presentation to the hon.cerc on performance of geb managed thermal power stations

Gen. Dept., GEB,HO,Vadodara 1

Presentation To

The Hon.CERCon

performance of

GEB Managed Thermal Power Stations

New Delhi Nov.11,2003


Introduction GEB Established under Section 5 of

E(S) Act 1948 in 1960 Present network

Available Generation(MW)

8576

Transmission network(CKM)

30862

Distribution Network (RKMs)

206543

Consumer Population 7332979


Power Scenario of Gujarat during 2002-03

Installed Capacity MW - 8576 Max.Daily MUs Catered - 173 Max.Daily GEB MUs Catered-

88.869 Max.U/R Demand MW - 9040 Max.Demand Catered MW - 7743


Generation Capacity for Gujarat System in MW GEB GEN.capacity

4888 Pvt. Sector Capacity 2156 Central Sector (Share) 1532

Gujarat System Total 8576


Generation and PLF for GEB Managed Thermal Power Stations

Year Gen.in MUS PLF% 1998-99 22518 63.74 1999-00 24139 63.70 2000-01 25640 67.85 2001-02 25749 68.14 2002-03 26338 69.69


•

Our Good Performance attributed to the following activities

Maximize the utilization of available generation capacity Adopted good O&M practices as suggested by CENPEEP. Implementation of recommendations made by M/s TERI

for fuel stock management Carrying out R&M activities to improve Generation level

at all power stations. Use of washed coal up to 30% at Ukai TPS and imported

coal up to 25% at Gandhinagar TPS. Change of Milling system by MPSP system at Ukai TPS &

Wanakbori TPS. Energy and Thermal audit in thermal power stations. Intensive boiler tube thickness survey during AOH.


Performance Optimization with participation of working level engineers from operation, maintenance, C&I, O&E Deptt.

Fixation of monthly performance targets and action plan for major problem area by performance group.

Routine performance testing on boiler system with accurate instrument

Feed back of work done to promote efficiency,heat rate improvements

Implementation of recommendations made by Centre for Power Efficiency & Environment Protection(CENPEEP) for performance optimization


Implementation of recommendations made by M/s TERI for fuel stock management

The stocks are not spreaded to entire length of the yard and are well organised and consolidated

Coal is stacked in smaller and regular shapes preferably trapezoidal or conical shapes to facilitate accurate measurement

Coal stocks are kept compressed by using dozers to remove air pockets to avoid fires

Bulk densities of compressed coal stock is determined regularly to arrive at an average figure for reporting actual physical stock


Implementation of recommendations made by M/s TERI for fuel stock management (contd..)

Direct feeding of Indian coal is done to bunkers as far as possible to avoid unnecessary stocking/reclaiming

Coal stocks are used on first come first out basis to avoid deterioration in coal quality resulting in lowering of TPS performance

Ground stocks are minimised to reduce rehandling costs

Coal reject is being monitored vigorously so that it remains within the limit of 0.5 to 1 %

100 % coal reject utilization.


Major R&M activities on hand RLA study for renovation of 2x120

MW units of Ukai TPS (BHEL) RLA study for renovation of 2x120

MW units of Gandhinagar TPS ( NTPC)

Renovation programme for 2x 70 MW units of KLTPS

Repowering of 4x63.5 MW units of Dhuvaran TPS


Year Aux. Cons %

Savings in Rs.Crores

Sp.Oil Cons

ml/kwh

Savings in

Rs.Crores

1998-99

9.96 - 3.94 43.87

1999-00

9.71 10.50 3.41 10.93

2000-01

9.62 4.04 2.03 33.79

2001-02

9.37 12.30 1.01 27.62

2002-03

9.38 - 0.94 2.40

Saving due to reduction in aux.consumption and Sp. Oil consumption compared previous year for GEB & GSECL Thermal Power Stations


Stationwise performance UKAI

Year Gen MUs

PLF %

PAF %

Aux. Cons

%

Heat Rate Kcal/K

Wh

Sp.Oil

Cons. Ml/

KWh

1998-99

4251 57.09

68.23

10.07

2760 4.82

1999-00

4445 59.50

70.97

10.04

2536 3.90

2000-01

5380 72.25

79.89

9.30 2595 1.76

2001-02

4750 63.80

69.36

9.17 2608 0.86

2002-03

5313 71.36

79.52

9.26 2590 0.94


Stationwise performance G’nagar ( Unit 1 to 5)

