Presentation of

Energy Efficient Renovation & Modernization (R&M)

By

H.S.BediSr. Vice President

(Power Engineering and Energy Services)

India’s plan is for 8-9% of GDP growth; which would require corresponding growth in electricity generation

Coal based electricity generation capacity is 54.8% by March 2011 (99,503 MW out of total of 181,558 MW)

By 2030,it may reach around 450,000 MW

This would lead to

Huge Investment needs

Depletion of natural resources (coal & water)

Higher emissions to environment

EE R&M: Present National Scenario

Renewable Sources of Power Generation

New Capacity Addition

Renovation & Modernization (R&M)of old plants(>25

years)

Energy Conservation

Supply Side and Demand Side Management

EE R&M: Power Generation Options - Feasible Alternatives

Grid Access/Switchyard.Cooling water Availability.Access to Infrastructure.Permission for Power generation and evacuation.Fuel Supply agreements.Trained Operation and Maintenance Personnel.Administrative facilities and residential

accommodation

EE R&M of old PS: Comparative Edge owing to existing facilities

EE R&M of old PS: Improvement required in 25 years old units

Due to continuous operation, many of the plant equipment and system have undergone ageing process, resulting in:- Reduced output. Technological Obsolescence.

Large number of smaller capacity, very old units like 50 / 62.5/100/210/500 MW are operating with poor efficiency, which may become techno-economically viable after RLA and Energy Audit study.

The concept in R&M has recently shifted from primarily generation maximization & remaining life extension, to performance enhancement at the same time that is Energy Efficiency, Net heat rate (NHR) Improvement.

Coal is an exhaustible natural resource. Hence, its saving by way of increasing old plants efficiency is desirable. EE-R&M helps in lowering specific coal consumption, increased plant availability hence it’s cost effective .

Present day R&M concept: Energy efficiency Enhancement

Old plants can be renovated and Modernized at lower costs and optimum life extension is achieved.

R&M implementation is carried out during longer / annual shut down, there by assuring sustained power to users.

Availability and efficiency can be improved. Energy Conservation, reduction in Aux. power consumption &

performance improvement is achieved, new tech. adopted. No R&R problems. For new plants Limited availability of new site, land, water and road etc.

and power evacuation. High initial cost, longer gestation period of new plant. To comply to Stringent Environmental and safety norms. Coal, Water Linkages and Land Litigation becoming hurdles in

Green/Brown Field Plants

EE R&M of old plants Vs new plants: Comparative Edge

The benefits accrued from EE-R&M in a typical 200/210 MW (LMZ) steam turbine unit include:

• Restoration / Increased output by about 3 to 5 % of the design rating.

• Improved unit heat rate by 2 to 2.5 % of design value resulting in fuel saving .

• Extending Plant Life by about 15-20 years with very low outages

• Additional economical power generation from old units becomes available in short duration.

Present day R&M concept: Energy efficiency Enhancement

Performance evaluation and conductance of energy audit of the old units is most desirable in addition to RLA study of complete plant for designing the scope of work for EE R&M.

Present day R&M concept: Energy efficiency Enhancement

To enhance Life of Units by 15-20 years.

Improve PLF above 85%,

Increase availability above 90%,

Up-gradation/Restoration of Rated Load considering the present worst coal GCV.

Reduction in Auxiliary consumption

Ensure emission level (SPM) sustained below 50-70 mg/Nm3 at full load.

To evaluate the different option of up-rating the unit.

To improve unit net heat rate as compared to design.

Key objectives of the EE-R&M study

Go through QCBS procedure of selection and select the best agency Selection may be in 70:30 weight ratio for selection of key

design specialist of Boiler, Turbine, C&I, Generator , BOP etc. and Price.

Mere selection on L1 basis may not meet your objectives of study Judge the technical capability also, based on(not only QR):-

ask for Procedure/methodology to be followed and grade accordingly

ask for manpower available presently and to be deployed, can one keep provision to ensure at site?

ask to submit list of calibrated instruments to be used for measurements of the Parameters

Right Selection process Selection of Right agency Right Study and evaluation Meeting the objectives

Selection of EE R&M Design Consultant

Preliminary Survey Carrying out RLA & Report preparation

Conducting Energy Audit & Report preparation

Preparation of Technical Audit Report

Step- I

Step- IIPreparation of DPR , techno-economic viability of various options

Step- IIITenderization process up to order finalization and handing over the job to ISC Step – IVProviding support to owner during execution of job (optional)

Plant may take guidance from R&M Design Consultant

Services offered by a design consultant:

1. Review previous studies carried out on the unit

2. Carrying out technical audit of the various equipment and related BoP

3. Undertake energy audit for baseline assessment of the entire unit

4. Undertake RLA/LE study of Boiler, Turbine including steam path audit , Generator & electrical equipment & Civil structures and foundations of unit.

5. Prepare an exhaustive list of Run/Repair/Replace decision Matrix for various equipment including Valves, Hangers and Supports, Expansion Joints, Ducts, Insulation, Motors, Cables, Pumps, Fans, C&I equipment, Impulse lines , etc

6. Assess techno-economically various R&M options

Steps of activities of design consultancy

7. Prepare the detailed Scope of Works with cost estimate and assess the cost effectiveness of alternative rehabilitation options including new Units and suggest the optimum solution

8. Prepare a DPR giving the various options (including scope of work in each option), techno-economic financial analysis of various options and recommend the best option for Energy Efficient rehabilitation project including strategy for dealing with surprises.

9. Prepare the Bidding documents both Technical and Commercial.

10. Assist the owner through the bidding process

11. Assist in Post bid discussions and award.

Steps of activities of design consultancy

Presently working on four(4) EE-R&M assignments as Design Consultant Awarded through QCBS(Quality & Cost Basis Selection)of the World Bank. 1. Panipat Thermal Power Station (2x110 MW),HPGCL Draft DPR

submitted

2. Chandrapur Super Thermal Power Station(2x210 ,MSPGCL Energy Audit and RLA for both units completed and reports submitted except that for Unit#1 RLA

3. Bhusawal Thermal Power Station (1x210 MW),unit no.2, MSPGCL

RLA is completed on boiler, turbine, generator, elctrical, civil structures & steam path audit. Energy Audit also completed.

4. Parli Thermal Power Station (1x210 MW),unit no.3, MSPGCL Energy Audit is in progress

Energy Efficient Renovation & Modernization (EE R&M)