NTPC Ltd…

NATIONAL THERMAL POWER

StrivingCORPORATION
for Greener Future
LTD.
- A PROFILE
Presentation Outline

NTPC …. a brief overview

Performance Highlights
Power perspectives

Energy Efficiency
Technologies for Clean energy production
Environment Management
Renewable Energy
PIE…. Efficiency-improvement strategy promising
success

CenPEEP
O & M : Gearing up for future challenges
Conclusion
NATIONAL THERMAL POWER
NTPC Ltd .… Overview
CORPORATION LTD.
- A PROFILE
NTPC - Vision and Mission

Our Vision
A world class integrated power major, powering
India’s growth, with increasing global presence

Our Mission
Develop and provide reliable power, related products
and services at competitive prices, integrating multiple
energy sources with innovative and eco-friendly
technologies and contribute to society”
 NTPC- Today

 The largest power generation company in India, with

comprehensive in-house capabilities in building and
operating power projects
 Current operating capacity – 28,644 MW (including JV)
 18 coal based (23209 MW) and 8 gas based (5435 MW)
power plants

Business  Setting up hydro based power plants (2471 MW under

implementation)
 Developing coal mines for captive use (47 mtpa by 2017)
 Exploring oil / gas blocks in consortium with partners
 Subsidiary & JV companies for taking up generation,
power trading, distribution business and for setting up of
small hydro plants (<250 MW)
 Plans to become 50,000 + MW company by 2012
 NTPC- Today

 ONE OF THE LARGEST INDIAN COMPANIES WITH A MARKET CAP OF

MORE THAN US$ 50 BILLION
Size
 HAS A NET WORTH OF AROUND US$ 13 BILLION
 HAS TOTAL ASSETS OF AROUND US$ 20 BILLION

 THE LARGEST GENERATOR IN INDIA WITH 20% OF INSTALLED

CAPACITY & 28% GENERATION OF THE COUNTRY
 NTPC COAL BASED UNIT PLF FOR 06-07 WAS 89.43 AGAINST ALL INDIA
PLF OF 76.8. AVAILABILITY FACTOR FOR NTPC WAS 90.1%
Stature
 494TH LARGEST COMPANY IN THE WORLD: 6TH LARGEST UTILITY IN
ASIA (FORBES RANKING – 2006)
 PLATTS HAS RANKED NTPC AS NO. 1 INDEPENDENT POWER PRODUCER
COMPANY IN ASIA, 2007.

 GOVERNMENT HAS 89.5% STAKE

Ownership
 10.5% WITH PUBLIC
Business strength - Market
Share

TOTAL CAPACITY GENERATION

AS ON 31.03.2007 2006-07

20.18% 28.5%
NTPC
NTPC 188.67*
26350* MW - NTPC BUs - NTPC
20.18 % 28.5%
of of
All All REST
India REST
India OF
OF INDIA
130,539 INDIA 662.43
MW BUs

* excluding JVs * excluding generation from JV companies

•MORE THAN ONE-FOURTH OF INDIA’S GENERATION WITH ONE-FIFTH CAPACITY

• THE NEXT LARGEST POWER UTILITY OWNS 7.9% OF MARKET SHARE IN TERMS OF
CAPACITY AND 8.12% OF SHARE IN TERMS OF UNITS GENERATED
Unmatched Competitive Position
- Supplier to all major states
As per Forbes Global 2000 ranking for the
year 2005, NTPC ranks:
KOLDAM
KOLDAM
(800
(800 MW)
MW) LOHARINAG
LOHARINAG PALA
(600
(600 MW)MW)
PALA ¾ 463rd biggest company in the World
¾ 5th biggest Indian company
RUPSIABAGAR
RUPSIABAGAR KHASIABARA
KHASIABARA
DADRI
DADRI (260MW)
(260MW)
(817
(817 MW)
MW)
LATA
LATA TAPOVAN
TAPOVAN
FARIDABAD
FARIDABAD (162
(162 MW)
MW)
(430
(430 MW)
MW)BTPS
BTPS TAPOVAN VISHNUGAD
NCTPP TAPOVAN VISHNUGAD
NCTPP
(705
(705 MW)
MW) (840 (520 MW)
MW) (520 MW)
(840 MW)
TANDA
TANDA
(440
(440 MW)
MW)
ANTA
ANTA UNCHAHAR
UNCHAHAR
RAMMAM III
(413
(413 MW)
MW) (840
(840 MW)
MW) KAHALGAON RAMMAM III
KAHALGAON
(90
(90 MW)
AURAIYA
AURAIYA
(652
(652 MW)
MW)
(840
(840 MW)
MW) MW)
As per ADB’s Memorandum, NTPC is:
SINGRAULI
SINGRAULI RIHAND
¾2nd Largest Asian Power Generator.
RIHAND
(2,000
(2,000 MW)
MW) (2,000
(2,000 MW)
MW) BARH
BARH
FARAKKA
FARAKKA
VINDHYACHAL (1,600
(1,600 MW)
MW)
VINDHYACHAL
GANDHAR
GANDHAR (2,260
(2,260 MW)
MW)
(648
(648 MW)
MW)
KORBA
KORBA
(2,100
(2,100 MW)
MW) TALCHER
TALCHER KANIHA
(3,000
(3,000 MW)
MW)
KANIHA
No of Capacity (MW)
KAWAS
KAWAS SIPAT
SIPAT plants
(645
(645 MW)
MW)
TALCHER
TALCHER Thermal
Thermal
(460
(460 MW)
MW) NTPC Owned
RAMAGUNDAM
RAMAGUNDAM
SIMHADRI
1. Coal 14 22895
(2,600
(2,600 MW)
MW) SIMHADRI
(1,000
(1,000 MW)
MW)
2. Gas / Liquid Fuel 7 3,955
Total 21 26850
THERMAL POWER STATION Owned by Joint Ventures
HYDRO POWER PROJECTS 3. Coal 3 314
KAYAMKULAM
KAYAMKULAM GAS POWER STATIONS 4. Gas / Liquid Fuel 1 1480
(350
(350 MW)
MW)
ONGOING PROJECTS
Grand Total 25 28644
Capacity Addition Programme
Growth Strategy Total Installed capacity envisaged
MW
75000+
80000 (Estimated)
• Multi pronged approach to
capacity addition 70000
• Greenfield projects 60000 51000+
• Brownfield expansion
• Joint ventures / 50000