Year Gen MUs

PLF %

PAF %

Aux. Cons

%

Heat Rate Kcal/K

Wh

Sp.Oil

Cons. Ml/

KWh

1998-99

4693 68.74

88.43

10.05

2455 7.58

1999-00

4397 57.54

78.27

10.66

2456 8.14

2000-01

4676 61.35

84.81

10.88

2489 4.52

2001-02

5315 69.74

85.58

10.16

2513 1.52

2002-03

5858 76.87

85.90

9.71 2505 0.99


Stationwise performance Wanakbori ( Unit 1 to 7)

Year Gen MUs

PLF %

PAF %

Aux. Cons

%

Heat Rate

Kcal/KWh

Sp.Oil

Cons. Ml/ KWh

1998-99 (Unit

1-6)

8422 76.30 81.01

9.91 2501 0.62

1999-00

9954 77.09 81.07

9.31 2528 0.70

2000-01

10453

81.17 83.82

9.01 2472 0.57

2001-02

10993

85.37 87.65

8.91 2464 0.38

2002-03

10725

83.29 86.73

8.94 2459 0.58


Stationwise performance- Sikka

Year Gen MUs

PLF %

PAF %

Aux. Cons

%

Heat Rate Kcal/K

Wh

Sp.Oil

Cons. Ml/

KWh

1998-99

894 42.51

51.83

10.88

2480 6.21

1999-00

961 45.57

53.62

10.99

2501 2.47

2000-01

1097 52.20

60.36

10.96

2506 2.50

2001-02

1139 54.19

63.74

10.89

2665 2.36

2002-03

1130 53.73

60.46

10.63

2724 1.44


Stationwise performance- KLTPS

Year Gen MUs

PLF %

PAF %

Aux. Cons

%

Heat Rate Kcal/K

Wh

Sp.Oil

Cons. Ml/

KWh

1998-99

1010 53.61 71.0 12.61

3329 10.75

1999-00

963 51.01 68.06 13.16

3349 7.30

2000-01

966 51.27 70.63 12.95

3404 6.75

2001-02

981 52.06 66.68 12.31

3250 4.37

2002-03

1037 55.08 79.63 12.83

3662 3.68


Stationwise performance- Dhuvaran TPSYear Gen

MUs

PLF %

PAF %

Aux. Cons

%

Heat Rate

Kcal/KWh

1998-99

2185 46.71

73.97

10.65

2933

1999-00

2358 50.28

81.44

9.63 2879

2000-01

2350 50.25

81.16

10.22

2978

2001-02

1792 38.32

65.84

9.97 2993

2002-03

1386 29.63

61.69

10.99

3001


Stationwise performance- 135 MW Utran Gas based TPSYear Gen

MUsPLF

%PAF

%Aux. Cons

%

Heat Rate Kcal/K

Wh

1998-99

960 81.14

90.66

5.06 2020

1999-00

1059 89.33

92.95

4.70 1919

2000-01

718 60.70

78.37

5.42 2029

2001-02

779 65.85

79.16

4.70 2165

2002-03

888 75.10

84.80

4.98 1961


Performance for 200/210 MW thermal units (13 units,cap-2710 MW)

Year Gen MUs

PLF %

PAF %

Aux. Cons %

Heat Rate Kcal/KWh

Sp.Oil Cons. Ml/ KWh

1998-99

15290 69.82

81.29

9.72 2572 3.05

1999-00

17114 72.09

80.59

9.50 2487 3.00

2000-01

18551 78.14 79.90 9.19 2498 1.59

2001-02

19047 80.23 79.15 8.99 2500 0.543

2002-03

19796 83.39 86.99 8.98 2496 0.675


Performance for 120 MW thermal units (6 units, Cap-720 MW)

Year Gen MUs

PLF %

PAF %

Aux. Cons %

Heat Rate Kcal/KWh

Sp.Oil Cons. Ml/ KWh

1998-99

2881 45.69

63.76

12.04

2624 11.11

1999-00

2644 41.93

58.07

12.12

2544 7.85

2000-01

3054 48.43

66.86

12.02

2569 4.23

2001-02

3150 49.95

68.17

11.64

2635 2.79

2002-03

3230 51.21

67.50

11.23

2652 1.79


Performance for 63.5 MW LSHS thermal units(4 units, Cap-254 MW)

