UPGRADE OFFERING - BOILER AND STEAM TURBINE , GENERATOR

2/24/22

Confidential. Not to be copied, distributed, or reproduced without prior approval.

Presented By
GE Power India Limited
Upgrade Team , Noida
 Upgrade product portfolio
Digital offering
Boiler island • Boiler Optimization
• PP replacement/upgrade • Monitoring & Diagnostic(M&D)
• firing system upgrade • Generator Health Monitoring(GHM) AQCS
• Mill upgrade • ESP/FF Upgrade
• De-NOx upgrade • FGD
• Fuel Conversion
• Low Load Operation/Flexibility

Turbine island
Section/Module Upgrade
Control System Upgrade
+1000 +1300
Generator -Rotor/Stator Rewinding
Boilers
Steam Turbine +1500
module AQCS product
Upgraded
upgraded Upgraded All
globally for All
globally for All OEM globally
OEM
OEM

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© 2019, General Electric Company. Proprietary information. All rights reserved. 
Upgrade Solutions – Delivering Power Plant KPI’s

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GE - Most of the major global Boiler OEMs
use GE Technology…

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GE Boiler Technology
PROVEN COMPETETIVE BOILER
Original Equipment Designer & Manufacturer T E CH NO L O G Y & K N O W- H O W
(OEM of >60 MW boilers in India)
• 210 MW Boiler, Mills
• The initial units were designed by GE & supplied by BHEL. BHEL Licensee from 1971

• 500MW Subcritical Boilers with Mills and APH

• The initial units (Tata Trombay, NTPC Rihand, Korba, Ramagundam were designed by GE & supplied by BHEL Since
1982)

With the availability of the Original Design Details - Drawings, Performance analysis Boiler Models, provides GE the
capability to undertake :

• Modifications/ upgrades to optimize the performance with changed fuel quality and operating conditions
• To introduce state of the art modern upgraded etc.)

India boiler installed base by BHEL & majority of Chinese uses GE technology

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© 2019, General Electric Company. Proprietary information. All rights reserved. 
GE- Boiler Services offerings

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Boiler Offerings for Industrial and Utility- Coal ,Oil &
Coal Mill Offering
Gas
Pressure Part Upgrade Economizer/APH* Modifications
Performance Improvement by Re-
Back End Temperature Optimization
Surfacing Pressure Parts (SH & RH)
Life Extension by Design Improvement
Life Extension by Material Upgradation
* Can be offered as part of Boiler Upgrade
Capacity Enhancement
Package
Applicable for All OEM

Firing System Upgrade Digital Solutions

Low NOx Control Boiler Ops
Fuel Conversion (Oil- Gas & HFO-LDO) DB+ Solutions
Correction in Gas Temperature Imbalance Soot Ops

Flexibility & Low Load

Plasma Ignition System
Boiler Firing System Upgrade
Other system upgrade
• Capacity Restoration/ Enhancement
• Performance Improvement
Plasma Ignition System
Conversion of Startup oil system to • Operation Flexibility
Plasma Ignition System • Digital Mill optimization

GE expertise covers Upgrade for all boiler technologies portfolio, all fuel types
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GE- Boiler Services offerings

Life Extension & Performance Improvement

Solutions for Pressure Part

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 Pressure Parts Upgrade
Key Issue Solutions for Life Extension and Performance

 Pressure Parts failure  Pressure Parts redesign and replacement

 Drop in SH temperature Performance Improvement by Re- Surfacing

Pressure Parts (SH, LTSH & RH)
 Drop in HRH temperature
 Economizer/APH* Replacement/modification
 Increase in SH and RH spray
For Back End Temperature Optimization & Life
 High Back End temperature Extension by Design Improvement
 High skin metal temperature  Complete metal temperature assessment and
 Drop in Boiler efficiency material upgrade.

 Capacity/Other issue due to  Solutions for capacity enhancements in Utility &

change in fuel GCV i.e. Design industrial units all OEM.
Vs. Current Coal conditions

* Can be offered as part of Boiler Upgrade Package

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De-NOx Solutions Overview
De-Nox Solutions
Comprehensive Nox Emissions Legislation enacted by India
Low Nox SOFA
Installed Data Nox Limit(mg/Nm3) (Combustion SCR
Burner Modification)

Power Plant Installed before 31st Dec 2003 600

Power Plant Installed between 2004 - 2016 450
     
     
     
Power Plant Installed from 2017 onwards 100

450 mg/Nm3 100 mg/Nm3

(Combustion Modifications)

GE offering optimal emission control technologies to control Nox

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De-Nox, Firing System, Fuel Conversion
Sofa installation Typical Low NOx Burner
SS Coal Nozzle

GE Product Basket
 New Low NOx Burner (UTFS)
 Sofa Installation
 Firing System Upgrade