Acquisitions 40000 28644

• Diversification in related 20249
30000 24249
business areas 16795
• Hydro projects 20000 11333
• Coal Mining 3100
10000 200
• Power trading
• Oil / gas exploration 0
82

87

92

97

02

06

07

12

17
• LNG value chain
19

19

19

19

20

20

20

20

20
• Consultancy services
Capacities under execution – 13,860 MW

NTPC investment plan for the period 2007-2012: USD 40 Billion

NTPC Going Forward

• Globalization
¾ Setting up of power plants
• Hydel Power abroad • Power trading
~9,000 MW by 2017
¾ International Consultancy • Power
• Nuclear Power Distribution
2000 MW by 2017
LATERAL FORWARD
• Non-conventional INTEGRATION INTEGRATION
1000 MW by 2017

BACKWARD RELATED
INTEGRATION DIVERSIFICATION

• Seven coal mine blocks • Sectoral Support

(~47 MTPA cap.) allocated • R&M of power
• PIE stations
• One oil/gas block
allocated. • APDRP • JV for Captive
• NTPC requirement for gas • Rural Electrification Power
~ 5 MTPA by 2010 • Training under DRUM
 NATIONAL THERMAL POWER
NTPC .…CORPORATION
Performance Highlights
LTD.
- A PROFILE
Operational Performance

NTPC Availability Levels

100
Dadri Singrauli Stage 2 Environmental
Environmental Focus
Focus
95
Singrauli Stage 1
90
• World’s largest ESPs used by NTPC
85
• Environmental monitoring emphasis
80 • Efforts to increase Energy efficiency
75

70

65

60
Source : AT Kearney NTPC stations are regular recipients of
CEA’s meritorious performance awards.
0 50,000 100,000 150,000 200,000 250,000

Accumulated number of operation hours

12
12 NTPC
NTPC Stations
Stations achieved
achieved PLF
PLF
11
11 NTPC
NTPC Stations
Stations amongst
amongst top
top
of
of above
above 85%
85% during
during 2005-06, 33
2005-06,
20
20 in
in the
the country
country in
in 2005-06
2005-06
of
of these
these stations
stations achieved
achieved PLF
PLF of
of
including
including 33 taken
taken over
over plants.
plants.
above
above 90%.
90%.
High Capacity Utilization (PLF)

93 91.2
89.91
88.7 88.79
90 86.54
86.2 87.51 87.54
87 84.38 84.41
83.6
84 80.4 81.8 81.1
PLF(%)

81
78
74.3 73.6
75 72.7
72.2
72 69 69.9
69
67.3
66
63
60
1999-2000 2000-2001 2001-2002 2002-2003 2003-2004 2004-2005 2005-2006

All India PLF NTPC PLF NTPC AvF

 Turnaround Capability

Unchahar Plant PLF Talcher Plant PLF

120 100 87.6

95.7
100 80
80
60

%
%

60
* 40
40 18.7
18.0
20 20

0 0
Take n over in 1992 2006 Tak e n ove r in 1995 2006

Tanda Plant PLF Badarpur Plant PLF

100 86.39 100 87.12

80 80
60 60
%

40 40 31.94
14.9
20 20

0 0
Take n over in 2000 2006 Managed Since 2006
1978
Man-Mw Ratio Over the Years

1.27*
1.4
1.10*
1.07* 1.02*
1.2 0.98*
Man-Mw Ratio

0.91*
1 0.56
0.49 0.47
0.8 0.46 0.41
0.38 0.38
0.6
0.4 0.71
0.61 0.6 0.56 0.57 0.53 0.53
0.2
0
1996- 2000- 2001- 2002- 2003- 2004- 2005-
97 01 02 03 04 05 06

O&M Non-O&M
*Total (O&M and Non-O&M)
Man MW Ratio excluding Badarpur and JVs/Subsidiaries
Energy Efficiency

NATIONAL THERMAL POWER

Setting the Scene today for a future-oriented
Sustainable Energy production
CORPORATION LTD.
- A PROFILE
 Efficiency Roadmap

43%

42%
Gross Efficiency, GCV Basis

320/600/620
(800-1000 MW)
41% 280/600/620
(800-1000 MW)
247/565/593

40% (660/800 MW)

247/537/565
(660 MW)
39%
170/537/537
(500 MW)
38%

‘00 ‘02 Xth ‘07 XIth ‘12 XIIth ‘17 XIIIth ‘22
Plan Plan Plan Plan
 Lower Plant Efficiency in India

The reported efficiency of Indian power plants is

generally lower as compared to efficiency of plants
abroad, primarily due to

• Poorer condenser vacuum due to hot climatic

conditions
• Higher unburnt carbon losses in boiler due to low
grade high ash Indian coal
• Efficiency is reported on HHV basis of coal (same
as the practice followed in USA) as against LHV
used elsewhere.

