Thermal Project Renovation & Modernisation Division - Brief Description
Chief Engineer:
Chief Engineer:
At the time of Independence, power generating capacity in the country was 1362 MW only. Many new units were installed after Independence. Up to 1980, the total installed capacity of thermal power stations was 14,250 MW which comprised many imported units of sizes from 30 MW to 120 MW. The average Plant Load Factor (PLF) of thermal power stations during 1976-77 was 56%. However, due to various reasons, the PLF gradually started deteriorating as seen from the table given below:
Year | PLF |
---|---|
1976-77 | 55.9% |
1977-78 | 51.4% |
1978-79 | 48.3% |
1979-80 | 44.7% |
1980-81 | 4.6% |
As a result, thermal generation fell short of the targets, leading to a power shortage of about 11%, as compared to the requirement at that time.
A number of efforts were made to improve the operation of the units. Task Forces/Roving Teams consisting of experts from CEA, BHEL and ILK were constituted, which went around various thermal stations with a view to identify the defects/reasons for poor performance and to prepare action plans to address the problems. Based on the reports of Roving Teams, many State Electricity Boards (SEBs) prepared schemes for attending to the problems identified and included them in their annual plans. However, lack of adequate funds with some of the States led to lower priority being given to such programmes though there was an urgent need to attend to the problems of the thermal stations.
The reasons identified for poor performance of thermal stations included the following:
During the early 1970s, it was decided to install bigger units of size 200/210 MW and BHEL started the manufacture of these units. Many such units were installed during 1979-82. Though a large capacity of about 5,000 MW was installed, these units were giving a lot of problems since the beginning and the PLF of these units was as low as 40%. Concerned with this, Stabilisation Teams comprising engineers from CEA, BHEL, ILK and the concerned power utilities were formed. These Stabilisation Teams visited all the stations where 200/210 MW units were installed and identified the problem areas. There were many teething problems and failures due to inherent design defects. These defects were studied and analysed in detail. BHEL and other original equipment manufacturers carried out the required modifications. Most of the modifications were carried out free of cost by the manufacturers on all the existing units irrespective of occurrence of the failure. The modifications were also incorporated for future units. As a result, the performance of these units substantially improved and got stabilised. Because of that efforts, 200/210 MW units are now operating at a level comparable to the of the best in the world. At present, there are about 160 units of 200/210 MW comprising about 44% of the total thermal installed capacity in the country.
(i) | Number of thermal power stations covered | 34 |
(ii) | Number of thermal units covered | 163 |
(iii) | Total capacity involved | 13570 MW |
(iv) | Average PLF of 163 units before R&M programme | 46% |
(v) | Anticipated PLF after completion | 53% |
(vi) | PLF achieved after completion | 56% |
(vii) | Anticipated additional generation after completion of R&M programme | 7000 MU/annum |
(viii) | Actual additional generation achieved after completion of R&M Programme | 10000 MU/annum |
(ix) | Year of completion | 1990-91 |
(x) | Total expenditure incurred | Rs.1066 Crores |
a) Central Loan Assistance | Rs.402 Crores | |
b) State Plan resources | Rs.664 Crores | |
(xi) | Expenditure incurred on environmental activities | 47% |
The details of units covered are given in Annexure-I.
Encouraged with the results of implementation of PHASE-I R&M programme, the PHASE-II R&M programme for 44 thermal power stations in the country was taken up in the year 1990-91 for completion during the 8th Plan period. The CEA prepared the guidelines for preparation of R&M Scheme by SEBs and the Roving Teams constituted for PHASE-II of the programme visited various thermal power stations and assisted SEBs in the formulation of R&M schemes. Power Finance Corporation (PFC) was assigned the responsibility to provide loan assistance to the SEBs for R&M works.