Customer Benefit post Upgrade

Coal Nozzle Tips  Low NOx
 Fuel Adaptability
 Reduce Temperature Imbalance
 Reduce RH Spray Quantity

Combustion Modifications

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Coal Mill –Leveraging Technology Developments
GE VERTICAL
Dynamic Classifier 136 t/h MILLS
TECHNOLOGY
120

100
DELIVERING
Latest HIGHER MILL
Capacity (t/h)

Generation PERFORMANC
80 Vane Wheel E
17 – 91 t/h
60

5 – 48 t/h
40
2 – 27 t/h
17 t/h
20

MILL Type RB RPS RP HP 603 HP 1303

1950 1960 1970 1980 1990 2000 2010

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© 2019, General Electric Company. Proprietary information. All rights reserved. 
 GE References for Key Boiler Upgrade
Customer Unit Size(MW) OEM Solutions Industry
NTPC Barh 3x660 Russian Make Pressure Parts Replacement Fossil

NTPC Dadri 2x490 BHEL Combustion Modifications Fossil

NTPC Baruni 2x250MW BHEL Combustion Modifications Fossil
NTPC Lot1 9980(19 Boilers) BHEL Combustion Modifications Fossil

TATA Jojobera 2X120 BHEL Combustion Modifications Fossil

UPRVUNL 2420(8 Boilers) BHEL Combustion Modifications Fossil
NTPC Rihand 2x500 NEI E-Mill Replacement Fossil
Hindustan power 600 Harbin Firing System Upgrade Fossil
Vedanta Jharsuguda 2X600 Harbin(Chinese) Eco Replacement Combustion Aluminum Plant
Modifications
IOCL Haldia 150 TPH (Oil) GE Fuel Conversion Refinery(Oil & Gas)
BORL, Bina 3X275 TPH BHEL Pressure Parts Replacement Refinery(Oil & Gas)

CPCL Industrial GE Fuel Conversion Refinery(Oil & Gas)

JSW Bellary Industrial BHEL Mill Modifications Steel Plant
CPP, Lalkaun Industrial Enmass Economizer Replacement Paper Plant

Confidential. Not to be copied, distributed, or reproduced without prior approval. Title or Job Number | XX 13
Month 201X
GE- Steam Turbine & Generator Upgrade offerings

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Steam Turbine for Industrial & Utility-60 MW-660 MW
Upgrade Package for
OEM/OOEM Focus Segmentation SCOPE
LMZ
OEM/OOEM KWU
 Capacity Enhancement Target -16% Target - 16%
 BHEL Utility
 Heat Rate Improvement HP&Actual
IP full- 6%
Module / InnerActual
Block -
 Central Forecast Replacement
– Q2 17 Forecast – Q4 17
 Availability and reliability
 CHINESE  State
improvement  IPP
 Load Flexibility
 SIEMENS
(Low Load & Fast Ramp)
Industrial Segment
 Control System upgrade
 ANSALDO (> 60 MW)
 Generator (As a part ST  Steel,
Retrofit Package)  Aluminum
 TOSIBHA
 Longer duration between two  Chemicals
outages
 MHI

Localized Solution, Complete Engg., Manufacturing in GE Sanand factory LP Inner Block Replacement

Attractive ROI with Module Replacement & Control System

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Generator for Industrial & Utility- 60 MW-660 MW
Retrofit / Service as combined package with Steam Turbine

Indian Make
Measure Water-Cooled
or H2/ Air Cooled Stator

Engineer
Chinese Make
Water-Cooled
300/ 330/ 600/660 MW
Procure
or any other make

Rewind H2/ Air-Cooled – Rotor

Any Repair or Rewind
at Site / Sanand
or ANY OTHER MAKE
Any Make Full Capability Any Size
* Water Cooled/ H2 Cooled / Air Cooled
30 MW to 1000 MW

Confidential. Not to be copied, distributed, or reproduced without prior approval. ** Typically for full rewind 16
GE References for Key Turbine Upgrade
Customer Project Name Plant Site Product Type oOEM Fleet OED
GSECL Ukai ST retrofit Ukai Steam Turbine Fossil BHEL LMZ 210 LMZ

GSECL Wanakbori ST retrofit Wabakbori Steam Turbine Fossil BHEL LMZ 210 LMZ

BPDB Ghorasal unit 3 Repowering – ST Ghorasal Steam Turbine Fossil LMZ 210 V3 LMZ

NTPC Ramagundam Unit 1 Ramagundam Steam Turbine Fossil Ansaldo GE

NTPC Ramagundam Unit 2 Ramagundam Steam Turbine Fossil Ansaldo GE

NTPC Ramagundam Unit 3 Ramagundam Steam Turbine Fossil Ansaldo GE

Hindalco Renusagar 6 Retrofit Renusagar Steam Turbine Industry BBC Mannheim Alstom

Hindalco Renusagar 5 Retrofit Renusagar Steam Turbine Industry BBC Mannheim Alstom

