisation of

gland steam system M09 Modernisation of
IP part and HP-IP M10 Modernisation
LP part blading
of
LP part outlet
M04 HP & LP By-pass pedestals system (impulse)
M05 Modernisation of
system M05 Modernisation of M17 Condenser gland steam system
gland steam system modernisation
M07 Control of by-pass M06 Control system
system (EHC) modernisation
Binary control and
starting automatics

List of developed packages - MODERNISATION 38

ALSTOM Turbine Retrofit solutions for 120 MW NASL

120 MW turbine after full shaft-line retrofit 39

ALSTOM Turbine Retrofit solutions for 120 MW NASL

blading system with Baumann stage

thin stator blades with non-aerodynamic

profiles and low efficiency

no sealing of rotor blades at shrouds

the stellited inlet edges of the rotor

blades of the two last stages are the
source of damages of condenser pipes

Original LP part (before LP retrofit) 40

ALSTOM Turbine Retrofit solutions for 120 MW NASL
12 applications
- Poland (11 units)
- Croatia (Plomin)

120 MW turbine Baumann stage removal 41

ALSTOM Turbine Retrofit solutions for 120 MW NASL

120 MW turbine LP part retrofit - KORADI P.P. (India)

42
 NASL

Electrostatic Precipitator
Retrofit Solutions

43
ESP Retrofit - Why is it required NASL
CHANGE IN EMISSION NORMS
Past Present Future trends
Emission norms (mg/NM3) 250-300 100-150 50-100

CHANGE IN PROCESS PARAMETERS

¾ Gas volume (velocity, treatment time)
¾ Temperature
¾ Inlet dust load (coal quality)
¾ Moisture
¾ Dust Resistivity (Ash Composition)- Sulphur in Coal, Fe2O3 & Na2O in Fly
ash
¾ Grain size (surface area)

44
ESP Retrofit – Why is it required NASL
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

45
ESP Retrofit – Techniques NASL

• 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

46
ESP Retrofit Solutions NASL

Field addition
Height increase and
Field addition

And / OR

Addition of parallel ESP

47
GNDTP Bathinda Units 1&2 (2x110 MW)–Photographs NASL

View of additional field in the ESPs 48

GNDTP Bathinda Units 1&2 (2x110 MW)–Photographs NASL
Site Photos

View of additional field in the ESPs between Chimney & CHP

49
 NASL

¾ NASL – Introduction

¾ NASL Promoters’ strengths

¾ Retrofit Solutions

¾ Role of CDM

¾ R&M / Retrofit solution – case Studies

50
 NASL
Retrofit Projects Result in GHG Emission
Reductions
Retrofit

increased increased
efficiency Reliability

decreased
increased
fuel consumption
capacity

increased reduced kWh

decreased Output costs
emissions
per kWh

NEW ASSET = CER

A Retrofit Project can be registered as a CDM project
51
CDM Potential for R&M/Up-rate Project NASL

Case study-1: 1x110 MW unit

Capacity 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 = 99,213 /year

generation

CERs for electricity generated above the present level = 17,159 /year
(Base line: average heat rate of all 110 MW units in
the state grid)
Total CERs generated = 116,272 /year
NOTE: 1 CER = 1 MT CO2
52
 NASL

¾ NASL – Introduction

¾ NASL Promoters’ strengths

¾ Retrofit Solutions

¾ Role of CDM

¾ R&M/Retrofit solution– Case Studies

53
 NASL

STEAM TURBINE RETROFIT

BY NASL

TORRENT AEC ‘D’ STATION

UPRATING OF 110 MW UNIT TO 120 MW

54
Torrent AEC Sabarmati - D Station, 110 MW NASL
Project Schedule

™ Overall (LOA date to commercial operation): 17.0 Months

™ Deliveries: 13.5 Months
™ Shutdown (bar to bar): 100 Days

Achievements
Parameter Before R&M After R&M
™ Turbine Heat rate - 2477.3 Kcal/kWh 2030 Kcal/kWh

™ Output - 105 MW 120MW Plus

™ Availability - 90.5% (3 years) > 98% ( for last 30 months)

™ Average PLF > 83.5% (3 years) > 90% (for last 30 months)

™ Uninterrupted continuous run - 185 days (Dec’05 to June’06)

™ Highest PLF 101.2% (April-June’06)

55
Torrent Power Sabarmati D Station, 110 MW NASL

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

56
Turbine Retrofit - D Station, 110 MW NASL
Key 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

In-situ machining of Turbine Casing

™ Re-machining of existing casings on
existing foundation

57
Torrent AEC Sabarmati - D Station, 110 MW NASL
Turbine Train Retrofit Solution
IP inner casing / LP bladed Rotor
Bearing 3 & 4
HP Bladed Rotor Bearing 2 blade carrier

Bearing 1

HP inner casing IP Bladed Rotor LP diaphragm /

blade carrier Bearing 5

Cross section with new rotors, inner casings, stationary blades, blade carries , bearings and steam sealings
Glands steam sealing system modified
Outer casings, bearings, pedestal, lube oil / governing oil system retained

Turbine supervisory Instruments,

58
Torrent Power Sabarmati D Station, 110 MW NASL

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

59
 Torrent Power Sabarmati D Station, 110 MW NASL

Russian Design before R&M

ALSTOM Design after R&M

60
 NASL

PSEB, GNDTP BATHINDA

TURNKEY R&M OF UNITS 1&2 (2x110 MW)

BY NASL

61
PSEB GNDTP Bathinda Unit 1&2 (2x110 MW) NASL

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%

62
PSEB GNDTP Bathinda Unit 1&2 (2x110 MW) NASL

Boiler

™ Conversion to membrane type

water walls

™ Replacement of all pressure

parts

™ New “THIRD” pass for

Airheater

™ New auxiliaries – ID / FD / PA &

Vapour fans

™ New field addition in ESP

63
PSEB GNDTP Bathinda Unit 1&2 (2x110 MW) NASL

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

64
PSEB GNDTP Bathinda Unit 1&2 (2x110 MW) NASL

DCS and Instrumentation

™ State 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
65
 NASL

Thank You

66