PETITION FOR APPROVAL OF COMPREHENSIVE RENOVATION & MORDERNIZATION WORKS
AT
SGTPS BIRSINGHPUR, UNIT NO. 1 & 2 (2X210 MW)
Petition for Approval of R&M works at Unit No. 1&2, SGTPS, Birsinghpur April, 2017
INDEX
S.No. PARTICULARS Page No.
1. PETITION 3 - 42
2. PRAYER 43
3. AFFIDAVIT 44 - 45
4. AUTHORISATION 46
5. MPERC Fee Details 47
6. LIST & ANNEXURES 48 - 68
M.P. Power Generating Co. Ltd Page 2 Petition for Approval of R&M works at Unit No. 1&2, SGTPS, Birsinghpur April, 2017
BEFORE THE M.P. ELECTRICITY REGULATORY COMMISSION BHOPAL
Petition No of 2017
IN THE MATTER OF
Petition for approval of Renovation & Modernization Works at SGTPS Birsinghpur, Unit 1&2 (2x210MW), under proviso 21 of MPERC (Terms And Conditions For Determination of Generation Tariff) Regulations, 2015 {RG-26 (III) of 2015}
PETITIONER M.P. Power Generating Company Ltd, Jabalpur.
Vs
RESPONDENT M.P. Power Management Company Ltd, Jabalpur.
The above named Petitioner, M.P. Power Generating Company Ltd (MPPGCL) respectfully submits as under:-
1. The petitioner is wholly owned company of Government of M.P engaged in generation of electricity in the State of Madhya Pradesh. It is a successor entity of erstwhile Madhya Pradesh State Electricity Board (MPSEB).
2. The Company has been incorporated as part of implementation of the power sector reform in M.P., initiated by the Government of MP. The Company has taken over the generation activities of MPSEB. The company while operating and maintaining its existing Units and is also constructing new power plants for increasing generating capacity in the State of Madhya Pradesh. The Company is registered under Companies Act 1956 and was incorporated on 22.11.2001. Its registered office is at Shakti Bhawan, Rampur, Jabalpur.
3. The activities of Generation, Transmission and Distribution have been looked after earlier in the State of M.P. by the integrated utility i.e.
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MPSEB constituted under Section 5 of Electricity (Supply) Act 1948. The Government of MP enacted M.P. Vidyut Sudhar Adhiniyam 2000 and in the spirit of said Act, the unbundling process of the MPSEB was initiated by registering the following five Companies;
(i) Madhya Pradesh Power Generating Co. Ltd., Jabalpur (MPPGCL) (GENCO). (ii). Madhya Pradesh Power Transmission Co. Ltd., Jabalpur (MPPTCL) (TRANSCO). (iii). Madhya Pradesh Poorva Kshetra Vidyut Vitaran Company Ltd. Jabalpur (MPPKVVCL) (EAST DISCOM). (iv). Madhya Pradesh Madhya Kshetra Vidyut Vitaran Company Ltd. Bhopal. (MPMKVVCL) (CENTRAL DISCOM). (v). Madhya Pradesh Paschim Kshetra Vidyut Vitaran Company Ltd. Indore (MPPKVVCL) (WEST DISCOM).
4. The above mentioned five companies which were registered in November 2001 entered into Operation & Management Agreement with MPSEB and they worked as agent of MPSEB from July 2002 to May 2005. The companies started independent functioning w.e.f. 01.06.2005 under Cash flow mechanism as per order dated 31.05.2005 of State Government.
5. A sixth Company, namely MP Power Trading Company Ltd, was incorporated as per the State Government’s Notification dated 03.06.2006 specifying the functions of TRADECO for purchase of electricity in bulk from Generating companies /Traders, from within & outside the State and to supply electricity in bulk to the Electricity Distribution Companies in the State of Madhya Pradesh.
6. GoMP vide letter No. 6074/13/12/02 dated 29.03.2012 has changed the name of M.P. Power Trading Co. Ltd. to M.P. Power Management Company Limited. It has been made the holding company for all the DISCOMS of M.P. Further, GoMP, vide its Notification dated 26.04.2012, has merged M.P. State Electricity Board with M.P. Power Management Company Limited.
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7. MPPMCL and the three DISCOMS of MP have entered into a management and corporate functions agreement on 05.06.2012, whereby the three DISCOMS have engaged MPPMCL to represent them in all the proceedings relating to power procurement and tariff petitions filed or to be defended before CERC, MPERC and other regulatory authorities, Appellate Tribunals, High Courts, Supreme Court and CEA etc.. Therefore the three DISCOMS have not been made as respondents, separately.
8. GoMP vide its notification dated 03.06.2006 has provided that MP Tradeco, now MP Power Management Company Ltd., shall purchase entire power from the Genco (MPPGCL) at the tariff to be determined by MPERC.
9. MPPGCL entered into Power Purchase Agreement (PPA) with MP Tradeco (now M.P.P.M.C.L.) on 29.11.2006. The PPA provides that the tariff payable by Tradeco to Genco and terms & conditions related thereto shall be as determined by the State Commission. MPPGCL has therefore raised the bills of energy sold to Tradeco since 1.6.2005 as per the tariff determined by Hon’ble Commission from time to time.
10. MPPGCL is having various Thermal and Hydro power stations/projects in the state of Madhya Pradesh. Sanjay Gandhi Thermal Power Station (SGTPS) is one such power station of the Petitioner located at Birsinghpur, Dist Umaria, Madhya Pradesh.
11. SGTPS, Birsinghpur is located 10 Km from Birsinghpur-Pali Railway station situated on Bilaspur-Katni section under SECRLY. It has the Thermal capacity of 1320MW detailed as under :-
Power Unit Capacity Age Make of Make of CoD House No. in MW in Years TG Set Boiler 1 210 26-Mar-93 24 BHEL ABL PH-1 2 210 27-Mar-94 23 BHEL ABL 3 210 28-Feb-99 18 BHEL ABL PH-2 4 210 23-Nov-99 17 BHEL ABL PH-3 5 500 28-Aug-08 08 BHEL BHEL Total 1340
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12. As evident from the above table, Unit No. 1 & 2 has almost completed 24 & 23 years of its useful life, respectively. 13. The operating parameter wise past performance of the units are detailed as under:- SGTPS Birsinghpur Unit # 1&2 (2 x 210 MW) Financial PLF PAF Aux. Cons Sp Oil Con Heat Rate Year % % % ml/kWh kCal/kWh 2006-07 68.27% 74.13% 10.95% 1.84 3098 2007-08 64.31% 59.13% 10.19% 1.14 3156 2008-09 60.75% 68.46% 10.06% 1.38 3247 2009-10 51.44% 58.44% 11.22% 1.79 3390 2010-11 51.94% 53.96% 11.45% 2.99 3101 2011-12 55.22% 64.17% 10.19% 2.50 2990 2012-13 70.72% 72.24% 9.88% 1.80 3052 2013-14 62.41% 74.86% 10.11% 1.37 3025 2014-15 48.37% 58.34% 10.82% 1.78 3043 2015-16 47.53% 72.30% 10.38% 0.93 2853 2016-17 42.71% 74.46% 10.08% 1.20 2856
14. As per clause 2.3 of Article 2,”Scope of the Agreement” of the Power Purchase Agreement (PPA) (Annexure-1) with MPTRADECO now MPPMCL, MPPGCL has to take steps to renovate, modernize, refurbish, expand and augment capacity in the existing Generating Stations and projects under construction subject to additional capitalization approved by the State Commission, duly informed to MP Tradeco and such additional capitalization shall be included in the capital cost of the Generating Station. 15. The Energy Department, Government of MP, vide letter No.AF-3- 20/2014/13 Dated 28.01.2017 (Annexure-2) has extended the term period of above Power Purchase Agreement upto Retirement / De- Commissioning of Units. The MPPMCL has also intimated the same to MPPGCL vide letter No 04-01/128 dated 01.02.2017(Annexure-3).
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16. Brief Description of PH-1 & 2 SGTPS Birsinghpur. M/s ABL and M/s BHEL are the Original Equipment Manufacturers (OEMs) for the Boiler and Turbo-Generator of PH- 1 & 2 of SGTPS Birsinghpur. The boiler is provided with front & rear firing system. Condenser cooling system of the unit is designed on once through cooling system. Power generated from the unit is being supplied to the State grid. Power is being evacuated at 220KV. The primary fuel is domestic coal sourced from South Eastern Coal Fields Limited. The consumptive water for the power plant is being sourced from Johila Dam. The other details are as under:-
S.No Feature Details 10 K.M. from Birsinghpur Railway Station 1 Location situated on Bilaspur Katni Section of S.E. Rly. PH-1 (2x210MW), PH-2 (2x210MW) 2 Capacity of Power Station & PH-3 (500MW) Johila Dam, Area- 1810 Hectare on Johila 3 Source of Water River 4 Dam Capacity 171 Million Cubic Meter Primary Fuel:- Coal 5 Fuel Secondary Fuel :- Furnace Oil/Light Diesel Oil 6 Coal Source South Eastern Coal Field Limited 7 Coal Area Korea- Rewa Area & Korba Area. 8 Mode of Transport Rail 9 Coal Linkage 63.60 LMT( Approx.) per annum(2007-08) Birsinghpur,Rewa,Satna Power Evacuation 200 KV 10 Birsinghpur, Katni(2) Line Birsinghpur, Amarkantak(2)
19. EQUIPMENT DETAILS:
19.1. BOILER & AUXILIARIES (a) BOILER - Manufacturer: ACC-BABCOCK Limited (ABL):-
Boiler Type: Opposed fired, Balanced Draft, Natural Circulation, Radiant with two passes, Re heater type, Dry Bottom, Furnace pulverized coal fired boiler.
