THERMAL POWER IN INDIA-PROBLEMS,

PROSPECTS AND LATEST DEVELOPMENTS

A SEMINAR REPORT
Submitted by
PAVAN
(8
th
semester, USN-2BV07IPxxx)
Towards partial fulfillment for the award of the degree of
BACHELOR OF ENGINEERING
DEPARTMENT OF INDUSTRIAL AND PRODUCTION
ENGINEERING
B V B COLLEGE OF ENGINEERING & TECHNOLOGY
HUBLI - 580031 (India)
March-2011
1
K L E Society`s
B.V.B. COLLEGE OF ENGG AND TECHNOLOGY
HUBLI-31
Department of Industrial & Production Engineering
CERTIFICATE
This is to certify that the SEMINAR REPORT entitled THERMAL POWER IN INDIA,
PROBLEMS, PROSPECTS AND LATEST DEVELOPMENTS su!itted y Pavan to the
B.V. Bhoomaraddi College of Engineering and Technology" #uli $%00&1 'India( to)ards
*artial fulfill!ent for the a)ard of the de+ree of Bachelor of Engineering is a ona-fide record
of )or, carried out y hi! under our su*er-ision. The contents of this se!inar re*ort" in full or
in *arts" ha-e not een su!itted to any other institute or uni-ersity for a)ard of any de+ree or
di*lo!a.
Head of the Department Guide
Dr. B. B. Kotturshettar Prof.Prasanna Raravi
2
ACKNOWLEDGEMENT
At the outset" I e/*ress !y dee* sense of +ratitude to !y +uide" Prof. Prasanna Raravi for his
-aluale and ins*irin+ +uidance throu+hout the course of this )or,. I )ould li,e to than, hi! for
*ro-idin+ !e an e/cellent a!ience and freedo! of thou+ht. I ha-e al)ays een ad!irin+ his
*atience" *erse-erance and +uidance. #e has dri-en !e to an e-erlastin+ det of +ratitude
throu+h his -aluale +uidance and su**ort in rin+in+ out this se!inar re*ort.
I )ish to e/*ress !y sincere than,s to Prof. B.B.KOTTURSHETTER" #ead of The
0e*art!ent of IN01STRIA2 PRO013TION" B.V.BHOOMARADDI COLLEGE OF
ENGINEERING AND TECHNOLOGY" #uli-$%00&1 for *ro-idin+ his +uidance.
3
ABSTRACT
0ue to the +ro)th in *o*ulation and industrial +ro)th the de!and for *o)er is increasin+ in the
country y lea*s and ounds. 4ut the *o)er *roduction throu+h hydro-electric *ro5ects and
throu+h nuclear *o)er *ro5ects is not ,ee*in+ *ace )ith the de!and. Ther!al *o)er offers a ray
of ho*e in this scenario. Po)er de-elo*!ent is the ,ey to the econo!ic de-elo*!ent. The *er
ca*ita consu!*tion of electricity in the country also increased fro! 1$ ,6h in 17$0 to aout &&%
,6h in 1778 -7%" )hich is aout 2& ti!es. #o)e-er this is -ery s!all co!*ared to the
de-elo*ed )orld. Still aout 1$9 of the -illa+es are not electrified. The :uality and :uantity of
electricity su**ly is also -ery *oor.
3oal ased ther!al *o)er stations are *resently the !ainstay of *o)er de-elo*!ent and this is
li,ely to e so in the i!!ediate future also" considerin+ the *resent status of the *ro5ects and
-arious constraints in de-elo*!ent of hydro and nuclear *o)er. There are se-eral ad-anta+es as
)ell as disad-anta+es for ther!al *o)er +eneration. #o)e-er the ad-anta+es o-er)ei+h the
disad-anta+es. The ther!al *o)er is the only ray of ho*e for the country.
India;s lar+est *o)er co!*any" NTP3 )as set u* in 178$ to accelerate *o)er de-elo*!ent in
India. NTP3 is e!er+in+ as a di-ersified *o)er !a5or )ith *resence in the entire -alue chain of
the *o)er +eneration usiness. A*art fro! *o)er +eneration" )hich is the !ainstay of the
co!*any" NTP3 has already -entured into consultancy" *o)er tradin+" ash utili<ation and coal
!inin+. NTP3 needs to e encoura+ed in all *ossile !anner not only to increase the ther!al
*o)er *roduction ut also to increase its efficiency y ado*tin+ latest technolo+ical inno-ations.
1ltra Me+a Po)er *ro5ects '1MPP( are a series of a!itious *o)er *ro5ects *lanned y the
=o-ern!ent of India. 6ith India ein+ a country of chronic *o)er deficits" the =o-ern!ent of
India has *lanned to *ro-ide >*o)er for all> y the end of the ele-enth *lan 'y 2012(. This )ould
entail the creation of an additional ca*acity of at least 100"000 M6 y 2012. The 1ltra Me+a
Po)er *ro5ects" each )ith a ca*acity of ?000 !e+a)atts or ao-e" are ein+ de-elo*ed )ith the
ai! of rid+in+ this +a*. Already so!e 1MPP;s are under i!*le!entation at Saasan-'Reliance
Ener+y(" Mundra-'TATA *o)er(" @uda+i-'NTP3( etc.