Typical variation due to above = 3.0 to 4.0 % points (Approx.)

Heat Rate Improvement over the Years
Heat Rate Improvement (%)

P = 247 ata
14 MST = 565
P = 247 ata
RHT = 593
MST = 537
12 RHT = 565
P = 170 ata
P = 170 ata MST = 537
10 MST = 537
P = 170 ata RHT = 565
RHT = 537
8 MST = 537
P = 150 ata RHT = 537
6 MST = 537
RHT = 537
4 P = 130 ata
MST = 537
2 RHT = 537

200 LMZ 200 KWU 500 KWU 500 KWU 500 High 660 SC 660/800
(1978) (1979) (1982) Mod RH (2006) (2004) SC (2008)
(1998)
Technologies For
Clean Energy Production
NATIONAL THERMAL POWER
CORPORATION LTD.
- A PROFILE
Adoption of new technologies
NTPC has been a pioneer in introducing new technologies in the
country.
Currently, super critical technology, advanced class GTs are some of
the technologies under induction
NTPC has worked on development of Integrated Coal Gasification
Combined Cycle (IGCC) technology suitable to Indian coal through its
collaborative effort with USAID . Further developments are continuing.
Our Energy Technologies Centre is working in both fundamental and
applied fields and has a well-defined mandate to develop various
technologies which will enhance plant reliability, efficiency etc. Setting
up of this centre by NTPC meets a long-term need of such a centre in
Indian power sector.
MGR, DDCMIS, HVDC transmission, Sliding Pressure Operation of
boilers, Combined Cycle power generation, 765 KV transmission are
some of the technologies introduced by NTPC fot the first time in
India.
Technologies… for cleaner
environment

High Concentration Ash Slurry Disposal

System
Pneumatic Conveying System for Fly Ash
Pipe Conveyors for Cross Country Coal
Conveying
Vapor Absorption Refrigeration System for all
Air Conditioning Requirements of Station
Ash Water Recirculation System
 Steam Generator - Online systems

Online Systems

Online Life Assessment

Online coal Flow Acoustic Steam Leak Flame Viewing Acoustic
Measurement Detection System System Pyrometers

On-line system for On-line fuel

monitoring/ assessment measurement facility
of remaining life of for accurate measure- PC based Acoustic Flame viewing Temperature
critical components of ment of coal mass flow steam leak Detection system with Flame measurement at
steam generators rate & air fuel ratio in system
each PF pipe from each Cameras for Exit plane &
coal pulverizer. Operators assistance Economiser outlet

All critical areas/ pressure

parts such such as thick •sensors/ working on
welded headers, critical
microwave technology
Boiler tubes, nozzle
connections etc. covered • Adjustable orifice in in
in the on-line life each PF pipe for online
Monitoring System adjustment of coal flow
 Steam Generators - Softwares
PADO
• PC based On-line
Plant Performance Analysis,
Diagnosis & Optimization
system for the station
• Provides proper guidance
to the plant operator
• Performance analysis &monitoring
of systems, process & components
• Emission Analysis and monitoring
• System and performance diagnosis
& optimization
• Boiler performance optimization
• Boiler stress condition analysers
• Interactive water and gas
chemistry management system.
• Regenerative cycle performance
optimization system, Trip analysis
• Calculation for Heat rate, eff, merit
• order rating, COG, Aux Power
SOFTWARES
BMW 3D MODELLING
• Boiler Maintenance Workstation • Review software for 3D model
of complete plant layout
software (EPRI or equivalent) for
systematic compilation of Boiler
Tube Failures/Pressure Parts
history for analysis purpose
• Record the outage details of the Software functions include
plant
• Record the events in pressure parts • interference check,
• walk-through animation,
viz BTF, Inspections and modification
• simulation,
• Record the repair history for the
• visual effect,
above events
• Carry out the analysis of BTF,
• photo realism
remaining life assessment and wear
patterns.
• Web enabled with provision of
centralized database management.
ELECTROSTATIC PRECIPITATOR

NTPC has installed high efficiency Electrostatic Precipitators (ESP)

in all its coal fired units.