Hindalco Renusagar 7 Retrofit Renusagar Steam Turbine Industry BBC Mannheim Alstom

Hindalco Renusagar 3 Retrofit Renusagar Steam Turbine Industry Siemens Siemens

Hindalco Renusagar 4 Retrofit Renusagar Steam Turbine Industry Siemens Siemens

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© 2019, General Electric Company. Proprietary information. All rights reserved. 
 GE Manufacturing Capabilities

Supporting to “Make in India Mission”

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 BOILER
Boiler Manufacturing at Durgapur, WB Manufacturing

In House Manufacturing to Optimize Cost & Lead time

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GE-Durgapur Boiler Factory 1 s t B O I L E R M A N U F C AT U R I N G
FA C I L I T Y O F I N D I A
Factory Site History

Land : 1,215,000 m2

Covered Area : 69,000 m2

Journey
Location Advantage Mode of
Transport Port of Entry Distance

Kolkata and
Sea 160 Km
Haldia

Air
Kolkata 160 Km
(International)

Air (Domestic) Durgapur 30 Km

Railway Durgapur 3 Km

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© 2019, General Electric Company. Proprietary information. All rights reserved. 
GE Durgapur Plant & Facilities

Presentation Title Confidential. Not to be copied, distributed, or reproduced without prior approval. 2/24/22 21
GE Durgapur Product Portfolio

Presentation Title Confidential. Not to be copied, distributed, or reproduced without prior approval. 2/24/22 22
GE Sanand factory
State of the art Manufacturing facility TURBINE & GENERATOR
MANUFACTURING

• Located in GIDC, Sanand (Gujarat)

Near Ahmedabad
• Factory spread over 50 acres
• Fully integrated for manufacturing
and testing of :
− Steam Turbines
− Generators
− Related Auxiliaries
• Capacity of 4 to 6 supercritical units ranging from 600 to
1000MW
• Production commenced beginning 2015

Localization through state of the art Manufacturing operation & Fully integrated facility

Presentation Title Confidential. Not to be copied, distributed, or reproduced without prior approval. 2/24/22 23
Turbine - Manufacturing Capability- Sanand, Gujarat

Rotor-Product capabilities
• 600MW - 1200MW steam turbine HP/IP/LP rotor and Generator rotor

Horizontal Rotor slotting/ Horizontal Boring

Lathe machine

GE POWER SYSTEMS INDIA PRIVATE LIMITED

Turbine manufacturing Capabilities – Sanand, Gujarat

Casing-Product capabilities
• 600MW - 1200MW steam turbine HP/IP/LP inner casing, outer casing, module assembly,
Valve & Pedestal, generator housing

Gantry Universal machining Vertical Turning m/c Horizontal Boring m/c

GE POWER SYSTEMS INDIA PRIVATE LIMITED

Turbine-Manufacturing Capability- Sanand, Gujarat

Blades-Product capabilities
• HP/IP/LP steam turbine blades

3–Axis BladeMachine
2 x 5-Axis Machine Blade Machine
GE POWER SYSTEMS INDIA PRIVATE LIMITED
Turbine-Manufacturing Capability- Sanand, Gujarat
Rotor Stands
Turbine Assembly Stands

Special purpose machines: Rotor Blading

+ machining – To address uni-flow during
Rotor manufacturing

GE POWER SYSTEMS INDIA PRIVATE LIMITED

Generator- Manufacturing Capability- Sanand, Gujarat
Generator-Product capabilities
• 600MW-1000MW generator stator machining & assembly,
generator rotor machining & assembly
• Stator Bars

Generator Rotor Generator Stator winding &

winding facility assembly facility

GE POWER SYSTEMS INDIA PRIVATE LIMITED

Generator Manufacturing Capability- Sanand, Gujarat
High Speed Balancing Facility - Schenck
- Weight 125 Tons
- Length : 19500mm
- Diameter up to 4800mm
- Maximum balancing speed of 4,500 rpm
- Main drive motor max : 6400KW
- Vacuum 1 mbar

Balancing Facility one of the largest in India

GE POWER SYSTEMS INDIA PRIVATE LIMITED

Way Forward

Input Technical Commercial

Outline of
Collection & Discussion Discussion
Solution
Review & closure & closure

Site Visit , If Required

 List of Key Inputs
Boiler
 Coal Analysis
Ultimate & Proximate Analysis
Ash Analysis
 Contract Data sheet original and Post Major retrofit, If any
 BTL, RLA & PG Test Report
 PPA drawings, Boiler General arrangement drawings, Duct layout drawings
 Existing Mill, APH and auxiliaries' details
 DCS operating data 60% MCR, 80%MCR, 100%MCR

Turbine
 HBD
 Original Contract sheet
 PG Test
 Last Three Overhauling Report
 DCS operating data 60% MCR, 80%MCR, 100%MCR