Year Gen MUs

PLF %

PAF %

Aux. Cons %

Heat Rate Kcal/KWh

1998-99

1250 56.18

86.83

10.48

2577

1999-00

1225 55.06

88.69

9.35 3003

2000-01

1165 52.34

82.89

9.90 3108

2001-02

911 40.93

70.53

9.69 3245

2002-03

576 25.89

50.33

11.16

3081


Performance for 140 MW LSHS thermal units(2 units, Cap-280 MW)

Year Gen MUs

PLF %

PAF %

Aux. Cons

%

Heat Rate

Kcal/KWh

1998-99

935 38.12

62.3 10.87

2752

1999-00

1133 46.20

74.85

9.94 2747

2000-01

1186 48.34

79.58

10.53

2858

2001-02

882 35.94

61.59

10.26

2716

2002-03

810 33.03

71.99

10.87

2936


Outage details for 200/210 MW thermal units (13 units,cap-2710 MW)

Year Blr tube leakage

Forced Outage

Planned outage

Total Outage

1998-99

2.78 10.53 12.06 22.59

1999-00

2.29 5.70 10.88 16.58

2000-01

2.62 6.45 7.90 14.35

2001-02

2.65 6.14 9.69 15.83

2002-03

2.17 6.69 6.38 13.07

In percentage



Forced Outage

Planned outage

Total Outage

1998-99

6.01 17.73 18.59 36.32

1999-00

6.33 18.73 22.94 41.67

2000-01

6.42 17.75 15.40 33.15

2001-02

6.54 24.49 7.38 31.87

2002-03

4.59 13.25 19.29 32.54

In percentage

Outage details for 120 MW thermal units (6 units, Cap-720 MW)



Forced Outage

Planned outage

Total Outage

1998-99

0.45 13.17 00 13.17

1999-00

1.96 7.13 3.74 10.87

2000-01

3.82 17.12 0 17.12

2001-02

0.41 20.62 8.92 29.54

2002-03

0.13 37.25 12.45 49.70

In percentage

Outage Details for 63.5 MW LSHS thermal units(4 units, Cap-254 MW)



Forced Outage

Planned outage

Total Outage

1998-99

4.67 38.00 00 38.00

1999-00

1.67 15.86 10.15 26.02

2000-01

12.57 17.18 6.96 24.14

2001-02

3.38 18.86 19.54 38.40

2002-03

7.44 16.45 11.56 28.01

In percentage

Outage Details for 140 MW LSHS thermal units(2 units, Cap-280 MW)



Forced Outage

Planned outage

Total Outage

1998-99

6.01 18.96 9.86 28.82

1999-00

1.23 16.81 15.02 31.83

2000-01

0.86 20.70 8.32 29.02

2001-02

1.57 24.49 9.18 33.67

2002-03

1.92 17.65 2.63 20.28

In percentage

Outage Details for 70/75 MW Lignite thermal units (3 units, Cap-215 MW)


R & M Activities carried out during last five years

Ukai TPS Replacement of water gland sealing with steam gland

sealing in 120 MW unit no.1 Introducing MPSP system in all coal mills. Replacement of bituminous class-B insulation of Generator

stator winding with epoxy class-F insulation in unit no.3 &4 Installation of Dual flue gas conditioning system to improve

flue gas SPM emission level in unit no. 4 Filling up of Dummy fields and providing microprocessor

based control in ESP of Unit 3,4&5 to improve the performance of ESP.

Replacement of excitation system with static excitation system in unit no 1&2.



Gandhinagar TPS Replacement of low temperature superheater in unit No

1 Replacement of suction type coal mill with new pressure

type coal mill in unit no.1. Work in progress for unit no.2 Replacement of top and middle air preheater blocks in

unit no.1. Work in progress for unit no. 2 Renovation and Modernisation of complete ash disposal

system in progress. Replacement of 2 nos. ABB make 220 KV circuit

breakers with SF6 circuit breakers.