(i) | Number of thermal power stations covered | 44 |
(ii) | Number of thermal units covered | 198 |
(iii) | Total capacity involved | 20870 MW |
(iv) | Expenditure incurred | Rs.862 Crores |
(v) | Anticipated additional generation after completion | 4000 MU/annum |
(vi) | Total additional generation achieved | 5000 MU /annum |
(vii) | Capacity taken up for Life extension Work (Units 1,2,8&9) of Neyveli TPS) | 300 MW |
The details of units covered are given in Annexure-II.
Encouraged with the results of R&M/Life Extension works carried out during 7th and 8th Plan, the 9th Plan R&M Programme was taken up in 127 units at 29 thermal power stations. Most of the R&M activities identified under 9th plan programme have been completed.
The economic deigned life of the thermal power units is considered to be 25 years. 25 nos. of thermal units which had already completed their designed life were planned for LE works based on Residual Life Assessment (RLA) studies during the 9th Plan. The LE works on all the units have now been completed.
Sl.No. | Particulars | R&M | LEP |
---|---|---|---|
(i) | Number of thermal power stations covered | 29 | 7 |
(ii) | Number of thermal units covered | 127 | 25 |
(iii) | Expenditure incurred | Rs.850 Crores | Rs.1560 Crores |
(iv) | Total Capacity involved | 17305 MW | 1685 MW |
(v) | Expected capacity after LEP | - | 1741 MW |
(vi) | Average PLF of the units before R&M/LE programme | 61.5% | 46% |
(vii) | PLF anticipated after completion | 63% | 75% |
(viii) | Anticipated additional generation / annum | 2350 MU | 4600 MU |
(ix) | Actual additional generation achieved | 5100 MU | 4600 MU |
(x) | Units on which LE works completed | - | 25 Units |
The details are given in Annexure-III & IV.
The CEA has identified 106 thermal units in consultation with SEBs/State Generation Corporations for LE during the 10th Plan so as to extend their economical life by another 15-20 years and to recapture /up-rate their capacities by implementing comprehensive R&M schemes based on RLA studies. In addition, another 57 units of 14270 MW capacity which are comparatively new also need some R&M work to sustain/improve their performance.
The salient features of the programme:
Sl.No. | Particulars | |
---|---|---|
(i) | Number of thermal power stations | 32 |
(ii) | Number of thermal units | 106 |
(iii) | Estimated Cost | Rs.9200 Crores |
(iv) | Total Capacity involved | 10413 MW |
(v) | Average PLF of the units before LE programme | 49% |
(vi) | Anticipated PLF after completion | 75% |
(vii) | Anticipated additional generation/ annum | 23700 MU |
(vii) | Capacity expected after completion of LE works | 10747 MW |
The details are given in Annexure-V.
Sl.No. | Particulars | |
---|---|---|
(i) | Number of thermal power stations | 13 |
(ii) | Number of thermal units | 57 |
(iii) | Estimated Cost | Rs.977 Crores |
(iv) | Total Capacity involved | 14270 MW |
The details are given in Annexure-VI.
During the 11th Plan, 53 units with a total capacity 7,318 MW are programmed to be taken up for LE. Another 76 units with a capacity of 18,965 MW would be taken up for R&M.
Sl.No. | Particulars | R&M | LEP |
---|---|---|---|
(i) | Number of thermal power stations | 21 | 23 |
(ii) | Number of thermal units | 76 | 53 |
(iii) | Estimated Cost | Rs.4487 Crores | Rs.12433 Crores |
(iv) | Total capacity involved | 18,965 MW | 7,318 MW |
The details are given in Annexure-VII & VIII.
R&M is not a substitute for regular Operation and Maintenance (O&M) of the plant. There is a need to improve the O&M practices and carry out regular O&M as per schedules to sustain the improvement obtained through R&M. It should be ensured by the SEBs/Power Utilities that adequate and timely O&M funds are made available to the power stations
Ministry of Power in January 2004 issued a comprehensive guidelines for undertaking R&M and LE works in respect of thermal power plants for timely implementation of the entire R&M/LE works identified for completion during 10th Plan period. A copy of the guidelines is given as Annexure-IX