• Typical Indian coal has 3300 kcal/kg GCV with 45 % ash content
• Four/Six pass ESPs with 10/9 fields each for 500/660 MW unit
• NTPC’s ESPs are amongst the world’s largest. The largest in NTPC will
be at BarhI project with collection area of 364,000 m2 and foot print
size of 66 metres x 112 metres

Highlights

• Electrode spacing of 400 mm

• TR Set Rating of 95 KVA

• ESP efficiency of the order of 99.97%

• Limits Outlet Dust Burden at outlet to 20 mg/Nm3 with design coal

ELECTROSTATIC PRECIPITATOR

Performance of older ESPs are also being improved by using some of the following
technologies:

SN ESP Method in Brief Result / Data Potential /

Performance Limitation
Enhancement
Technology
1 Ammonia Spraying ammonia Encouraging results The method
conditioning of into flue gas at ESP with reduction in has High
Flue Gas inlet. emissions to less than potential for
100 mg/Nm3. adoption in
ESPs.
No associated
problems.
2 FGC system Spraying SO3 in to Encouraging results The method
with SO3 flue gas at ESP inlet. with reduction in has High
emissions to less than potential for
100 mg/Nm3. adoption in
ESPs.
No associated
problems.
3 Retrofit of ESPs By adding additional Limitation of
fields/increasing space
 Flue Gas Desulphurization (FGD)

• Provision of space is being kept in all existing plants for

installation of FGD in future

• NTPC is putting up Flue Gas Desulphurization (FGD) plant

for its Bongaigaon TPP (3 x 250 MW) which is proposed
to use high sulphur (as high as 2%) coal.
Highlights

• Adoption of wet lime stone based Gypsum recovery Process

• SO2 removal efficiency> 90%

• FGD with Dry Stack involving Gas to Gas Heat Exchangers

• Utilisation of Gypsum envisaged

 IGCC Developments

NTPC has undertaken following two feasibility studies for 100 MW IGCC plant based
on Indian coal (Raw as well as washed):
¾ feasibility of 100 MW IGCC plant based on indigenous fluidised bed gasifier technology
¾ feasibility of 100 MW IGCC plant based on international technology.

IGCC World Experience- all on low ash coal

•Industry is directed towards entrained bed
•Fluidized and Fixed Bed- most suited for Indian coal
•Limited experience on fluidized bed and fixed bed gasifiers world wide

Indian Coal Characteristics

¾ High Ash
¾ Low GCV
¾ Fairly Reactive
¾ High Ash Fusion Temperature

Gasifier Efficiency lower due to high ash Indian Coal and air blown operation
Adoption of IGCC: Techno-economic
barriers

„ NTPC has carried out two feasibility studies on IGCC: one in

collaboration with USAID and the other with an indigenous
manufacturer
„ Impediments to adoption of IGCC
– Low carbon conversion
– Low cold gas efficiency
– Plant efficiency lower than PC Plant
– Requirement of a big cleaning system for gases carrying large amount
of highly abrasive particulate matter
– Inadequate experience with higher gasifier pressure
– 80 to 100% increase in capital cost w.r.t. to conventional plant
– Relative inexperience with typical coal w.r.t. erosion and availability
Computational Fluid Dynamics (CFD)

„ CFD simulation of Boiler and ESP were introduced as part of the

Technical Specification, with involvement of NTPC engineers in CFD
modeling work.
‰ 500 MW ESP flow simulation is being carried out using Star CD Software
for validation with model test and improvement in flow distribution.
‰ Boiler and ESP simulations shall be carried out by the respective vendors
for 500/660 MW projects.

„ The following in house studies have been conducted to solve station

related problems, using Star-CD software.
‰ Validation of Flow Modification in convective pass of 62.5 MW to reduce
Boiler Bank tube erosion.
‰ 500 MW Boiler CAVT Validation using CFD.
‰ Flue Gas Duct (APH to ID Fan) Pressure Drop Reduction in 210 MW Unit
Electrical
NATIONAL … Targeting
THERMAL POWER
Reliability and Efficiency
CORPORATION LTD.
- A PROFILE
Electrical Systems: Thrust Areas

State of art Electrical System Controls

Equipments for High reliability and
Efficiency
Operational and Protection Philosophy
Continual Improvements
State Of Art Electrical System
Controls
Soft Logic in Plant DCS Systems for all Electrical
Breakers.
Substation Automation System introduced for all green
field projects.
Communication Protocol IEC 61850 being used for
communication between various IEDs and OWS.
Switchyard LAN extended to Main Plant Control Room to
facilitate un-manned switchyards. Data is soft linked to
the plant DCS system.
EQUIPMENTS…EHV

Adoption of Controlled switching of transformer and

reactors.
Up-gradation of transmission voltage from 400kV AC to
765kV AC.
To improve reliability of EHV transformers NTPC has
introduced certain specification enhancements.
Enhancements have been carried out in each of the
important area of transformer viz.,
Dielectric
Magnetic circuit
Mechanical strength
Thermal
EQUIPMENTS… Transformers

BIL levels have been increased, (Typ. Values for 400kV System):
1300kVp to 1425kVp and Switching Impulse Voltage increased from
:1050kVp to 1180kVp
Temperature rise levels have been reduced for oil from 50 deg C to
35 Deg C and winding from 55 Deg C- to 40 Deg C.
Type of oil has been changed from Paraffinic to Napthenic type which
has a better oxidation stability and thus better life.
Online DGA. FRA recordings for speedy analysis, identification and
rectification of problem.
For 765kV Class of Transformer, On line Gas Monitoring system &
Provision of Dry-keep has been adopted.
EQUIPMENTS… Continued

