1. EXPERIENCE SHARING
4th April 2016
SSBG

2. Options for Old Units ??? Retirement Capital Overhaul / Refurbishment
Mandatory maintenance & operate for an extended period and retire
Capital Overhaul / Refurbishment
R & M and LE
R & M, LE and Up-rating

3. Factors causing the Dilemma
Age / Hours of operation
Present Heat rate
Availability / PLF
Reduced Output
Continuous deterioration
Latest stringent emission norms
GOI has identified 65 sets (~ 5860 MW), which have completed more than 25 years of life, for replacement with modern and environment-friendly (super-critical) ones.

4. Comparison of New Unit V/s R&M
New Units
R&M
Cost of a New Unit is X Cr.
R&M will be approx. X/2 Cr. (as per CEA guidelines)
Latest technology
The latest technologies are incorporated in the existing systems/ equipments upto the extent possible
Option of higher capacity sets with superior heat rate
Recapture rated Output, Reliability and Availability with improvement in efficiencies, Marginal gain in output
Reliable operation with minimum maintenance for next 20 years
Extension of economic useful life by about 15 years
Requirement of experienced new manpower
Extant manpower may be trained
Longer gestation period
Smaller gestation period
New infrastructure to be augmented
No such requirements
Transfer of knowledge/ know-how/ know -why
New vendor base for spares / services
Various statutory clearances to be obtained

5. Issues regarding R & M and LE
Capital overhauling with retrofitting is only a short term measure
RM & U requires total design change
Increase in cost due to vast scope in RM & U
Uncertainty about post RM & U benefits
Longer shutdown requirement v/s peak power shortage in RM & U

6. General Scope of R&M /L E
Boiler & Auxiliaries
Replacement/augmentation of pressure parts
Retrofitting/ modification of air pre-heater
Augmentation of milling system
Provision of flame scanner, igniters
Renovation of draft system
Retrofitting of ESPs
TG & Auxiliaries
Replacement of Turbine rotors & inner casing- with latest design blades
Modernization of condenser by change of tube materials, augmenting with online tube cleaning systems
Modernization of power cycle equipments with more efficient pumps, regenerative heaters etc
Modification of air evacuation system with vacuum pumps
C&I
Replacement of obsolete C&I system with state of the art technology (maxDNA)

7. Future Scenario Package-wise Retrofitting Turbine Modules Retrofitting
LP Turbine Modification
Condenser Retrofitting
C&I Retrofits
(SG, TG & Station)
Boiler Retrofits
ESP Retrofits
FGD Retrofits
Mill / Feeder Retrofits
VFD Retrofit

8. Typical Benefits of R&M
Power Station
Unit
Rating
PLF before R&M
PLF after R&M
Improvement in PLF
Improvement in output
R&M of Korba (E) TPS of CSEB
(completed in 2003 & 2005) 5
120 MW
62.8 %
> 80 %
>20 %
(achieved)
>24 MW 6
59.6 %

9. Post-R&M Performance (Panipat TPS)

10. R&M /LE orders finalized in country
Total units ordered (110 MW and above)
40 sets (5300 MW)
Orders placed on BHEL
30 sets (3890 MW)*
(75 %)
Orders placed on others
10 sets (1410 MW)
(25 %)
* Orders for 3 nos. sets cancelled (340 MW)

11. R&M/ LE - Ordering Trend (MW)
CEA’s Plan vs Actual
7060 (59 sets)*
2600 (19 sets)
3750 (26 sets)*
890 (8 sets)
16532 (72 sets)
Planned
36.83%
23.73% MW
620 MW (3 sets)
3.75%
* Only BHEL sets are considered

12. Challenges in R&M and LE
Limited agencies for R&M and LE implementation in the country
Unfavorable cost benefit analysis, if the scope is not optimized
R&M activity to be limited with plant shutdown
Many surprises during execution of R & M and LE
Limited BOP suppliers
BOP suppliers are loaded with new plant orders
Many BOP suppliers are not willing to take up R & M and hence quote exorbitantly
Contd..