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The design parameters are as under:-
Design Description Units Parameters Steam Flow at Final SH outlet T / hr 680 Steam Pressure at SH outlet kg/cm2 156.6 Steam Temperature at SH outlet 0C 540 Re-heater Steam inlet Pressure kg/cm2 39.04 Re-heater Steam inlet Temperature 0C 345 Steam Pressure at RH outlet kg/cm2 37.07 Steam Temperature at RH outlet 0C 540 Feed Water Temperature at inlet of 0 C 245 Economiser Feed Water Temperature at outlet of 0 C 277 Economiser.
(b) FURNACE:- The boiler is equipped with a water cooled furnace of balanced draft and fusion welded membrane wall construction. It is equipped with twenty four (24) numbers of coal burners and twenty four (24) Nos. of light oil burners and four (4) Nos. of load carrying burners. The size of furnace is as under:-
Description Units Design Parameters Type - Membrane Walls of water cooled Width metre 15.85 Depth metre 10.058 Volume Cu. metre 4763
(c) FUEL BURNING EQUIPMENT:- The boiler is working on a direct firing system. The pulverized coal is being dried and transported to the coal burners by means of hot primary air supplied by primary air fans. The boiler is having front and rear firing system.
Description Units Design Parameters No. of PF Burners Nos. 24 No. of Light up oil Burners Nos. 24 Load carrying Oil Burners Nos. 4
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(d) CHARACTERISTICS OF DESIGNED FUEL:-
Design Description Units Parameters Fixed Carbon % 29.7 Volatile Matters % 24.03 Moisture % 8.0 Ash % 38.8 GCV Kcal/Kg 3750 Grind ability Hard Groove Index 50
(e) SUPER HEATER (HEATING SURFACE):- The super heaters are composed of three sections, Primary, Platen section and Final super heater. The sizes are as under:-
Design Description Units Parameters Primary Super Heater - - a. Horizontal Bottom Bank M2 1919 b. Horizontal intermediate Bank M2 1328 c. Horizontal Top Bank M2 1743 d. Vertical Section M2 307 Platen Super heater M2 82.1 Final Super heater M2 1530
(f) REHEATER /EFFECTIVE HEATING SURFACE:-
The sizes are as under:-
Design Description Units Parameters Horizontal Bottom Bank & Intermediate M2 3374 Bank Horizontal Top Bank M2 1737 Vertical Leg M2 307 Re-heater Pendent above Primary Super M2 608 heater horizontal bank
(g) RAW COAL BUNKERS:- The boiler is provided with six (6) raw coal bunkers. The total capacity of the bunkers is to meet 8 hour’s requirement at maximum mills capacity of the unit. The conical portion is also having lining of stainless steel. Each outlet of the bunker is
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provided with an isolation gate which is motor operated. In addition to the isolation gates, rod gates have been provided to control the flow of coal from the bunkers.
(h) COAL MILLS:- The unit is provided with six (6) numbers of coal mills. The rated capacity of each mill is 27.4 T/hr. The other parameters are as under:-
Design Description Units Parameters Type 8.5 E9 Make ABL Capacity TPH 27.4 Motor KW KW 225 System - Pressurised
(i) ATTEMPERATORS:-
The relevant parameters are as under:-
Design Description Units Parameters Type Spray Type No. of Stages Nos. 2 Medium of Spray - Feed water
(j) ECONOMISER:-
The relevant parameters are as under:-
Description Units Design Parameters
Type Continuous Loop Type
No. of Sections Nos. 2
(k) AIR PRE-HEATER :- The air pre-heater is of tube type.
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(l) COAL FEEDERS :- Chain link type of raw coal feeder has been provided for each coal mill.
(m) PRIMARY AIR FANS:- Six Primary Air (PA) Fans have been provided for each boiler. Each PA Fan is designed to meet 60% MCR condition of the boiler. Details are given below:
Design Description Units Parameters Type of Fans - BAB11 Number of fans per boiler Nos. 6 Capacity m3/sec 22.7 Discharge Pressure mmwg 1216 Temperature of Hot Air 0C 263 Motor Rating kW 390 Method of Regulation - Axial Vane Control
(n) FORCED DRAFT FANS:- Two Forced Draft (FD) Fans have been provided for each boiler. Each FD Fan is designed to meet 60% MCR condition of the boiler. The FD Fans supply combustion air to the boiler, mill air through PA Fans and tempering air to control the classifier temperature of the mills. Details are given below:
Description Units Design Parameters Centrifugal double inlet, Type of Fans - backward aerofoil bladed Number of fans per boiler Nos. 2 Capacity m3/sec 130 Discharge Pressure mmwg 470 Temperature of Air 0C 49 Motor Rating kW 775 Method of Regulation - Vane control
(o) INDUCED DRAFT FANS :- Two Induced Draft (ID) Fans have been provided for each boiler. Each ID Fan is designed to meet 60% MCR condition of the boiler. Each ID Fan evacuates flue gases through parallel paths
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of ESP and discharges them into stack through ducting. Details are given below:
Description Units Design Parameters Centrifugal, double inlet Type of Fans - backward aerofoil bladed Number of Fans per Boiler Nos. 2 Capacity m3/sec 209.8 Discharge Pressure mmwg 350 Temperature of Flue Gases 0C 160 Motor Rating kW 988 Variable Speed Hydraulic Method of Regulation coupling
(p) WALL BLOWERS AND LONG RETRACTABLE SOOT BLOWERS (LRSBS):- As per original design, Wall and Long Retractable Soot Blowers (LRSBs) are available but not being used since commissioning for cleaning the soot deposited on the heating surfaces of the water walls and super heaters respectively. Manual soot blowing system has been provided. The other features are as under:-
Design Description Units Parameters Wall Blowers (Available but not in service) Diamond IR 2D Make and Model of Wall Blowers - single nozzle short retractable No. of Wall Blowers per boiler at water Nos. 26 walls Medium of soot blowing at water walls - Steam LRSBs Diamond Power Make and Model of LRSBs - 1K-300 LR No. of LRSBs per boiler at pendant Nos. 28 surfaces of pressure parts Medium of soot blowing at pendant - Steam surfaces of pressure parts No. of LRSBs per boiler at convection pass Nos. 4 tube banks Medium of soot blowing at convection pass - Steam tube banks
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(q) ESP :- Electrostatic Precipitator (ESP) has been installed on the cold end side of the Air Pre-heater to remove the particulate matter from the flue gases. The ESP has been provided with Gas Distribution System, Collecting Electrodes, Discharge Electrodes, Transformer Rectifier Sets and rapping system. Details are given below:
Design Description Units Parameters ACC-Vickers- Make and Model of ESP - Babcock Ltd. Number of fields per pass Nos. 6 Number of Hoppers per ESP Nos. 18 Dust concentration at outlet mg/Nm3 50 Type of Control Analog Gas Velocity in ESP m/sec 1.05 Storage Capacity of ESP Hoppers hrs 8
19.2. TURBINE & AUXILIARIES:-
(a) STEAM TURBINE :- The steam turbine is of three cylinder, 3000 rpm, tandem compound, condensing type designed to operate on a re-heat and re-generative feed water cycle. The turbine is provided with HP/LP bypass system of 60% capacity of Boiler MCR. The turbine is provided with an electro - hydraulic control system, automatic turbine run up system and turbo supervisory instrumentation. The condensing system consists of a surface condenser of single shell and two pass, divided water box construction. Cooling water being supplied to the condenser is of raw water/ clarified water quality. The design parameters of the steam turbine are furnished below:
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Design Description Units Parameters Pressure of Steam at inlet of ESV of HPT kg/cm2 150
Temperature of Steam at inlet of ESV of 0 C 535 HPT Pressure of Cold Reheat (CRH) Steam kg/cm2 38.1 Temperature of Cold Reheat (CRH) Steam 0C 334.8 Pressure of Hot Reheat (HRH) Steam kg/cm2 34.3 Temperature of Hot Reheat (HRH) Steam 0C 535 Pressure at the inlet of LP Turbine kg/cm2 7.1 Temperature at the inlet of LP Turbine 0C 315.1
(b) CONDENSER:- The condenser is a double pass, horizontal, surface type with integral air cooling section designed to maintain a pressure of 76 mm of Hg at turbine exhaust with a cooling water temperature of 33 deg C and an outlet temp of 41.33 deg C. The condenser is capable of operation with 5% tubes plugged and has hot well storage capacity of 27.5 m3.