On-line PD testing for monitoring the condition of the

Generator stator winding insulation.
State of art MV and LV switchgears with communicable
numerical relays
Reliable DC system with Ni-Cd /Plante type Batteries for
relatively maintenance free operations.
Energy Efficient LT Motors and Lighting appliances.
VFD drives
VPI insulation For MV Motors
Wireless I/O modules in Ash Handling and Coal handling
areas for controls.
Protection and Operational Philosophy

Disturbance Recorders for Generators, have been

introduced.
Numerical Relays have been introduced for all EHV
system
Integrated frequency based islanding scheme for
Staggered tripping of grid lines has been introduced.
Controls & Instrumentation
NATIONAL THERMAL POWER
CORPORATION
….. State of Art LTD.
- A PROFILE
 Transition in C&I

SINGRAULI (1982)

SIPAT II (2006)
LATEST TECHNOLOGICAL
ADOPTION IN C&I

 Introduction of plant wide CCTV network for security and surveillance

 Graphical interface units (GIU) used in remote plant
 Ultrasonic and radar based instruments are used for level
measurements
 Ambient air monitoring system is being introduced
 Graphical interface unit introduced for remote local control panel
 Focus is on getting more diagnostics information from field devices;
 Hart based field bus based technology is under various stages of
adoption
 Wire-less LAN, transmitters and I/Os are being introduced for
geographically distributed area
INVESTING IN FUTURE

„ INITIATED COLLOBORATION WITH ACADEMIC INSTITUTES AND

RESEARCH INSTITUTION IN FOLLOWING AREAS
– INTELLIGENT SOOT BLOWING SYSTEM

– BOILER FEED PUMPS RTD FAILURE ANALYSIS AND SUBSTITUTE

THERE-OF

– ACOUSTICS/AUDIO SIGNAL BASED CONDITION MONITORING OF

EQUIPMENTS

„ State of the art integrated simulator with remote training terminals

for 660 MW supercritical technology and hydro power plant are soon
to be implemented

„ CCTV based infrared cameras in selected areas for night vision

 NATIONAL THERMAL POWER
CORPORATION LTD.
Environment
- AManagement
PROFILE
Environment Management… by design

NTPC has a well defined Environment management Policy

NTPC has actively gone for adoption of best international practices
on environment, occupational health and safety areas and has
pursed EMS system ISO 14001 and OHSAS 18001. All NTPC Stations
have ISO 14001 & OHSAS 18001 certifications by International
certifying agencies.
Pollution controls systems like ESP, Flue gas Stacks, Low Nox
burners, Neutralization pits, Coal settling pits and DE & DS systems
for better air quality are in place in all power plants.
Cooling Towers, Ash dyke and Ash disposal systems and Ash water
recycling are installed for better water management and saving
fresh water.
Environment Management …in
operations
Monitoring of Environmental parameters
All Pollutants discharged from the power plant such as Stack
emission, ash pond effluents , main plant effluents , domestic
effluents are monitored at stipulated frequencies. Ambient air,
Surface water and ground water quality are also regularly
monitored.
Upgradation and Retrofitting of Pollution control systems
In order to keep pace with changing environmental norms
retrofitting and up gradation of pollution monitoring and control
facilities in existing plants is also taken up
On Line data Management is in place for environmental
performance of the power stations.
 Reducing and Recycling Waste

Hazardous waste management as per GOI rules of

1989 is done and recyclable wastes and non
recyclable waste are suitably treated. The non
recyclable wastes are sent to the State Pollution
Control Board for common treatment, storage and
disposal facility.
Land Use/ Bio-Diversity… As a Policy NTPC lays
special emphasis on land use . Development of
green belts, energy plantations, , reclamation of
Ash ponds and EIA studies for ecological
monitoring in the project areas and its
surroundings.
Reclamation Of Abandoned Ash Ponds… Extensive
plantations has been undertaken on dry ash
mound at NTPC DADRI
Fly Ash Utilization Record

Highest ever utilisation of Fly Ash a testimony to ecology

preservation

25
22.3
Ash Utilisation in Million tonnes

19.6
20

15
12.7

10
7.5
5.7
5 3.0 3.7

0.3
0
1991-92 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07
Afforestation …

Forest Banks concept

NTPC has created a Green wealth of 18.2
Million Trees by Summer 2007
Plantation of 1.25 Million trees around
Ramagundam Project has resulted in
Summer Peak temperature reduction
by 3 deg C
Ash Mound Reclamation and Dry ash
disposal system
Way ForwardTHERMAL
NATIONAL .... POWER
CORPORATION
Renewable energy & LTD.
- A PROFILE
Distributed Generation
Renewable energy & Distributed
Generation

Renewable energy (RE) is being perceived as an alternative

source of energy for "Energy Security" and subsequently
"Energy Independence" by 2020..

Broad base generation mix by evaluating conventional and

non-conventional sources of energy to ensure long run
competitiveness and mitigate fuel risks.