13. Challenges in R&M and LE
Non availability of Civil foundation details and sub-surface details with customer
No details available for modifications carried out earlier / spares used earlier
The changes/ deterioration during the time from CA to execution need to be addressed by customer

14. Factors attributing delay in execution of R&M Projects
Delay in shut down of unit for R&M
Long delay between RLA and R & M execution
Lack of maintenance during this period causes further deterioration and increase in scope.
Additional scope /surprises during execution
Difficulties in interfacing of new system with the existing system
Lack of suitable offers for bought out items from original vendors due to obsolete design
Contd..

15. Factors attributing delay in execution of R&M Projects
Not getting clearance for PG Test immediately after stabilization of unit leading to delay in contract closure
Inadequate documentation of process parameters by utilities
Long deliveries quoted by vendors for rotor forgings etc.
RLA, CA & PET to be carried out by the agency responsible for R & M
Difficulty in procurement of sub vendor items
Non existence of original vendors
Non availability of original equipment details, specifications etc.

16. Partnership for Win-Win Scenario
Provision should be made in contract for RLA/CA study of Critical Components affecting the guarantee parameters, by the R&M executing agency, just before releasing the Unit for R&M.
RLA – Scope final Ordering Engg., Manufacture & Supply Site Execution (Shutdown Period) PG Test
(RLA of Critical Components)
R&M supplier must be intimated well in advance for award of job to carry out R&M works so that necessary action could be taken proactively in the interest of the project.
Hand holding approach during execution of R&M
(12 months)
(12 months)
(18-24 months)
(8-12 months)
(6 months)

17. Advantage – BHEL (Experience & Infrastructure)
Original Equipment manufacturer
Manufacturing facilities for Spares
Availability of original design data & performance test results
Minimum dependence on external sources
First hand knowledge of O&M practices and problems
Vast experience with Indian coal
Contd..

18. Advantage – BHEL (Experience & Infrastructure)
Geared up to take up comprehensive R & M including BOP
Developed technologies / retrofits to improve the performance
Well developed labs for testing of coals, ash, material etc.
Spares & Services Business Group (SSBG) has been created within BHEL to provide a ‘single window facility’ regarding R&M requirement of customers.

19. THANK YOU

20. REVISED EMISSION NORMS (dt. 7th Dec’15)
Year of Commissioning of Unit
Capacity
Target emission Level as per new norms
A. Level of ‘SOx’ emission to be achieved
Installed before Dec 2003
Capacity < 500 MW
600 mg/Nm3
Capacity > 500 MW
200 mg/Nm3
Installed from Jan 2004 to Dec 2016
B. Level of ‘NOx‘ emission to be achieved
All ratings
300 mg/Nm3
C. Level of ‘Particulate Matter’ emission to be achieved
100 mg/Nm3
50 mg/Nm3

21. BHEL Experience in R & M AND LE ( Completed Projects)
S.N.
Project 1
4 X110 MW KOTHAGUDEM, APGENCO (Up-rating to 4x120 MW) 2
2X120 MW KORBA, CSEB 3
2X110 MW ENNORE , TNEB 4
2 X 120 MW UKAI, GSECL 5
1X110 MW PANIPAT, HPGCL (Up-rating to 117 MW) 6
1X110 MW PANIPAT, Unit 2 (HPGCL) 7
2X110 MW BATHINDA, PSPCL (Up-rating to 2x120 MW) 8
2X110 MW MUZAFFARPUR, KBUNL 9
1X110 MW HARDUAGANJ, UPRVUNL 10
1x200 MW OBRA, UPRVUNL (Up-rating to 216 MW)
Contd..

22. BHEL Experience in R & M AND LE (Projects under execution)
S.N.
Project 1
1x210 MW KORADI, MAHAGENCO (Up-rating to 228 MW) 2
2X110 MW PATRATU, JSEB (Rehabilitation) 3
4X200 MW OBRA, UPRVUNL 4
2X110 MW BARAUNI, BSEB

23. List of Units (5857 MW) identified for retirement
S.N.
STATION
UNIT
CAPCITY (MW) 1
PANIPAT TPS
1, 2, 3 & 4
4x110 2
OBRA TPS 40 3 50 4 8 94 5
PANKI TPS
105 6
HARDUAGANJ TPS 60 7
UKAI TPS
1 & 2
2x120
AMARKANTAK EXT TPS 9
DSPM TPS Korba
4x50 10
KORADI TPS
4x105 11
KOTHAGUDEM TPS
4x60
Contd..