Description Units Design Parameters Water Cooled Surface Type of Condenser - Condenser Total Cooling Surface m2 9656 Number of Cooling Water Tubes Nos. 19208 Material of Tubes - 90-10 Cu Ni Diameter and thickness of tubes mm 25.4 X 1.245 Cooling Water Quantity through Condenser m3/h 28500
Cooling Water Temperature at the inlet to 0 C 33 Condenser Condenser Vacuum mm Hg 76
(c) EJECTORS :- The Condenser is provided with one quick starting ejector to remove large volumes of air for raising the initial vacuum during the starting of the Unit. Two main ejectors of 100% capacity each have been provided to remove air and non condensable gases from the condenser to maintain the required vacuum in the condenser during the normal operation of the unit.
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(d) CONDENSATE EXTRACTION PUMPS:- Two (2) Nos. Condensate extraction pumps are of vertical, multistage, centrifugal and canister type with following design parameters:-
Description Units Design Parameters Make and Model - Weir/En5540 D - 30 A Vertical, Multistage, Type - Centrifugal, Canister type Capacity TPH 625 TDH Mlc 201 Speed RPM 1480 Motor Rating kW 500
(e) GLAND STEAM CONDENSER:- A Gland Steam Condenser has been provided to condensate the leak-off steam from intermediate chambers of end sealing of HP and IP turbine, thereby heating the main condensate water. The Gland Steam Cooler consists of shell, tube bundle and removable water box.
(f) LP HEATERS AND DRAIN COOLERS:- Steam turbine is provided with three numbers of low pressure heaters to increase the temperature of the condensate in stages. LP Heaters are of shell and tube design and have been placed vertically. An integral drain cooling section is provided in each LP Heater. The design details of LP Heaters are furnished in the table below:-
Heater No. 1 2 3 Extraction Steam taken from LP Turbine LP Turbine LP Turbine Bled Steam Pressure (Bara) 0.216 0.858 2.37 Bled Steam Temperature (deg C) 62 107 200
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(g) DEAERATOR:- The deaerator is of horizontal spray type. It is designed to remove dissolved oxygen from the condensate in excess of 0.005 cc per liter. The feed water storage tank has a capacity of 125m3.
(h) BOILER FEED PUMPS:- The boiler feed pumps are horizontal, multi stage centrifugal pumps of barrel type, motor driven with hydraulic coupling taking the suction from the deaerator. The boiler feed pumps discharge feed water through HP heaters to the economizer of the boiler. The other parameters are as under:-
Design Description Units Parameters BHEL/200 KHI- Make and Model - 18/6 No of stages Nos. 6 Capacity TPH 395 Head mwc 2095 Feed water temp 0C 163.36 Minimum flow TPH 100 Method of Speed Regulation - Hydraulic Coupling Pump Input shaft Power kW 2985
(i) HP HEATERS :- Steam turbine is provided with two numbers of high pressure heaters to increase the temperature of the feed water in stages. The Heaters are of shell and tube design and have been placed vertically. The design details of HP Heaters are furnished in the table below.
Heater No. HPH-5 HPH-6 IP turbine HP turbine Extraction Steam taken from extraction exhaust Bled Steam Pressure (kg/cm2) 16.03 36.52 Bled Steam Temperature (deg C) 240 290
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(j) HP/ LP BYPASS:- HP/LP bypass system has a capacity of 60% of BMCR (Boiler Maximum Continuous Rating). HP bypass system has been provided between the Main Steam Line and Cold Reheat Line. LP bypass system has been provided between the Hot Reheat Line and the Condenser. HP bypass water spray has been taken from the discharge of Boiler Feed Pumps. LP bypass water spray has been provided from the discharge of Condensate Extraction Pumps.
(k) TURBINE GOVERNING SYSTEM :- The turbine is equipped with an electro-hydraulic system (with a back of hydro mechanical system) of automatic governing for the smooth and stable operation of turbo-set under all conditions of operation. The system is designed to sustain full load dump from the generator. The system is provided with a quick closing Emergency Stop Valve (ESV), to interrupt the supply of steam from the boiler and stop the turbine under emergency conditions.
19.3. ELECTRICAL SYSTEM
(a) GENERATOR:-
The Generator is a 15.75 kV, 50 Hz, 0.85 power factor machine, directly coupled with steam turbine operating at 3000 rpm, with static type of excitation system and digital programmable voltage regulator. The Generator has direct water cooled stator winding and direct hydrogen cooled rotor winding. The stator winding cooling water is cooled in a closed cycle cooling system using DM water, while the hydrogen in the machine is cooled in gas to water hydrogen coolers mounted inside the machine. The Parameters of the Generator are briefly mentioned below:-
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Design Description Units Parameters Rated MW Capacity MW 210 Rated MVA Capacity MVA 247 Rated Terminal Voltage KV 15.75 Rated Power Factor - 0.85 Rated Stator Current A 9050 Rated Speed RPM 3000 Rated Frequency Hz 50 Efficiency at Rated Power Output and % 98.55 Rated Power Factor Excitation Current A 260 Excitation Voltage at Rated Power Output V 310 and Rated Power Factor Short Circuit Ratio - 0.49 Negative Sequence Current Amp 22 Phase Connection - Double star Type of Excitation - Static Method of Cooling the Rotor - Hydrogen Method of Cooling the Stator - Water Rated Hydrogen Pressure kg/cm2 3.5
(b) STATION TRANSFORMER :-
One Station Transformers have been provided to meet the station auxiliary loads of the power plant. The Station Transformers have been provided with on-load tap changers to keep the station 6.6 kV voltage constant. Cooling of this transformer is ONAN/ONAF/OFAF and has 2x50 % separately mounted radiators and 2x50% oil pumps. The Parameters of the Station Transformers are briefly mentioned below:-
Design Description Units Parameters Crompton Make - Greaves Capacity / Rating MVA 30/40 Voltage Ratio - 220/6.9 KV Type of Cooling - ONAN/ONAF Quantity Nos. 1
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(c) GENERATOR TRANSFORMER:-
The power output from each Generator is being stepped up to 220 kV through a 250 MVA step up Generator Transformer. It has 2x50% coolers and 2x50% oil pumps. The Parameters of the Generator Transformer are briefly mentioned below
Design Description Units Parameters Make - Telk Capacity MVA 250 Voltage Ratio - 15.75/240 Type of Cooling - ONAN/ONAF/OFAF
(d) UNIT AUXILIARY TRANSFORMER :-
Unit auxiliary transformers have been provided for meeting all unit auxiliary loads. The transformers are provided with on-load tap changers. The Parameters of unit auxiliary transformers are briefly mentioned below:-
Design Description Units Parameters Make - Volt amp Capacity MVA 16 Voltage Ratio - 15.75/6.9 Type of Cooling - ONAN/ONAF Quantity Nos. 2
(e) ELECTRICAL AUXILIARY POWER DISTRIBUTION SYSTEM :-
Unit auxiliaries receive their normal power supplies at 6.6 kV through two unit transformer. For lower rating drives, 6.6 kV is further stepped down to 415 V by two (2) nos. unit service transformers. The 415 V distribution systems feed a number of Motor Control Centers (MCCs) for running 415 V drives. 6.6 kV unit switchgears are connected to station switchgear for start up and emergency power supply.
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(f) CONTROL & INSTRUMENTATION:-
The existing control system consists of Centum XL Control system of Yokogawa make. The Turbine Control; monitoring & protection system including ATRS, TSE, ATT etc. is based on analog discrete cards as supplied by BHEL. The Boiler Protection & BMS is Allen Bradley PLC 2-17 based system.
19.4. BALANCE OF PLANT (BOP)
(a) COAL HANDLING PLANT :- Coal Handling Plant is a common facility which is feeding all the units of the power plant having a total installed capacity of 2X210 MW. Coal is brought through railways by wagons and is unloaded by track hoppers. One crusher has been provided for crushing the coal from 200 mm size to 20 mm size. The plant is provided with one stacker re-claimer to stock the crushed coal. The coal stock yard has a storage capacity of 20 days. For feeding the coal to the bunkers of all the units, two streams of conveyors having a capacity of 1500 TPH have been provided. The coal handling plant operates for 16 hrs a day. The other parameters are as under:-
Design Description Units Parameters Length of Track Hopper M 170 No. of streams of conveyor Nos. 2 Capacity of each conveyor T/hr 1500 Type of Crushers - Ring Granulator Number of Crushers Nos. 4 Capacity of Crushers T/ hr 600 No. of Stacker Re-claimer Nos. 1 Stacking Capacity TPH 1500 Reclaiming Capacity TPH 1500 Storage Capacity of Stock Yard days 20
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(b) ASH HANDLING PLANT :- Ash Handling System is of continuous type. The bottom ash from the furnace falls into bottom ash hopper having a storage capacity of 160 Tons. The ash is removed with the help of submerged Scrapper Chain Conveyors. The ash from the air pre- heater and economizer hoppers is being disposed off along with bottom ash. The ash in the form of ash slurry is conveyed through sluice channels to the ash slurry pump house with the help of high pressure jets, from where, it is pumped to the ash pond located at a distance of 2.5 KM. The ash slurry pump house is provided with 8 numbers of ash slurry pumps of rating 630 m3 /hr, out of which 4 pumps are normally working. The ash slurry disposal system is having 4 numbers of identical streams of ash slurry pumps connected to two (2) numbers of ash slurry pipelines going to the ash pond. Fly ash is collected in dry form below the ESP hoppers and the same is then conveyed by vacuum system to surge hoppers from where it is either conveyed through pressurized system to dry fly ash silos or is sent to ash pond in the form of slurry. From the dry fly ash silos, the ash is disposed off through the covered trucks.