NTPC has formulated its' business plan of capacity addition

of about 1,000 MW thru renewable resources by 2017
Portfolio of renewable power

SN Renewable Energy
Capacity
o Sources
1. Wind energy farms 650 MW
2. Small Hydro Project 300 MW
3. Solar PV Power Project 5 MWe
4. Solar Thermal 10 MW
Foray into Renewable Energy
5. Biomass Power Project 15 MW
Geothermal Power 9 100 MW wind farm
6. 30 MW
Project 9 8 MW hydro based plant at Singrauli
9 4 MW hydro based plant at Rihand
9 5 MW biomass based power plant
9 1 MW bio-diesel based power plant
(in cluster of villages)
9 Identification of potential site (s) for
geothermal based power plant
Renewable Power & Distributed
Generation
The traditional model of centralized grid extension could not achieve the
goal as :

™ Grid extension not viable for remote areas due to low demand &
high distribution network cost.
™ Kerosene Oil still preferred source as villagers get light when they
need it.
™ Rural Feeders remain neglected by utilities due to low revenue
realization. Importance given to urban feeders for commercial
reasons.

By harnessing Renewable Energy Sources, Distributed Generation is a

viable option to provide electricity to the millions of people in remote
areas.
NTPC’s Commissioned DG Projects

Jemara (Korba), 10kW, 100HH, Biomass (Woody) 13.02.05

Jaraha-Chetwa (Rihand), 10.5 kW, 200 HH, Solar PV 28.03.05

Bhaogarh (Anta), 10kW, 89 HH, Biomass (Mustard crop) 23.03.06

Bagdara (Korba), 20 kW, 110 HH, Biomass (Woody) 12.07.06

Uchlenga (Korba), 20 kW, 134HH, Biomass (Woody) 19.10.06

Khirti ( Korba), 20 kW, 105 HH, Biomass (Woody) 05.11.06

Piprahar (Rihand) , 25 kW, 160 HH, Biomass (Woody) 28.04.07

Mahuli (Rihand), 30 kW, 183 HH, Biomass (Woody) 29.06.07

NATIONAL THERMAL POWER
Partnership in Excellence
CORPORATION LTD.
- A PROFILE
Partners in Excellence (PIE)

NTPC has brought about Performance turnaround in 13 low performing

stations of India having 5050 MW
NTPC assisted stations to generate additional 2833 million
units which is equivalent to 430 MW capacity at 75 %
average PLF
Three Tier Approach was envisioned. The first steps were

9 Gap analysis
9 Formation of Counter Teams
9 Up front improvement in generation through optimization of
operation parameters, vacuum improvement, Mill maintenance,
combustion optimization and focus on water chemistry.
Introduction of O &M Systems and Procedures & Initiate practice of
opportunity Maintenance
Planned Major overhauls
 PIE Program … an Impact analysis

Million
Units
23800
25000 19566
18477
20000

15000 Revenue Revenue

gain gain

2050 8500
10000 Million
Million
Rupees Rupees
5000

0
2004-05 2005-06 2006-2007
 The Turnaround

ADDITIONAL MW ADDED PLF REVENUE

GENERATION TO THE GRID
Wave I 1025 MU 235 MW 73.7 % 205 Cr INR
(0ct05-Mar06)

Wave II 2572 MU 390 MW 73.5% 514 Cr INR

(Apr06-Dec06)

Wave III 2833 MU 861 MW 75% 797 Cr INR

(under progress) (till Nov 07)

The Turn around was based on NTPC practices and procedures with
customization of needs for each Individual Station and utility.
 CenPEEP - Symbol of NTPC’s
Commitment for
NATIONAL THERMAL POWER
CORPORATION
Sustainable Development LTD.
-&
A PROFILE
Successful International Cooperation
CenPEEP - Centre for Power Efficiency
& Environmental Protection

CenPEEP - Symbol of NTPC’s

Commitment for

Sustainable Development
&
Successful International Cooperation
Centre for Power Efficiency &
Environmental Protection

• Institution set-up to implement Indo-US project

of ‘Greenhouse Gas Pollution Prevention
Project (GEP)’
• Window for technology transfer
• An example of NTPC's concern for
environmental protection and commitment to
sustainable power development in India
 CenPEEP Partnership

• NTPC
CenPEEP • USDOE
• Guj. Gen Co • NETL
• Maha Gen CO • EPRI
• AP Gen CO • TVA
• PSEB • GAI
• UPRVUN GEP • Southern
• WBPDCL Research
• Jharkhand
Partners • Structural Int.
• IPGCL • Domain Experts
Guided by
Advisory Board & Executive Committee
Members from NTPC, USAID and Govt of India,
State & Private Power Utilities, industry, research institutes, etc.
Utility Challenges for Efficiency
Improvement

• Access to state-of-art technologies

• Lack of expertise and agency for evaluation and
gap analysis
• Lack of system documentation
• Training expertise
• Lack of resources for implementation &
sustainability
CenPEEP Approach
State-of-the art technology & practices for GHG reduction
from existing coal fired power stations and new power
generation capacities

Technology Sustainability
Selection & through implementation
Acquisition of
Systems & Procedures
Technology
Transfer
Training &
Technology
Technology
Demonstration Dissemination
 Grass Root Interventions

Candidate Interventions
• Boiler Performance Optimization
• Air heater tests and gap analysis
• Burner to burner PF balance tests Benefits
• Steam Turbine measurements
• Significant GHG
• Condenser Water Pressure Cleaners reduction
• Condenser Helium leak detector
• Fuel Savings in
• CW flow measurement - dye dilution power sector
• Cooling Tower tests
• Reliability Centered Maintenance
• New overhaul practices

CenPEEP is a resource center for Plant performance optimization, Diagnostics & Solutions
Performance Gaps (Typical Heat
Rate Losses)

RH Spray (7%)