24. List of Units (5857 MW) identified for retirement
S.N.
STATION
UNIT
CAPCITY (MW) 12
KOTHAGUDEM TPS
5, 6, 7 & 8
4x120 13
RAMAGUNDEM - B TPS 1
62.5 14
ENNORE TPS
1 & 2
2x60 15
3, 4 & 5
3x110 16
PATRATU TPS
1, 2 & 3
3x40 17 5 90 18 8
105 19
SANTALDIH TPS
1, 2, 3 & 4 20
D.P.L. TPS 3 70 21
4 & 5
2x75

25. List of Units (4800 MW) identified for R&M
S.N.
STATION
UNIT
CAPCITY (MW) 1
RAJGHAT TPS
67.5 2
GANDHINAGAR TPS
1 & 2
2x120 3
SIKKA REP. TPS
120 4
SATPURA TPS 6
200 5
7, 8 & 9
3x210
NASIK TPS
3, 4 & 5 7
KORADI TPS 8
210 9
BHUSAWAL TPS
2 & 3
2x210 10
PARLI TPS 11
CHANDRAPUR (MH.) TPS
1, 2, 3 & 4
4x210

26. CHANDRAPUR (ASSAM) TPS
List of Units (4800 MW) identified for R&M
S.N.
STATION
UNIT
CAPCITY (MW) 12
PATRATU TPS 4 40 13 6 90 14 7
105 15
D.P.L. TPS
110 16
CHANDRAPUR (ASSAM) TPS
1 & 2
2x30 17
BOKARO ‘B’ TPS 1
210
TOTAL 29
4800

27. BHEL Experience in ESP Retrofitting
S.N.
Project 1
UKAI & WANAKBORI, GSECL (4x210 MW) 2
SINGRAULI, NTPC (5x200 MW + 2x500 MW) 3
UNCHAHAR, NTPC (2x210 MW) 4
KORBA, NTPC (3x200 MW + 3x500 MW) 5
TALCHER (Kaniha), NTPC (2x500 MW) 6
TALCHER, NTPC (2x110 MW) 7
VINDHYACHAL, NTPC (6x210 MW + 2x500 MW) 8
IB VALLEY, OPGCL (2x210 MW) 9
ROURKELA, NSPCL (2x60 MW) 10
SAIL, Sinter Plant (2 sets)
Total
37 sets
Contd..

28. BHEL Experience in C&I Retrofitting
S.N.
Project 1
KORBA NTPC (3x200 MW) 2
FARAKKA, NTPC (2x500 MW) 3
DADRI, NTPC (4x210 MW) 4
NEYVELI, NLC (4x210 MW)
Total
13 sets

29. R&M/LE Orders Finalized in India
S.N.
Customer
Project
Rating (MW)
Job awarded to 1
AECO
Sabarmati Extn
110
NASL 2
Doosan 3
APGENCO
Kothagudem
BHEL 4 5 6 7
BSEB
Barauni 8 9
CSPGCL
Korba East
120 10
Contd..

30. R&M/LE Orders Finalized in India
S.N.
Customer
Project
Rating (MW)
Job awarded to 11
GSECL
Ukai
120
BHEL 12 13
Gandhinagar 14 15
200
NASL 16
Wanakbori
210 17
HPGCL
Panipat
110 18
JSEB
Patratu 19 20
KBUNL
Muzaffarpur
Contd..

31. R&M/LE Orders Finalized in India
S.N.
Customer
Project
Rating (MW)
Job awarded to 21
KBUNL
Muzaffarpur
110
BHEL 22
MAHAGENCO
Koradi
210 23
MPPCL
Amarkantak Ext.
120
NASL 24 25
PSEB
Bhatinda 26 27 28 29
TANDEDCO
Ennore 30
Contd..

32. R&M/LE Orders Finalized in India
S.N.
Customer
Project
Rating (MW)
Job awarded to 31
TANDEDCO
Ennore
110
SKODA 32
UPRVUNL
Harduaganj
BHEL 33
Obra
200 34
100 35 36 37 38 39 40
WBPDCL
Bandel
210
Doosan