(c) RAW WATER SYSTEM :- The consumptive water for the plant is sourced from Johila dam made on Johila River. The intake water pump house is installed with 4 nos. intake pumps of capacity 400 m3/hr, out of which 2 pumps are normally working and the remaining 2 pumps are on standby.
(d) CW / ACW SYSTEM :- CW system works on once through cooling system. CW pump house is a common facility for both the units of the power plant. There are three CW pumps of capacity 10,000 m3/hr provided for each unit. One common CW pump is standby for both the
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units. Three (3) Nos. ACW pumps of capacity 3000 m3/hr are provided for both the units.
(e) WATER PRE-TREATMENT PLANT :- Water Pre-Treatment Plant is a common facility for both the units of the power plant. Pretreatment plant supplies clarified water to DM plant, cooling water to the auxiliaries of BOP system, coal handling plant dust suppression and to the drinking water system. There are two numbers of clarifiers of capacity 900 m3/hr to meet all the clarified water requirements of the whole plant, except DM Plant.
(f) DM PLANT :- DM plant consists of three streams, each of 60 m3/hr capacity. A common regeneration system has been provided for all the three streams. There are three DM water storage tanks common for both units of 7.5 m (dia.) X 12 m (height).
(g) PLANT AND INSTRUMENT AIR SYSTEM :- Plant and instrument air system is a common facility for both the units of the plant. For meeting requirement of instrument air , 5 number of reciprocating compressors (2 working and 3 standby), each of 18 m3/min capacity and discharge pressure of 8 kg/cm2 have been provided along with dryers for each unit. The air drying plant for the instrument air has been provided to achieve a dew point of (-) 40 deg C at atmospheric pressure.
(h) FUEL OIL SYSTEM :- The fuel oil system has been designed for the use of LSHS but at present HFO is being used. Three tanks of 2500 m3 each have been provided for the storage of LSHS and two tanks of 1000 m3 each have been provided for the storage of LDO. The system has been provided with unloading, transferring and pressurization pumps along with necessary filters. Fuel oil system has been provided with heat tracing.
M.P. Power Generating Co. Ltd Page 22 Petition for Approval of R&M works at Unit No. 1&2, SGTPS, Birsinghpur April, 2017
20. Efforts made by MPPGCL
Due to the lower availability, higher Auxiliary consumption and excess Secondary Oil consumption and increased Station Heat Rates, the Units of SGTPS PH-1 are incurring commercial losses. Efforts have been made by MPPGCL to improve upon the loss by the way of improvement in O&M practices, yet the performance is not as per MPERC norms. Further improvement in these Units requires Capital Expenditure. Hon’ble MPERC has specified procedure, wherein a proper study is to be conducted through expert agency and a proposal then to be submitted before Hon’ble MPERC for seeking permission for Renovation and Modernization of the unit.
Accordingly, an order was placed on M/S TŰV-SŰD South Asia Pvt. Ltd, Pune to carry out Residual Life Assessment (RLA) and CA studies of Unit 1 & 2 SGTPS Birsinghpur and to submit Details Project Reports (DPRs) in accordance with the Guidelines for Renovation and Modernizations /Life Extension Works of Coal/Lignite based Thermal Power Stations issued by Hon’ble Central Electricity Authority, New Delhi in October 2009. The copy of the CEA’s Guidelines is enclosed as Annexure-4.
Consequently, the DPR’s has been prepared by M/S TŰV-SŰD South Asia Pvt. Ltd, after carrying out intensive Residual Life Assessment of the Units. The copy of the Details Project Reports is enclosed as Annexure-5A & 5B.
21. Works suggested in Detailed Project Reports:- The consultant M/S TŰV-SŰD South Asia Pvt. Ltd, Pune has suggested following two options in the DPRs for Renovation & Modernization:- (a) Option-I :- It involves broadly replacement of Boiler Re- heater Banks, Refurbishment of Boiler & BoP auxiliaries /
M.P. Power Generating Co. Ltd Page 23 Petition for Approval of R&M works at Unit No. 1&2, SGTPS, Birsinghpur April, 2017
equipments, Overhauling of Turbine and its auxiliaries and Electrical, C&I works.
(b) Option-II: - It involves broadly replacement of Boiler Re- heater Banks, Refurbishment of Boiler & BoP auxiliaries /equipments, Retrofitting of Turbine with complete replacement of HP, IP & LP Modules of latest and more efficient technology, Overhauling of Turbine and its auxiliaries and Electrical, C&I works. The details of above mentioned two options are well elaborated in the annexed unit wise DPRs.
22. Approval of Competent Authority for the said R&M Works:- Based on the recommendation made by the M/S TŰV-SŰD South Asia Pvt. Ltd, Pune in Chapter-10 of DPRs, MPPGCL has opted for the OPTION-II. The administrative approval for the same has been provided by Board of Directors of MPPGCL in the 87th meeting held on 28.12.2016. The copy of BoD resolution granting approval is annexed as Annexure-6A. Further, MPPGCL has approached CEA vide letter No. 07- 09/MPPGCL/R&M/SGTPS/217 dated 10.02.2017 for seeking necessary approval of above mentioned R&M/LE works for execution during the 13th Plan Period. The copy of letter is annexed as Annexure- 6B.
23. Conclusion of the studies carried out in Unit No.1 (210MW) On the comparison of actual operating data captured during various tests with design data, following has been concluded:- a) HP Turbine efficiency at design condition works out to be 86.84%. Actual HP Turbine efficiency is 86.52%. Though actual is very close to design, design efficiency is lower compared to latest available modern turbine in which cylinder efficiency up to 88% - 90% is achievable. In view of above, changing HP module with high efficiency module will result into improved turbine cycle heat rate.
M.P. Power Generating Co. Ltd Page 24 Petition for Approval of R&M works at Unit No. 1&2, SGTPS, Birsinghpur April, 2017
b) IP Turbine efficiency at design condition is 90.80% whereas actual efficiency is 83.53%. IP Turbine efficiency restoration up to 7% may not be possible by overhaul only. In view of this, it is suggested to change the IP Module with high efficiency module. c) Superheater & Reheater Spray: It is noted that superheater and reheater spray has increased substantially. This increase may be because of:- (i) Fouled condition of furnace. (ii) Less heat pick-up in furnace zone due to non operation of soot blowers. (iii) High flue gas exit temperature. (iv) High superheater and reheater spray. (v) Higher superheater and reheater spray is resulting into degradation in turbine cycle heat rate also. d) Condenser vacuum is not close to design value due to poor performance of the ejector system. Condenser is also suffering from tubes fouling and plugging of tubes. Increase in condenser CW line DP (0.41 kg/cm2) indicates the tubes plugging and fouling. e) HPH-6 performance can be considered as satisfactory and no need any immediate corrective action. HPH-5 performance is satisfactory in all three zones.
24. In view of above, to generate electricity economically and to improve reliability, R&M works of critical nature were urgently required to be implemented in these Units so as to improve their performance to satisfactory levels.
M.P. Power Generating Co. Ltd Page 25 Petition for Approval of R&M works at Unit No. 1&2, SGTPS, Birsinghpur April, 2017
25. Scope of work (Unit No. 1 SGTPS, Birsinghpur) The detailed Scope of Works at Unit No. 1 along with its estimated cost has been worked out, which are detailed below:-
Boiler and Auxiliaries - Unit No. 1 SGTPS
S. Prices R&M Works to be carried out Qty No. (Rs Crores)
A BOILER (PRESSURE PART)
Re-insulation work after replacement/repairing wherever required of 1 following components:
1.1 Boiler Drum & Root Valves Pipings
1.2 Water wall bottom ring headers including 1st pass
1.3 boiler Feed Water & Down-comer piping
1.4 Attemperator headers & Pipings 100% 4.60 1.5 Reheater outlet header
1.6 Main Steam Pipe (LHS, RHS) & BAS Line Pipings
1.7 Cold Reheat and Hot Reheat Piping
1.8 All Super Heaters Headers inside pent house
1.9 Eco Hoppers, Fans, Coal mills, Wind box etc.
1.10 Pent House
Replacement/Re-paring of Pent house casing including header Boxes Canopy of top Burner floor by 3/15mm HR sheet 2 100% 5.30 Canopy of top Burner Floor by 3/15mm HR Sheet
Complete replacement of all refractory, Refurbishment of skin casing, insulation & cladding of Boiler 2nd Pass. 3 100% 2.50 Refurbishment of Dead Chambers at Goose Neck Plat forms & Railing at different elevation at rear side of boiler 2nd Pass as per site requirement. Complete replacement of Hangers and Supports for MS, HRH and CRH 4 100% 3.00 Piping along with Coal pipe hangers. Replacement of Horizontal Reheater (Top, Middle, Bottom) & Pendent 5 Reheater coils with provision of additional metal temperature measurement 100% 22.00 instruments for the outlet section to enable proper monitoring
Replacement of Complete Economizer Side wall (LHS & RHS) header to 6 100% 2.00 header
Replacement of CBD & EBD including all drain and vent pipes along with 7 100% 0.50 insulation and motorised valves & actuators
M.P. Power Generating Co. Ltd Page 26 Petition for Approval of R&M works at Unit No. 1&2, SGTPS, Birsinghpur April, 2017
Boiler and Auxiliaries - Unit No. 1 SGTPS
S. Prices R&M Works to be carried out Qty No. (Rs Crores)
Replacement of 11 nos. Safety valves along with silencer/Muffler and all 8 drain & vents with new insulation materials (Drum:3 nos., BAS: 2 nos., 1100% 1.50 TAS: 2 nos. HP Heaters: 2 nos.& MS: 2nos.)