Wanakbori TPS Replacement of Air Pre heater elements in unit 1 to 6 Replacement of coal mills by MPSP system with

controlled rejection level in unit 1 to 6 Replacement of condenser tubes in unit 1 to 3 Replacement of HP heaters in unit 4 to 6 Replcement of Jyoti make 6.6 kV min.Oil Ckt.breaker

with vacuum SF6 circuit breaker Replacement of economiser coils in unit 1,2,3 Replacement of 1200 KW motors for ID and PA fans Providing 100% leak proof gas isolators in flue gas path

in unit 1 to 3



Dhuvaran TPS Residual Life Assessment of all 6 units carried

out during 1999-00 Replacement of old unserviceable HP heaters

of unit no 1 to 4 Construction of new IDCT for unit 5&6 Replacement of 11 KV min.Oil circuit breaker

with Jyoti make Vacuum circuit breaker


Materials management1. ARC for following consumable items to

reduce procurement process time and the inventory level

a) MPSP mills sparesb) Ash plant sparesc) Bearingsd) Welding electrodese) All chemicals

2. Procurement of spares from OEM3. Finalisation of orders within 90 to 120

days


SERVICE LIFE OF GEB POWER STATIONS

SR. NO.

POWER STATION

SERVICE LIFE TILL DATE

01 UKAI 18 TO 27 YEARS

02 GANDHINAGAR 13 TO 26 YEARS

03 WANAKBORI 17 TO 22 YEARS

04 SIKKA 11 TO 16 YEARS

05 KLTPS 7 TO 14 YEARS

06 DHUVARAN 32 TO 39 YEARS


O&M expenses for UKAI TPS

Year Capacity

in MW

O&m

Cost

Total cost

% O&M

cost of Total cost

O&M Cost per MW

Fixed assets

at beginning of year

% O&M

cost of fixed

assets

1998-99

850 60 544 11.02

0.071 417 14.38

1999-00

850 57 540 10.63

0.067 458 12.54

2000-01

850 55 665 8.29 0.065 490 11.26

2001-02

850 53 750 7.07 0.062 510 10.39

2002-03

850 61 833 7.32 0.072 573 10.65

Rs in Crores


O&M expenses for Gandhinagar TPS

Year Capacity

in MW

O&m

Cost

Total cost

% O&M

cost of Total cost

O&M Cost per MW

Fixed assets


% O&M

cost of fixed

assets

1998-99

660 55 677 8.10 0.083 681 8.05

1999-00

660 41 492 8.30 0.062 703 5.81

2000-01

660 80 577 13.94

0.122 725 11.09

2001-02

660 44 756 5.82 0.067 735 5.99

2002-03

660 51 774 6.59 0.077 817 6.24

Rs in Crores


O&M expenses for Wanakbori TPS

Year Capacity in MW

O&m

Cost

Total cost

% O&M

cost of Total cost

O&M Cost per MW

Fixed assets


% O&M

cost of fixed

assets

1998-99

1260 58 1129

5.15 0.046 694 8.37

1999-00

1260 63 1243

5.04 0.05 717 8.73

2000-01

1260 64 1205

5.34 0.051 799 8.05

2001-02

1260 61 1445

4.22 0.048 811 7.52

2002-03

1260 69 1473

4.68 0.055 902 7.65

Rs in Crores


O&M expenses for Sikka TPS

Year Capacity

in MW

O&m

Cost

Total cost

% O&M

cost of Total cost

O&M Cost per MW

Fixed assets


% O&M

cost of fixed

assets

1998-99

240 22 160 13.76

0.092 396 5.58

1999-00

240 21 168 12.57

0.088 413 5.10

2000-01

240 18 181 9.97 0.075 425 4.243

2001-02

240 18 243 7.40 0.075 430 4.186

2002-03

240 20 302 6.62 0.083 479 4.175

Rs in Crores


O&M expenses for Dhuvaran TPS

Year Capacity

in MW

O&m

Cost

Total cost

% O&M

cost of Total cost

O&M Cost per MW

Fixed assets


% O&M

cost of fixed

assets

1998-99

588 45 324 6.88 0.042 191 13.18

1999-00

588 25 350 7.16 0.042 191 13.13

2000-01

588 25 365 6.88 0.042 198 12.73

2001-02

561 28 387 7.23 0.050 207 13.53

2002-03

561 29 566 5.18 0.052 221 13.28

Rs in Crores


O&M expenses for Utran Gas based TPS

Year Capacity

in MW

O&m

Cost

Total cost

% O&M

cost of Total cost

O&M Cost per MW

Fixed assets


% O&M

cost of fixed

assets

1998-99

174 17 79 21.23

0.09 246 4.54

1999-00

174 15 88 16.64

0.08 249 5.87

2000-01

174 11 70 15.98

0.06 258 4.32

2001-02

174 12 125 9.60 0.07 258 4.65

Rs in Crores


Meritorious Awards received by GEB & GSECL Power Stations

SR. YEAR REMARKS

NO.