Condenser & CTs (31%)

Others (7%)

Unaccountable (20%)

Dry Flue Gas Loss (16%) Turbine HP/IP (19%)

Assessment of the performance gaps is the first step to improvement

Heat Rate Improvement Guidelines
for Indian Power Plants
Action

Training
Plans

& r ve y
Tools

s
Su

dit
Au
Pe
rf
or

n
m

tio
an

ta
ce

cu m
en
Los

Do ste
Te

m
s Are

Sy
sts

as & n t
dev Pla
iati e w s.
on N ec
Monitoring
Sp

FIELD DEMONSTRATIONS HEAT RATE GUIDELINES

Consolidation of Learning from CenPEEP Program

High Availability & Reliability - key to
sustained efficiency improvements

The Road Map

PdM Improvements
Risk Mitigation
Availability
Improvement
Initiatives

RCM-Living Program
Risk Screening
Widespread Dissemination

• 125 Workshops on Boiler & Turbine Analysis &

Performance Improvement; Diagnostics and
Knowledge Based Maintenance
• 14000 Training man days - Participants from
NTPC, DVC, GSCEL, UPRUVNL, TNEB,
APGENCO, PSEB, RRUVNL, MSEB, IPGCL etc.
• 319 Demonstrations - Hands-on training Optimisers
available on NTPC website
• Guidelines on Thrust areas
• Papers at various conferences
• Customized training programs organized at SEBs
as per their needs

Supported by 48 US team visits of over 1050 man days

Quarterly newsletter
CenPEEP program lead to CO2
abatement
2.5

Cumulative Reduction in CO2

• CO2 savings of 2

over 2.4 Million

(Million Tones)
1.5

Emission
Tons in NTPC 1

• Institutionalization 0.5

through EMC 0
97- 98- 99- 00- 01- 02- 03- 04- 05- 06-
98 99 00 01 02 03 04 05 06 07
Ye ar

Successful replication in SEBs:

¾ Maharashtra SEB: reported savings of about 4 million tons
of coal & of 5 million tons of CO2 in two years using
CenPEEP tools
¾ UPRVUNL reported reduction in coal consumption by 2.5%
in one year by implementing learning from CenPEEP
awareness Programs
Cooperation Impact - evaluating
performance for a longer term

Evaluation Dimensions
„ Competency Upgradation The interventions
„ Institution Scalability have been quite
effective to elevate
„ Roll out potential the contemporary
„ Sectoral Benefits sectoral conditions
but there is surely
„ Public benefits
scope to make the
„ Knowledge creation, impact deeper and
management & optimisation wider
„ IT Enablement

CenPEEP has made a good beginning, improvements to be sustained for a large fleet
 CTI’s World Climate
Technology Award 2002

USEPA
CLIMATE
PROTECTION
AWARD 2003

Awards & Recognitions

Operation
NATIONAL and Maintenance
THERMAL POWER
CORPORATION
- Gearing up for- Afuture LTD.
challenges
PROFILE
O & M : Gearing up for future
challenges
„ Regional Operation Performance reviews
„ Performance Evaluation Matrix
„ Institutional Building and Knowledge
Teams
„ Over Hauling Preparedness Index
„ Web based Enterprise wide MIS
„ OPC compliance for ERP
„ Automated SMS
„ Condition Monitoring of all major
equipments
„ RLA
„ Modular replacements Unchahar - Recipient of Best
Asian Power Plant Award 2006
All Time High Plant Load Factor

„ All time high PLF of 89.43% achieved by NTPC Coal

Stations in 2006-07

„ 9 Coal Stations amongst the top 20 stations of the

country in terms of PLF in 2006-07

„ 8 out of 13 Coal Stations have achieved 90% PLF in

2004-05

„ NTPC’s first power plant (Singrauli) maintaining average

PLF of 91% even after 25 years of operation
 No. of continuous running days

0
100
200
300
400
500
600

210 MW
559

(Vindyachal)

500 MW
406

(Ramagundum)
Established O&M Practices

GAS TURBINE
448

(Dadri-Gas)

STEAM
TURBINE
480

CCGT( Auraiya)
Maintenance Optimisation

„ Project REAP

– Phased implementation of shift in maintenance

strategy from enhanced predictive maintenance to
risk based maintenance

„ Latest diagnostic tools in use

– NFT for Generator stator, RSO for Generator rotor,

online DGA, FRA, DCRM for circuit breakers, online
LPT blade crack detection, increased use of
Thermography, etc.
 0
2
4
6
8
10
12
Singrauli

Rihand

Unchahar

Tanda

Dadri

Badarpur

Korba
Maintenance Marvel

Vindyachal

Ramagundum

Simhadri
Significant Reduction in

Farakka
Forced Outage of Coal stations

Kahalgaon

Talcher (H)

Talcher
2005-06
2006-07

NTPC
O&M Practices

„ Well defined guidelines for O&M of units

„ Safe and reliable operation in rated
parameters
„ Strict adherence to water chemistry and
environmental norms
„ Established procedures for startup and
shutdown
„ Compliance to statutory requirements
O&M Practices