Replacement of BAS/TAS control valves including Full Load & Low Load 9 400% 0.70 Lines (4 nos.)
Replacement of motorized valves & actuators, Critical valves like Attemperation spray control valves, Sampling valves & Manual isolating 10 valves which are damaged or not having the sufficient lapping space Lump-sum 2.30
(Approx. 48 Nos.) Including replacement of spray nozzles.
Replacement of Dipper plates along with seal trough as well as Z shaped 11 100% 1.00 Liner in side Bottom Ash Hopper
Erosion Shield for S panels & Goose neck of SS-310 materials (OR Coating). 12 100% 5.00 Cassette Baffles for Eco & Primary SH Bends of SS-304 and replacement of distorted Water Wall at rear side
Replacement of Baffle wall and cage rear wall from bottom (near to 13 100% 4.00 economizer) to pent house
B BOILER (NON PRESSURE PART) Replacement/Repairing of Flue duct from Eco to APH, APH to ESP and ESP to chimney along with re-insulation work after replacement/ repairing wherever required. 1 100% 13.00 Replacement of all expansion Joints in Flue and Hot air ducts. Repairing of Air duct-15 T. Replacement of existing drag chain system raw coal feeders with gravimetric feeders having variable speed digital drives for efficiency 2 improvement & statutory requirements and replacement of chute from coal 600% 7.00 feeders to mills with SS material along with expansion joint and coupling suitable for new gravimetric feeders wherever required
Replacement of old repaired gear boxes of Coal Mills with Planetary gear 3 700% 10.00 boxes
Replacement of new modified ignition systems (Ignitor/scanner) along with 4 replacement of burners with modified low NOx swirl burners with special 100% 16.00 long lasting burner tips Replacement of complete individual Seal Air System with centralised SA 5 system including retrofitting of supply module and Cabling including control 100% 3.60 logic 6 Oil Cooler of PA Fans to be replaced with upgraded/improved one 100% 1.00 Replacement of ID Fan Impeller Shaft Assemblies, repair of casing, 7 replacement of casing liners & replacement of expansion joint with fluid 100% 1.00 coupling
8 Refurbishment of PA Fan Impeller Shaft Assemblies & repair of casing. 100% 0.50
Replacement of Soot blowers including complete electrical, mechanical 9 100% 6.00 and C&I items
Supply and replacement of APH tubes including plates (No. of Tubes: 10 100% 14.50 30636)
M.P. Power Generating Co. Ltd Page 27 Petition for Approval of R&M works at Unit No. 1&2, SGTPS, Birsinghpur April, 2017
Boiler and Auxiliaries - Unit No. 1 SGTPS
S. Prices R&M Works to be carried out Qty No. (Rs Crores)
Re-hablitation work to be carried out in ESP by replacement of missing & collecting electrode, lifting device, hammers, gearbox etc. whereas 11 required, complete replacement of GD plates (CS) with GD Plates (SS), 100% 12.00 replacement of manhole gates and repairing of roof, casing, hoppers with re-insulation and necessary electrical works etc.
Total (Boiler & Aux.) 139.00
Steam Turbine and Auxiliaries - Unit No. 1 SGTPS Prices S. No. R&M Works to be carried out Qty (Rs Crores) Replacement of HP, IP and LP turbine modules with new improved design 1 100% 150.00 including Erection & Commissioning
Following works to be carried out in Condenser:
i) CW side of condenser to be repaired and 100% 2 Protective coating on tube plate & water box ii) Installation of Online tube cleaning system along with provision of 3.10 1 Set Debris Filter
iii) Replacement of plugged condenser tubes 300
Repair/Replacement of internal supports of Deaerator and internal piping 3 100% 0.50 for TAS Replacement of BFPs cartridges with new & improved design (With one 4 3 5.40 spare cartridge)
Replacement of complete Turbine drain piping and retrofitting of valves in 5 100% 0.70 Turbine Drain System including High Energy Drains
Replacement of existing Pennwalt make Turbine oil centrifuge at MOT by 6 2 0.80 latest design Alfa Laval make oil centrifuge
Replacement of Existing Condensate Extraction pumps (CEP) with 7 modified/upgraded pumps having higher capacity (with complete pump set 2 7.00 as spare)
8 Booster pumps with modified improved design 3 0.60 9 Screw air compressors with Motors & Accessories for Phase-I 3 9.00
Cost for Turbine & Aux. from Point 2 to 9 27.10
Cost of Erection & Commissioning for item 2 to 9 (@10%) 29.81
Total (Turbine & Aux.) 179.81
M.P. Power Generating Co. Ltd Page 28 Petition for Approval of R&M works at Unit No. 1&2, SGTPS, Birsinghpur April, 2017
Electrical System - Unit No. 1 SGTPS S. Prices R&M Works to be carried out Qty No. (Rs Crores)
Replace the existing LT boards with draw out type, numerical relay based 1 15 0.60 protection, electronic energy meter for >110 kW motors of LT Switchgear
12 5.00 Replacement of all the existing standard induction motors with energy 2 efficient motor of all HT motors for Coal mills, PA Fans etc. (Prefr. BHEL (6 COAL
make) MILLS + 6 PA FANS) Installation of the energy efficient luminaries for the complete plant with 3 Lump-sum 1.50 LED system Overhauling/Servicing of GT & 2 (UATs) by OEM with supply of 1 - GT 4 0.80 consumable 2 - UAT 5 Installation and commissioning of GPS clock 1 0.40 6 Procurement of various testing lab equipments Lump-sum 0.70 7 Replacement of Station/Unit Switchgear Old Bus Transfer Scheme 1 0.60 Retrofit the existing 6.6 kV station and unit switchgear with new one (SF6 8 breaker cum numerical relay protection) considering the unit life extension 28 2.10 to another 15-20 years Total (Electrical System) 11.70 Total (Electrical System including Erection & Commissioning @10%) 12.87
Instrumentation and Control - Unit No. 1 SGTPS Prices S. No. R&M Works to be carried out Qty (Rs Crores)
Replacement of Complete C&I system with latest full DCS including Boiler and Turbine Protection system, Turbine Controls EHC, Turbine 1 ATRS, Turbo-Supervisory system, HP/LP Bypass system including 100% 20.00 BMS etc., condition monitoring system and PLC for Ash handling system
Replacement of all Transmitters, Local Gauges, Switches (Pressure, 2 Temperature, Level, Flow) and RTD/ Thermocouple/ Thermowells Lump-sum 1.50 with new ones New mass flow meters with totalizer shall be provided for monitoring 3 4 0.50 liquid fuel at the boiler end & at fuel oil pump house Replacement of all signal, T/C compensating & Control cables as per 4 Lump-sum 0.40 requirements 5 Fire retardant JB's in fire hazardous area Lump-sum 0.20 6 Motorized Actuators & Pneumatic Actuators Lump-sum 0.70 7 Replacement of complete measuring instruments of condenser Lump-sum 0.30 All required analyzer, transmitters, flow meters etc. to be provided in 8 Lump-sum 1.50 DM Plant 9 Online Acoustic Measuring Tubes Lump-sum 0.50 Total (Instrumentation & Control) 25.60 Total (Instrumentation & Control including Erection & Commissioning @10%) 28.16
M.P. Power Generating Co. Ltd Page 29 Petition for Approval of R&M works at Unit No. 1&2, SGTPS, Birsinghpur April, 2017
Balance of Plant - Unit No. 1 SGTPS S. Prices R&M Works to be carried out Qty No. (Rs Crores) Coal Handling Plant: (a) Cleaning & Protective coating/Painting of all steel structure, repairing of welding wherever abnormalities have been observed as per CA report and 100% deformed & corroded structures of belt conveyors stringers, stringer supports and conveyor galleries including Wagon Tippler area etc.
(b) Reconditioning, Cleaning and Corrosion resistance painting of Wagon Tippler/Locomotive and Bull Dozers, Shawls etc.