#itachi has recently de-elo*ed *roducts and ser-ices for ad-anced su**ort for !aintenance and
*reser-ation throu+h the use of IT 'infor!ation technolo+y( and net)or, technolo+y" +oin+
eyond )hat has *re-iously een a-ailale. This technolo+ical inno-ation needs to e ado*ted
y the e/istin+ as )ell as forth co!in+ *o)er *lants not only to increase the efficiency of *o)er
*roduction ut also to increase the life of the *o)er *lants.
The *er ca*ita a-ailaility and consu!*tion of electricity is -ery less in the country as co!*ared
to the de-elo*ed )orld. The ra*id econo!ic +ro)th and the resultant increased standard of li-in+
of the *o*ulation calls for hu+e increase in su**ly of *o)er. The +ro)in+ *o*ulation as )ell as
ra*idly e/*andin+ industry also de!ands for a hu+e su**ly of *o)er. In this conte/t increasin+
ther!al *o)er *roduction assu!es +reat si+nificance in the country.
4
Chapter No. TITLE Page No.
Ac,no)led+e!ent &
Astract $
1. Introduction
1.1 #istory %
1.2 Efficiency %
1.& =ro)th of Indian *o)er sector 7
1.? 0e-elo*!ent of coal ased +eneration 10

2. 6or,in+ of Ther!al Po)er *lant 11
2.1 Ty*ical coal fired ther!al *o)er station 11
2.2 6or,in+ of Ther!al *o)er *lant 12
2.& Ad-anta+es 1&
2.? 0isad-anta+es 1&
&. En-iron!ental i!*act of ther!al *o)er stations 1?
&.1 Air *ollution 1?
&.2 Nitro+en O/ide 1?
&.& Sul*hur O/ide 1$
&.? Technolo+y u* +radation 1A
?. Role of NTP3 and Po)er =eneration 18
?.1 O-er-ie) 1%
?.2 Ash 1tilisation 17
?.& 3enPEEP 20
5
?.? NTP3>s A**roach 22
$. 1ltra Me+a Po)er Pro5ects 2&
$.1 The Sasan 1ltra Me+a Po)er Pro5ect Reliance 2&
$.2 1ltra Me+a Po)er Pro5ect Tata Po)er 2?
$.& 1ltra Me+a Po)er Pro5ect NTP3 2?

A. Ad-anced Technolo+ies of Pre-enti-e Maintenance for 2$
Ther!al Po)er Plants
A.1 O-er-ie) 2$
A.2 Introduction 2A
A.& A**lication of IT to Pre-enti-e 28
A.? Pre-enti-e Maintenance Technolo+y for 4oilers 28
A.$ Scheduled ins*ection rationali<ation technolo+y 2%
A.A Pre-enti-e Maintenance Technolo+y for Stea! 27
Turines
A.8 0e-elo*!ent of scheduled ins*ection technolo+y &0
for i!*ro-in+ in efficiency
A.% Pre-enti-e Maintenance Technolo+y for =as &2
Turines
A.7 2ifeti!e !ana+e!ent and re*air of hot +as *ath &2
3o!*onents
A.10 =as turine uc,et recoatin+ re*air &&
A.11 =as turine no<<le lade diffusion ra<in+ re*air &&
8. 3ON321SION &?
%. REBEREN3ES &A
6
LIST OF TABLE AND FIGURES
Description Page no
Po)er +eneration in IN0IA %
0ia+ra! of a ty*ical coal fired ther!al *o)er station 11
4loc, 0ia+ra! 11
Area )ise rea,-u* of utili<ation for the year 2007-10 1A
=ro)th of NTP3 1%
1ltra Me+a Po)er Pro5ects 2&
Pre-enti-e !aintenance solutions 2A
0ia+nostic Technolo+y 28
E2BOS 1T *erfor!ance 27
Mechanis! for detection of stea! lea,s &0
Screen I!a+es &2
7
Chapter-1
INTRODUCTION
The *o)er sector has re+istered si+nificant *ro+ress since the *rocess of *lanned de-elo*!ent of
the econo!y e+an in 17$0. #ydro -*o)er and coal ased ther!al *o)er ha-e een the !ain
sources of +eneratin+ electricity. Nuclear *o)er de-elo*!ent is at slo)er *ace" )hich )as
introduced" in late si/ties. The conce*t of o*eratin+ *o)er syste!s on a re+ional asis crossin+
the *olitical oundaries of states )as introduced in the early si/ties. In s*ite of the o-erall
de-elo*!ent that has ta,en *lace" the *o)er su**ly industry has een under constant *ressure to
rid+e the +a* et)een su**ly and de!and.
