1. RENOVATION & MODERNIZATION IN THERMAL POWER STATIONS
Another 30 Years !!
SANTOSH PARDHI
Deputy Manager
Adani Infra (India)Ltd.
1
2.
The requirement of power is felt as an important input for economic growth,
more so in a power deficit scenario like India.
Old operating units lose efficiency and capacity due to aging.
New boilers are more expensive and take longer to install.
Disposal of old operating boiler plant is a problem.
Renovation and modernization of older units is one of the least cost effective
means of generating additional power.
Fuel availability changes over years of operation .
Pressure Parts need replacement to ensure safe operation after certain length of
operation
Re-powering can increase the cycle efficiency and hence reduce emission of
greenhouse gases and pollutants
Operating pressure and temperature of these old plants are lower and there is
no reheating in some of the units
2
3.
R&M will involve up gradation of milling system, APH, ESP, firing system etc
and refurbishment of turbine, condenser, pressure parts, fans etc.
R&M may involve following changes in plant design :
• Adoption of higher steam parameters .
• Introduction of topping cycle, old turbine may be retained in bottoming
cycle.
• Bottoming turbine cycle efficiency improvement by adoption of high
efficiency blade design
New Plants –costly.
Longer gestation period of new plant.
Limited availability of new site.
Old plants can be renovated and Modernised at lower costs and life extension
achieved.
Availability and efficiency can be improved.
Pressure Part replacements that make use of improved materials and redesign
of heat transfer surface for extended boiler life.
3
4.
R&M solutions cost just a third of a new boiler in terms of cost & time
Improve performance by introduction of new technology.
To upgrade the units to comply with fast changing Environmental / statutory
standards / guidelines.
Clean Coal Technology to reduce .
SOX ,NOX & CO2 Emissions
Sub Critical Steam Parameters To Supercritical Parameters
Increase in Pressure and temperature to like 250bar and 565 deg C.
Re-powering Technology
For better efficiency, pollution control and less cost besides life extension
Minimum environmental impact and R&R problems for additional capacity.
Renovation & Modernization of old existing units is an important tool for
capacity enhancement, life extension and improvement in availability,
reliability & efficiency
4
5.
Operational History & Problems being faced to run the plant.
Major modifications carried out from the original design condition.
Age of the plant, its existing condition and generic problems in its inherited
design
Collect all engineering as build drawing and sketches.
Model the existing boiler plant based on original design data .
Input current operating condition to verify the model.
Input revised (new) operating conditions .
5
6.
BOILER & AUXILIARIES
◦ Replacement/Augmentation Of Pressure Parts.
◦ Retrofitting/ Modifications Air Pre Heater.
◦ Augmentation Of Milling System.
◦ Provision Of Flame Scanners, ignitors.
◦ Renovation of Draft System.
◦ Retrofitting Of ESPs.
TG & AUXILIARIES
◦ Replacement of turbine blades with latest design.
◦ Modernization of condensers by change in type and material of
tubes, augmenting with tube cleaning mechanism.
◦ Modernisation of power cycle equipment's with more efficient pumps
and improved Regenerative Heaters.
◦ Modification of air evacuation system with Vacuum pumps.
6