Apron feeders, Feeder Pan, Carrying, return rollers drive unit, gear box, 100% drive chain - The aged and worn-out components are to be replaced. Painting & Protective coating. Changing all lubricants
(c) Replacement of supporting structure & reconditioning of Primary 1 8.00 Crusher & Secondary Crusher (d) Supply & Installation of magnetic separator and providing redundant 100% supply for magnetic separator required additionally at conveyor 1A/B.
(e) Stacker-reclaimer system, Travelling Trippers, Paddle Feeders - 100% Refurbishment of complete system and up-gradation of interlocking system.
(f) Complete rehabilitation of fire fighting of CHP-1 including Wagon Tippler 100% area. as per site (g) Modification of conveyor No. 17A/B and 18A/B requirement Sub - Total (CHP) 8.00 Ash Handling Plant: (i) Refurbishment of :- (a) Seal plate and dipper plate at bottom ash hopper sealing arrangement. 100% (b) Construction of new pedestal for ash slurry line & replacement of old 50% pipes. (c) 18” swing disk valve 50%
(d) Vent valve 50%
(e) Pulse jet valve 50%
(f) Filter bags ( Cloth Material: Nomex) 100%
(g) Seat disk of intake valve 50%
2 (h) ESP diffuser valve 50% 22.00 (i) Feed gate assembly of bottom ash hopper 100%
(j) Combine tube 100%
(k) Water valve 100% (l) Fly ash Conveying line (i.e. 300 Mtr of 300NB, 200 Mtr of 350 NB & 200 50% Mtr. of 400 NB) (m) V Grove pulley of mechanical exhauster 100%
(n) Screw type Air Compressor 3 Nos.
(o) Overflow Transfer Pumps 100%
(ii) Complete rehabilitation of almost one non working stream 1
Sub - Total (AHP) 22.00
3 DM Plant:
M.P. Power Generating Co. Ltd Page 30 Petition for Approval of R&M works at Unit No. 1&2, SGTPS, Birsinghpur April, 2017
Balance of Plant - Unit No. 1 SGTPS S. Prices R&M Works to be carried out Qty No. (Rs Crores) (a) Replacement of all existing pipelines for dozing alkali & acids with 100% HDPE or better quality material. (b) Storage Tanks - Reconditioning including roof replacement. 3
(c) Regeneration pumps - Replacement 2 2.00
(d) Replacement of sludge transfer pump 3
(e) Replacement of measuring tank (acid) with dual laminated HDPE tank 4
Sub - Total (DM Plant) 2.00 CW System, ACW System, Raw Water System: 4 Refurbishment of Travelling Screen & Stop Log Gates 3 nos 0.50 Sub - Total (CW System, ACW System, Raw Water 0.50 Fuel Oil Handling System: (a) Replacement of unloading hoses and pipelines with insulation. 100%
(b) Replacement of complete heat tracing, insulation and cladding, pipe supports of FO handling pipelines from unloading area to fuel forwarding 100% pump house and from fuel forwarding pump house to boiler of unit-1
(c) Refurbishment of oil heating coils for tanks, heater in pump house, its associated pipe line including tracing lines, control valves, isolating valves 100% 5 strainers/fitters and replacement of damaged parts/equipments 3.00
(d)Replacement of insulation, supports, missing instruments like pressure 100% gauges etc. and reconditioning of valves in oil piping. (e)Reconditioning of strainer of HFO, LDO & Drain Oil Pumps. 100% (g) Replacement of two HFO storage tank with all accessories like fire 2 fighting, heating and oil draining system. Sub - Total (Fuel Oil Handling System) 3.00 Fire Protection System:
Replacement of Diesel Engine driven pump(1no) and Diesel Engine (1 no.) 6 - Reconditioning, replacement of damaged parts, instruments, painting and L.S. 4.00 protective coating and laying the pipeline above the ground
Sub - Total (Fire Protection System) 4.00 Air Conditioning & Ventilation System:
Reconditioning of
(a) Chilled Water Pumps (3 nos.) & Condenser Water Pumps (3 nos.) (b) Piping & Valves, rectification of support sagging, painting & protective 7 as required 0.50 coating (c) Blowers and chiller assembly
d) Air washer pump ( 5 nos. ) , Air handling unit of control room. Sub - Total (Air Conditioning & Ventilation System) 0.50 Total Balance of Plant 40.00
Total (Balance of Plant including Erection & Commissioning @10%) 44.00
M.P. Power Generating Co. Ltd Page 31 Petition for Approval of R&M works at Unit No. 1&2, SGTPS, Birsinghpur April, 2017
Civil Works - Unit No. 1 SGTPS Rate Prices S. No. R&M Works to be carried out Unit Quantity inRs. (Rs Crores)
Epoxy painting of foundations a) Boiler & Mill area m² 3500 1000 1 b) TG Building (Below ground level areas/basement) m² 7500 1000 1.85 c) Ash Handling Plant m² 1000 1000 d)Water Treatment Plant m² 6500 1000 Localised surface repairs with epoxy grouting a) Boiler & Mill area Kg 1950 1500 b) TG Building (Below ground level areas/basement) Kg 3000 1500 2 c) Ash Handling Plant Kg 1200 1500 3.54 d)Water Treatment Plant Kg 1950 1500 e) CW Pump House Kg 500 1500 f) Old CHP (Underground Tunnel portion) Kg 15000 1500 3 Concrete work for proper slope of TG basement m³ 110 10000 0.11 Total (Civil) 5.50
Summary of R&M Works at Unit No. 1 SGTPS Amount S. No. Particulars (Rs Crores) 1 Boiler and Auxiliaries 139.00 2 Steam Turbine Module 150.00 3 Steam Turbine Peripherals and Auxiliaries 29.81 4 Electrical System 12.87 5 Instrumentation and Control 28.16 6 Balance of Plant 44.00 7 Civil Works 5.50 Grand Total (Supply, Erection & Commissioning) 409.34 Contingency 10.00 15% Taxes & Duties 61.40 Grand Total 480.74 Say 481.00
M.P. Power Generating Co. Ltd Page 32 Petition for Approval of R&M works at Unit No. 1&2, SGTPS, Birsinghpur April, 2017
26. Scope of work ( Unit No. 2 SGTPS, Birsinghpur) The detailed Scope of Works at Unit No. 2 along with its estimated cost has been worked out and detailed below:-
Boiler and Auxiliaries - Unit No. 2 SGTPS S. Prices R&M Works to be carried out Qty No. (Rs Crores) A BOILER (PRESSURE PART) Re-insulation work after replacement/repairing wherever required of following 1 components: 1.1 Boiler Drum & Root Valves Pipings 1.2 Water wall complete including bottom ring headers 1.3 Boiler Feed Water piping 1.4 Attemperator headers & Piping 1.5 Reheater outlet header 100% 4.60 1.6 Main Steam Pipe (LHS, RHS) & BAS Line Piping 1.7 Cold Reheat and Hot Reheat Piping 1.8 All Super Heaters Headers inside pent house 1.9 Eco Hoppers, Fans, Coal mills, Wind box etc. 1.10 Pent House Replacement/Repairing of Pent house casing including header Boxes including 2 Furnace, Roof, Tubes, Replacement/Alignment. Canopy of 100% 5.30 top Burner floor by 3/15mm HR sheet Complete replacement of all refractory, Refurbishment of skin casing, insulation & cladding of Boiler 2nd Pass Refurbishment of dead chambers at gooseneck. 3 100% 2.50 Plat forms & Railing at different elevations at rear side of boiler 2nd Pass as per site requirement.
Complete replacement of Hangers and Supports for Entire MS, HRH and CRH 4 100% 3.00 Piping along with Coal pipe hangers.
Replacement of Horizontal Reheater (Top, Middle, Bottom)including cross over 5 pipes & Pendent Reheater coils with provision of additional metal temperature 100% 22.00 measurement instrumentsfor the outlet section to enable proper monitoring
Replacement of Complete Economizer Side wall (LHS & RHS) header to 6 header 100% 2.00 Replacement of CBD & EBD including all drain and vent pipes along with 7 100% 0.50 insulation and motorised valves & actuators Replacement of 11 nos. Safety valves along with silencer/Muffler and all drain 8 & vents with new insulation materials (Drum: 3 nos., BAS: 2 nos., TAS: 2 nos. 11 1.50 HP Heaters: 2 nos. & MS: 2 nos.) Replacement of BAS/TAS control valves including Full Load & Low Load Lines 9 4 0.70 (4 nos.)
Replacement of motorized valves & actuators, Critical valves like Attemperation spray control valves, Sampling valves & Manual isolating valves Lump- 10 2.30 which are damaged or not having the sufficient lapping space (Approx. 48 sum Nos.) including replacement of spray nozzles.
M.P. Power Generating Co. Ltd Page 33 Petition for Approval of R&M works at Unit No. 1&2, SGTPS, Birsinghpur April, 2017
Boiler and Auxiliaries - Unit No. 2 SGTPS S. Prices R&M Works to be carried out Qty No. (Rs Crores)
Replacement of Dipper plates along with seal trough as well as Z shaped Liner 11 100% 1.00 in side Bottom ash Hopper.