„ Standardised recommissioning procedures

„ Daily safety checks
– Oil & hydrogen quality checks, system
protections checks, trial of emergency
equipment, fire protection systems check, etc.
„ PTW system
– Isolation, lockout, maintenance and
normalisation activities are strictly through online
system
GAS TURBINE
Performance Monitoring and Improvement
Present Practice:
„ Capacity gap analysis carried out by various important
parameters like Ambient Temperature, Ambient Pressure,
Compressor discharge Temperature and Pressure, Turbine
exhaust Temperature, WHRB inlet and Exit Temperature etc.
„ Compressor efficiency, Heat Rate and Power Output is
calculated periodically for Combined Cycle based on the
available feed back of parameters On line as well as Off-line.
The calculated values are compared with Design and the
Operation of machine is further Optimised.
„ Remedial actions for repair and replacement of component or
system responsible for degradation is planned and executed in
shut down.
„ Off line Vibration analysis is carried out for Turbines and
Auxiliaries and Suggested remedial action is taken up during
shut down.
 Energy Conservation Efforts

Practices adopted for reduction of plant Auxiliary

Power Consumption
„ Monitoring of energy /specific energy consumption of individual drives
through Online Energy Management System.
„ Encouraging use of variable frequency drives in different areas like
Induced Draft Fans, Condensate Pumps etc.
„ Structured energy audits of different areas of the power plant to identify
energy loosing areas with timely implementation of recommendations to
plug these.
„ Polymer coating of pump internals for sustained efficiency improvement
of Circulating Water Pumps, Low Pressure / High Pressure Ash water
pumps etc.
„ Adoption of vapour absorption system (using environment friendly Lithium
Bromide) for central air conditioning of control rooms etc in place of
vapour compressor system (using ozone depleting freon gases).
„ Switching over from existing GLS lighting to energy efficient CFLs/FTLs.
Systems

„ Well defined Technical Compliance system

– Defines directives and guidelines for unit operation
and maintenance
„ Daily plant data forms 3 tier information system
– Analysed separately at station, region and corporate
„ Monthly review of station performance in ORT
„ Regional review by top management every
quarter
„ Additionally, regions and corporate undertake
Technical Audits, Peer Reviews, and Surveilance
ORTs on a planned schedule
„ Stations conform to ISO 9001
Institution Building

„ Knowledge teams
– Aims to strengthen technical resources
– Members selected on expertise, knowledge and
experience
– Functional in areas of Turbine, Boiler, Electrical,
C&I and Offsite
– Involvement in overhauls, troubleshooting, fact
finding, problem analysis
„ Specialized training programs
– Identified members are trained in specific areas
 Overhaul Quality
„ Minimise forced outage from overhaul to overhaul
„ Prepare comprehensive scope of work
– Inputs from past experiences, knowledge teams, RLA
analysis, failure history analysis, performance
assessments, etc.
– Finalised 2 yrs before overhaul
– Reviewed regularly
„ Operation Preparedness Index - OPI
– Assess preparedness of spares & service contracts for
overhaul
– OPI calculation, monitoring and corrective action is
through monthly ORT and quarterly review in ROPR
„ Emphasis on modular replacements to increase
performance and reliability
NATIONAL THERMAL
Conclusion POWER
CORPORATION LTD.
- A PROFILE
Summing Up

In its endeavor for greener future, NTPC is

committed to
• green house gas abatement
• ambient air quality improvement and
• effluents and waste management

For meeting these objectives, actions are taken at

following stages
• Planning and design stage
• Plant operation stage
• Assisting other utilities in achieving improved plant availability and
efficiency through PIE and CenPEEP
Summing Up

Design and Planning Steps

• Subcritical 500 MW units will have enhanced reheat steam temperature of
565OC instead of 537OC
• All future units of 660 MW and larger capacity shall be supercrtical units with
parameters of 247 ata/ 565OC/ 593OC
• Ultrasupercritical units to be adopted after gaining operational experience from
the supercritical fleet under execution now
• Broaden energy mix to include
• Renewables (1000 MW from wind and solar by 2017)
• Hydro, predominantly Run of River type (1920 MW under construction, 4791 MW under planning)

• Dry collection of fly ash and incentivization of entrepreneurs to make use of ash
• Ash water recirculation system to recycle decanted water from ash dykes
• Adoption of high concentration ash slurry disposal system
• Promote biomass/solar/wind based Distributed Generation in remote villages for
rural electrification
Summing Up

Maximizing plant efficiency during operation

• Robust system of plant performance review on monthly basis by experts
from stations/regional/corporate offices
• Plant efficiency being evaluated and compared with the design values on
a monthly basis by dedicated experts from Efficiency Deptt.
• All latest units (2004 onwards) equipped with PADO – a s/w based
diagnostic, analysis and optimization tool – for operator guidance
• Improvement in maintenance practices with long and rich experience has
led to sustained improved performance of coal pulverizers and air
preheaters, the two main culprits for bolier efficiency
• Planned inspection and intervention by CenPEEP to plug efficiency gaps
• Regular energy audits to review plant parasitic power consumption
Summing Up

Assistance/guidance to other utilities

through PIE & CenPEEP interventions
• Turnaround knowhow to State Electricity
Boards through dissemination of expertise &
operation & maintenance best practices.
• Efficiency enhancement and availability
improvements will lead to significant amount
of reduction in CO2 emissions
• The interventions have been demonstrated to
be effective in raising the contemporary
sectoral conditions
 http://www.ntpcindia.com

Thank you