1 1993 GANDHINAGAR 5.54 Incentive Award For Saving In Specific Fuel Oil SIKKA 2.95 Incentive Award For Saving In Specific Fuel Oil

2 1993-94 KLTPS 1.05 Meritorious Productivity Reward For Generation3 1994-95 DHUVARAN 5.58 Meritorious Productivity Reward For Generation

GANDHINAGAR 10.95 Meritorious Productivity Reward For GenerationSIKKA 3.35 Meritorious Productivity Reward For Generation

4 1994 GANDHINAGAR 7.63 Incentive Award For Saving In Specific Fuel Oil 5 1995 GANDHINAGAR 6.10 Incentive Award For Saving In Specific Fuel Oil

ConsumptionSIKKA 4.90 Incentive Award For Saving In Specific Fuel OilConsumption6 1995-96 GANDHINAGAR 9.18 Meritorious Productivity Reward For Generation & BronzeMedal & Shield

UKAI 7.28 Meritorious Productivity Reward For GenerationDHUVARAN 5.76 Meritorious Productivity Reward For GenerationUTRAN (GAS) 2.65 Meritorious Productivity Reward For Generation & ShieldKLTPS 0.52 Meritorious Productivity Reward For Generation

NAME OFTHERMAL POWER STATION

AMOUNT OFREWARD INLACS



SR. YEAR REMARKS

NO.

7 1996 SIKKA 7.53 Incentive Award For Saving In Specific Fuel OilConsumptionWANAKBORI 6.02 Incentive Award For Saving In Auxiliary Power Consumption

8 1996-97 SIKKA 4.28 Meritorious Productivity Reward For Generation & BronzeMedal & Shield

DHUVARAN 6.89 Meritorious Productivity Reward For Generation9 1997 UKAI 4.82 Incentive Award For Saving In Specific Fuel Oil

ConsumptionWANAKBORI 5.738 Incentive Award For Saving In Specific Fuel OilConsumption10 1997-98 WANAKBORI 10.4 Meritorious Productivity Reward For Generation & Shield

11 1998 UKAI 6.21 Incentive Award For Reduction In Secondary Fuel OilConsumption

WANAKBORI 5.72 Incentive Award For Reduction In Secondary Fuel OilConsumption

WANAKBORI 4.97 Incentive Award For Reduction In Auxiliary PowerConsumptionKLTPS 3.08 Incentive Award For Reduction In Auxiliary PowerConsumption12 1998-99 UTRAN(GAS) 1.79 Meritorious Productivity Reward For Generation & BronzeMedal & Shield

WANAKBORI 9.37 Meritorious Productivity Reward For Generation & Shield

KLTPS 0.84 Meritorious Productivity Reward For Generation

NAME OFTHERMAL POWER STATION



13 1999 WANAKBORI 6.57 Incentive Award For Reduction In Secondary Fuel Oil Consumption

SIKKA 6.62 Incentive Award For Reduction In Secondary Fuel Oil Consumption

WANAKBORI 6.57 Incentive Award For Reduction In Auxiliary Power Consumption

14 2000 UKAI 7.51 Incentive Award For Reduction In Secondary Fuel Oil Consumption

GTPS-5 7.51 Incentive Award For Reduction In Secondary Fuel Oil Consumption

WANAKBORI 6.43 Incentive Award For Reduction In Secondary Fuel Oil Consumption

WANAKBORI 6.01 Incentive Award For Reduction In Auxiliary Power Consumption

SIKKA 3.8 Incentive Award For Reduction In Auxiliary Power Consumption

15 1999-2000 UTRAN(GAS) 3.02 Meritorious Productivity Reward For Generation, Gold Medal &Sheild

WANAKBORI 13.02 Meritorious Productivity Reward For Generation & Shield

REMARKSNAME OFTHERMAL POWER STATION


SR.No. YEAR



O&M expenses for KLTPS

Year Capacity

in MW

O&m

Cost

Total cost

% O&M

cost of Total cost

O&M Cost per MW

Fixed assets


% O&M

cost of fixed

assets

1998-99

215 32 80 39.98

0.15 753 4.24

1999-00

215 28 69 40.80

0.13 753 3.73

2000-01

215 25 84 29.46

0.11 815 3.04

2001-02

215 24 255 9.41 0.11 815 2.94

2002-03

215 30 256 11.72

0.14 904 3.32

Rs in Crores

presentation to the hon.cerc on performance of geb managed thermal power stations

Documents