Erosion Shield for S panels & Goose neck of SS-310 materials (OR Coating). 12 Cassette Baffles for Eco & Primary SH Bends of SS-304 and replacement of 100% 5.00 distorted Water Wall at rear side.
Replacement of Baffle wall and cage rear wall from bottom (near to 13 100% 4.00 economizer) to pent house B BOILER (NON PRESSURE PART)
Replacement/Repairing of Flue duct from Eco to APH, APH to ESP and ESP to chimney along with re-insulation work after replacement/ repairing wherever 1 required. 100% 13.00 Replacement of all expansion Joints in Flue and Hot air ducts. Repairing of Air duct-15 T.
Replacement of existing drag chain system raw coal feeders with gravimetric feeders having variable speed digital drives for efficiency improvement & 2 statutory requirements and replacement of chute from coal feeders to mills with 6 7.00 SS material along with expansion joint and coupling suitable for new gravimetric feeders wherever required.
Replacement of old repaired gear boxes of Coal Mills with Planetary gear 3 7 10.00 boxes. Replacement of new modified ignition systems (Ignitor/scanner) along with 4 replacement of burners with modified low NOx swirl burners with special long 100% 16.00 lasting burner tips. Replacement of complete individual Seal Air System with centralized SA 5 system including retrofitting of supply module and Cabling including control 100% 3.60 logic. 6 Oil Cooler of PA Fans to be replaced with upgraded/improved one 100% 1.00 Replacement of ID Fan Impeller Shaft Assemblies, repair of casing, 7 replacement of casing liners & replacement of expansion joint with fluid 100% 1.00 coupling
8 Refurbishment of PA Fan Impeller Shaft Assemblies & repair of casing. 100% 0.50
Replacement of Soot blowers including complete electrical, mechanical and 9 100% 6.00 C&I items.
10 Supply and replacement of APH tubes including plates(No. of Tubes:30636) 100% 15.00
Rehabilitation work to be carried out in ESP by replacement of missing & collecting electrod, lifting device, hammers , gearbox etc. whereas required, 11 complete replacement of GD plates (CS) with GD Plates (SS), replacement of 100% 12.00 manhole gates and repairing of roof, casing, hoppers with reinsulation and necessary electrical works etc.
Total (Boiler & Aux. Including Erection & Commissioning) 139.50
M.P. Power Generating Co. Ltd Page 34 Petition for Approval of R&M works at Unit No. 1&2, SGTPS, Birsinghpur April, 2017
Steam Turbine and Auxiliaries - Unit No. 2 SGTPS S. Prices R&M Works to be carried out Qty No. (Rs Crores) Replacement of HP, IP and LP turbine modules with new improved design 1 100% 150.00 including Erection & Commissioning Following works to be carried out in Condenser: i) CW side of condenser to be repaired and Protective coating on tube plate & 100% water box 2 ii) Installation of Online tube cleaning system along with provision of Debris 1 Set 3.50 Filter. iii) Replacement of plugged condenser tubes (approx. 300Nos.) 300 Repair/Replacement of internal supports of Deaerator and internal piping for 3 100% 0.50 TAS. Replacement of BFPs cartridges with new & improved design (with one spare 4 4 7.20 cartridge).
Replacement of complete Turbine drain piping and retrofitting of valves in 5 100% 0.70 Turbine Drain System & including High Energy drains
Replacement of existing Pennwalt make Turbine oil centrifuge at MOT by latest 6 2 0.80 design Alfa Laval make oil centrifuge Replacement of Existing Condensate Extraction pumps (CEP) with 7 modified/upgraded pumps having higher capacity.(with complete pump set as 3 10.50 spare) 8 Booster pump with modified improved design. 3 0.80 9 Screw air compressors with motors and accessories for Phase-1 3 9.00 Total (Turbine & Aux. from Point 2 to 9 33.00 Cost of Erection & Commissioning for item 2 to 9 @10% 36.30 Total (Turbine & Aux. including erection & commissioning) 186.30
Electrical System - Unit No. 2 SGTPS S. Prices R&M Works to be carried out Qty No. (Rs Crores)
Replace the existing LT boards with draw out type, numerical relay based 1 15 0.60 protection, electronic energy meter for >110 kW motors of LT Switchgear
Replacement of all the existing standard induction motors with energy 12 (6 COAL 2 efficient motor of all HT motors for Coal mills, PA Fans etc. (Prefr. BHEL 5.00 MILLS + 6 make) PA FANS)
Installation of the energy efficient luminaries for the complete plant with LED 3 Lump-sum 1.50 system 1 - GT 4 Overhauling/Servicing of GT & 2 (UATs) by OEM with supply of consumable. 0.80 2 - UAT 5 Installation and commissioning of GPS clock 1 0.40 6 Procurement of various testing lab equipments Lump-sum 0.70 7 Replacement of Station/Unit Switchgear old Bus Transfer Scheme. 100% 0.60 Total (Electrical System) 9.60 Total (Electrical System including erection & commissioning @ 10%) 10.56
M.P. Power Generating Co. Ltd Page 35 Petition for Approval of R&M works at Unit No. 1&2, SGTPS, Birsinghpur April, 2017
Instrumentation and Control - Unit No. 2 SGTPS S. Prices R&M Works to be carried out Qty No. (Rs Crores)
Replacement of Complete C&I system with latest full DCS including Boiler and Turbine Protection system, Turbine Controls EHC, Turbine ATRS, Turbo- 1 100% 18.00 Supervisory system, HP/LP Bypass system including BMS etc., condition monitoring system and PLC for Ash handling system
Replacement of all Transmitters, Local Gauges, Switches (Pressure, Lump- 2 Temperature, Level, Flow) and RTD/ Thermocouple/ Thermo wells with new 1.00 sum ones New mass flow meters with totalizer shall be provided for monitoring liquid fuel 3 4 0.50 at the boiler end & at fuel oil pump house. Replacement of all signal, T/C compensating & Control to cables as per Lump- 4 0.40 requirements. sum Lump- 5 Fire retardant JB's in fire hazardous area 0.20 sum Lump- Motorized Actuators & Pneumatic Actuators 0.70 sum Lump- Replacement of complete measuring instruments of Condenser 6 sum 0.30 Lump- All required analyzer, transmitter, flow meters, etc to be provided in DM Plant sum Lump- 7 Online Acoustic Measuring Tubes 0.50 sum Total (Instrumentation & Control) 21.60
Total (Instrumentation & control including erection & commissioning @ 10%) 23.76
Balance of Plant - Unit No. 2 SGTPS S. Prices R&M Works to be carried out Qty No. (Rs Crores) Lump- 1 Replacement of Hydrogen Generation Plant in new located building sum 5.00 2 Ash Handling System Replacement of Valves (42 nos. in Ash intake pump house), Diffuser (12 nos.) Lump- 2.1 3.00 & Clinker Grinder Chains (4 nos.) sum 2.2 Ash Slurry Pump Gear Box (4 nos.) 4 0.50 AHP Compressed Air System including replacement of 2 nos. screw type air Lump- 2.3 5.00 compressors sum Lump- 3 DM Plant works including internal checking and rubber lining in Stream-A 0.50 sum Lump- 4 CW System, ACW System and Raw Water System 0.50 sum
Fuel Oil Handling System- Lump- 5 0.50 Replacement of Heating Tracing line, insulations & cladding Supports etc. sum
Lump- 6 Rehabilitation of Fire Fighting system piping etc.(included in Unit-1) 0.00 sum Total (Balance of Plant) 15.00 Total (Balance of Plant including Erection & Commissioning @ 10%) 16.50
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Civil Works - Unit No. 2 SGTPS S. Amount R&M Works to be carried out Unit No. (Rs Crores)
Epoxy painting of foundations 1 a) Boiler & Mill area Lump-sum 1.10 b) TG Building (Below ground level areas/basement) Lump-sum Localized surface repairs with epoxy grouting a) Boiler & Mill area Lump-sum 2 0.90 b) TG Building (Below ground level areas/basement) Lump-sum c) Ash Handling Plant Lump-sum 3 Concrete work for proper slope of TG basement Lump-sum 0.10 Construction of New Hydrogen Plant Building at new location near CW 4 Lump-sum 1.00 pump house Total (Civil) 3.10
Summary of R&M Works at Unit No. 2 SGTPS
Erection & Amount S. No. Particulars Supply Commissioning (Rs Crores)
1 Boiler and Auxiliaries - - 139.50 2 Steam Turbine Module - - 150.00 3 Steam Turbine Peripherals and Auxiliaries 33.00 3.30 36.30 4 Electrical System 9.60 0.96 10.56 5 Instrumentation and Control 21.60 2.16 23.76 6 Balance of Plant 15.00 1.50 16.50 7 Civil Works - 3.10 3.10 Grand Total (Supply, Erection & Commissioning) 379.72 Contingency 3.00 15% Taxes & Duties 56.96 Grand Total (Supply, Erection & Commissioning) 439.68 Say 440.00
27. In accordance with Proviso 21 of MPERC Regulations-2015 {RG-26 (III) of 2015} the instant petition has been prepared and is submitted by MPPGCL before Hon’ble Commission towards Renovation & Modernization works of Unit No. 1 & 2 SGTPS, Birsinghpur.
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28. Total Proposed Expenditure & Funding there of :- The total cost of R&M works proposed at PH-1 SGTPS, Birsinghpur works out to Rs. 966.60 Crores as detailed in respective DPRs. The Unit wise breakup is as under:-
Rs. Crores Particulars Unit-1 Unit-2 Total RLA Study 0.85 0.85 1.70 R&M 481.00 440.00 921.00 IDC on R&M 22.93 20.97 43.90 Total For R&M 504.78 461.82 966.60
Apart from above few essential works of capital nature are already in progress at these units amounting to Rs. 36.85 Crores. The details of the same are annexed as Annexure-7. However the summary of these works are tabulated hereunder:-
Amount Share of PH-1 Particulars Cr Rs Cr Rs Alternate Coal Path 48.90 24.45 Engine Escape Line 9.00 3.60 DCS system for U#2 2.84 2.84 Up gradation of UPS 0.40 0.40 PLC system for CHP 1.46 1.46 Mill & PA Fan Motors 2.80 2.80 PLCC Carrier panels 0.20 0.20 SF6 Circuit Breakers 0.90 0.90 Bus Bar protection Scheme 0.20 0.20 Total : 66.70 36.85 Accordingly, the total cost considered in the instant petition towards R&M works out to Rs. 1003.45 Crores (Rs. 966.6 +36.85 Crores).
Proposed Funding details:-
The funding of the proposed R&M works is based on the Debt: Equity Ratio of 70: 30 as per MPERC Regulations. The funding details are tabulated hereunder:-
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Funding Details Particulars Unit 1 Unit 2 Total 1 For R&M Works Cr Rs 504.78 461.82 966.60 2 % 70% 70% 70% Debt 3 Cr Rs 353.35 323.27 676.62 4 % 30% 30% 30% Equity 5 Cr Rs 151.43 138.55 289.98
MPPGCL is in discussion with various Financial Institutes for obtaining loan for afore said R&M works. Once the loan amount gets tied up, Hon’ble Commission shall be suitably intimated.
Apart from above, the funding of essential works detailed above is tabulated as under:-
in Rs. Crores Share of Unit Particulars 1 &2 Through PFC Loan 22.01 GoMP Plan funds 12.40 Internal resource 2.45 Total 36.85
29. Operational Parameters of MPERC:- The Operational Norms permitted by Hon’ble Commission for SGTPS PH-1 (Unit 1&2) vide its Regulation 2015 are tabulated hereunder:-
As per MPERC Operational Parameters Unit Regulation 2015
Normative Annual Plant Availability Factor % 80% Plant Load Factor % 80% Auxiliary Energy Consumption % 9.00% Sp. Fuel Oil Consumption ml/kWh 1.30 Gross Station Heat Rate kCal/kWh 2600
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30. Phasing of Expenditure:- The proposed phasing of expenditure as per DPR for R&M works at Unit No. 1 & 2 are detailed hereunder:-
Phasing of Expenditure of R&M Works Unit No.1 SGTPS Particulars Total Yr 1 Yr 2 Cr Rs FY-18 FY-19 RLA Study 0.85 0.85 R&M 481.00 30.00 451.00 IDC on R&M works 22.93 1.15 21.78 Total For R&M works 504.78 32.00 472.78
Phasing of Expenditure of R&M Works Unit No.2 SGTPS Particulars Total Yr 1 Yr 2 Cr Rs FY-18 FY-19 RLA Study 0.85 0.85 R&M 440.00 30.00 410.00 IDC on R&M works 20.97 1.15 19.82 Total For R&M works 461.82 32.00 429.82
31. The Hon’ble Commissioned vide its MYT order dated 14.07.2016 has determined tariff of SGTPS PH-1(4x210MW) for the Control Period FY 2016-17 to FY 2018-19 on consolidated basis. The Element wise break- up of proportionate tariff for Unit No. 1 &2 works out as under:-
Elements FY 17 FY 18 FY 19 Fixed Charges (Rs. Crores) Return on Equity 50.33 50.33 50.33 Interest on Loan 0.00 0.00 0.00 Depreciation 22.09 22.09 22.09 O&M Expenses 101.64 108.03 114.83 Special Allowance 0.00 0.00 0.00 Interest on Working Capital 33.24 33.61 34.01 Compensation Allowance 3.15 3.15 3.15 Total 210.45 217.21 224.41 Energy Charges ex-bus (Rs/kWh) 2.20 2.20 2.20
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32. Projected Operational Parameters:- The performance parameters after completion of the R&M works are projected as under:
As per Proposed by MPERC Operational Parameters Unit MPPGCL after Regulation R&M 2015
Plant Availability Factor % 80% 85%
Auxiliary Energy Consumption % 9.0% 8.5%
Sp. Fuel Oil Consumption ml/kWh 1.3 0.5
Gross Station Heat Rate k Cal/kWh 2600 2400
Project Duration Months 18
Shutdown Duration Months 04
Residual Life Extension Years 15-20 5th year Deterioration in performance Years onwards @1%
33. Life Extension:- The expected Life Extension after completion of R&M works at Unit No. 1 & 2 shall be 15-20 years.
34. Schedule of Completion:- MPPGCL is under process of finalization of all the related activities. On completion of the same, the works will start/initiated and the project shall be completed in 18 Months as envisaged in DPRs.
35. Cost Benefit Analysis:- The detailed Cost Benefit Analysis of the proposed R&M works at Unit No.1&2 of SGTPS, Birsinghpur is elaborated in Section-10 Financial Analysis of Options of DPRs of Unit No. 1 & 2 annexed as Annexure- 5A & 5B for kind reference. It can be seen that the Pay Back period for the Unit No.1 works out to 7.09 Years and for Unit No.2 works out to 7.06 Years.
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The summary of the same is detailed hereunder:-
Summary of Findings for Unit No. 1 SGTPS, Birsinghpur Particulars Value 1 Payback of Investment (MPPGCL) Years 7.09 Rs. Crores 555 2 Saving in ECR p/u 0.51
Summary of Findings for Unit No. 2 SGTPS, Birsinghpur Particulars Value 1 Payback of Investment (MPPGCL) Years 7.06 Rs. Crores 501 2 Saving in ECR p/u 0.48
36. MPPGCL humbly request Hon’ble Commission to permit MPPGCL to carry out Renovation and Modernization works at Unit No. 1 & 2 SGTPS, Birsinghpur in accordance to proviso 21 read with proviso 36.2 of Regulations, 2015 {RG-26 (III) of 2015} and allow its impact on generation tariff determined for the control period FY 2016-17 to FY 2018-19 and onwards.
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PRAYER
In view of the above submissions, the petitioner respectfully prays that in accordance with proviso 21 read with proviso 36.2 of Regulations, 2015 the Hon’ble Commission may kindly:-
a. Accord approval for capital expenditure as detailed in para 28, towards carrying out Renovation and Modernization works at Unit No. 1 & 2 SGTPS, Birsinghpur.
b. Allow its impact on generation tariff determined for the control period FY 2016-17 to FY 2018-19 and onwards.
c. Condone any inadvertent omissions / errors / short comings and permit the applicant to add / change /modify / alter this filing and make further submissions as may be required at later stages.
d. Pass such orders as Hon’ble MPERC may deem fit and proper and necessary in the facts and circumstances of the case, to grant relief to petitioner.
(S.C. Shukla) Date: 27/04/2017 Addl. Chief Engineer & OIC Place: Jabalpur O/o Chief Engineer (R&M) For & on behalf of M.P. Power Generating Co. Ltd. Jabalpur
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MPERC Fee Details
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LIST OF ANNEXURES
Annexure No. Particulars Copy of Clause 2.3 of Article 2, ‘Scope of the Agreement’ of the Power 1 Purchase Agreement (PPA) dated 29-11-2006 Energy Department, Government of MP, letter No.AF-3-20/2014/13 dated 2 28.01.2017 3 MPPMCL letter No 04-01/128 dated 01.02.2017 Guide Lines issued by Hon’ble Central Electricity Authority, New Delhi in 4 October 2009 for R&M/LE Works. Detailed Project Reports for R&M works at SGTPS Unit-1&2 Birsinghpur 5A & 5B prepared by M/S TŰV-SŰD South Asia Pvt. Ltd
BoD MPPGCL resolution granting approval for R&M works at SGTPS Unit- 6A 1&2 Birsinghpur.
Letter No. 07-09/MPPGCL/R&M/SGTPS/217 dated 10.02.2017 to Hon’ble 6B Central Electricity Authority, New Delhi for seeking necessary approval for R&M/LE works at SGTPS Unit-1&2 Birsinghpur.
7 Details of Essential works carried out at SGTPS Birsinghpur.
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Annexure-1
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Annexure-2
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Annexure-3
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Annexure-4
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Annexure-5A (DPR of Unit-1 SGTPS)
AND
Annexure-5B (DPR of Unit-2 SGTPS)
{ Placed separately }
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Annexure-6A
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Annexure-6B
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Annexure-7
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