A thermal power station is a *o)er *lant in )hich the *ri!e !o-er is stea! dri-en. 6ater is
heated" turns into stea! and s*ins a stea! turine )hich dri-es an electrical +enerator. After it
*asses throu+h the turine" the stea! is condensed in a condenser and recycled to )here it )as
heatedC this is ,no)n as a Ran,ine cycle. The +reatest -ariation in the desi+n of ther!al *o)er
stations is due to the different fuel sources. So!e *refer to use the ter! energy !enter ecause
such facilities con-ert for!s of heat ener+y into electrical ener+y. So!e ther!al *o)er *lants
also deli-er heat ener+y for industrial *ur*oses" for district heatin+" or for desalination of )ater
as )ell as deli-erin+ electrical *o)er. A lar+e *ro*ortion of 3O
2
is *roduced y the )orlds fossil
fired ther!al *o)er *lantsC efforts to reduce these out*uts are -arious and )ides*read.
Al!ost all coal" nuclear" +eother!al" solar ther!al electric" and )aste incineration *lants" as )ell
as !any natural +as *o)er *lants are ther!al. Natural +as is fre:uently co!usted in +as
turines as )ell as oilers. The )aste heat fro! a +as turine can e used to raise stea!" in
a co!ined cycle *lant that i!*ro-es o-erall efficiency. Po)er *lants urnin+ coal" oil" or
natural +as are often referred to collecti-ely as fossil"fuel power plants. So!e io!ass-fueled
ther!al *o)er *lants ha-e a**eared also. Non-nuclear ther!al *o)er *lants" *articularly fossil-
fueled *lants" )hich do not use co-+eneration are so!eti!es referred to as !onventional power
plants.
1.1-History
Reci*rocatin+ stea! en+ines ha-e een used for !echanical *o)er sources since the 1%th
3entury" )ith notale i!*ro-e!ents ein+ !ade y Da!es 6att. The -ery first co!!ercial
8
central electrical +eneratin+ stations in the Pearl Street Station" Ne) Eor, and the #olorn
Fiaduct *o)er station" 2ondon" in 1%%2" also used reci*rocatin+ stea! en+ines. The
de-elo*!ent of the stea! turine allo)ed lar+er and !ore efficient central +eneratin+ stations to
e uilt. 4y 1%72 it )as considered as an alternati-e to reci*rocatin+ en+ines Turines offered
hi+her s*eeds" !ore co!*act !achinery" and stale s*eed re+ulation allo)in+ for *arallel
synchronous o*eration of +enerators on a co!!on us. Turines entirely re*laced reci*rocatin+
en+ines in lar+e central stations after aout 170$. The lar+est reci*rocatin+ en+ine-+enerator sets
e-er uilt )ere co!*leted in 1701 for the Manhattan Ele-ated Rail)ay. Each of seventeen units
)ei+hed aout $00 tons and )as rated A000 ,ilo)attsC a conte!*orary turine-set of si!ilar
ratin+ )ould ha-e )ei+hed aout 209 as !uch.
1.2 Efficiency
The ener+y efficiency of a con-entional ther!al *o)er station" considered as salale ener+y 'in
M6( *roduced at the *lant" is ty*ically &&9 to ?%9 efficient. This efficiency is li!ited as all
heat en+ines are +o-erned y the la)s of ther!odyna!ics . The rest of the ener+y !ust lea-e the
*lant in the for! of heat. This )aste heat can +o throu+h a condenser and e dis*osed of
)ith coolin+ )ater or in coolin+ to)ers. If the )aste heat is instead utili<ed for district heatin+" it
is called co-+eneration. An i!*ortant class of ther!al *o)er station are associated
)ith desalination facilitiesC these are ty*ically found in desert countries )ith lar+e su**lies
of natural +as and in these *lants" fresh)ater *roduction and electricity are e:ually i!*ortant co-
*roducts.
1.3 Growth of Indian Power Sector
Po)er de-elo*!ent is the ,ey to the econo!ic de-elo*!ent. The *o)er Sector has een
recei-in+ ade:uate *riority e-er since the *rocess of *lanned de-elo*!ent e+an in 17$0. The
Po)er Sector has een +ettin+ 1%-209 of the total Pulic Sector outlay in initial *lan *eriods.
Re!ar,ale +ro)th and *ro+ress ha-e led to e/tensi-e use of electricity in all the sectors of
econo!y in the successi-e fi-e years *lans. O-er the years 'since 17$0( the installed ca*acity of
9
Figure 1.1
Po)er Plants '1tilities( has increased to %7070 M6 '&1.&.7%( fro! !ea+re 181& M6 in 17$0"
re+isterin+ a $2d fold increase in ?% years. Si!ilarly" the electricity +eneration increased fro!
aout $.1 illion units to ?20 4illion units G %2 fold increase. The *er ca*ita consu!*tion of
electricity in the country also increased fro! 1$ ,6h in 17$0 to aout &&% ,6h in 1778 -7%"
)hich is aout 2& ti!es. In the field of Rural Electrification and *u!* set ener+isation" country
has !ade a tre!endous *ro+ress. Aout %$9 of the -illa+es ha-e een electrified e/ce*t far-
flun+ areas in North Eastern states" )here it is difficult to e/tend the +rid su**ly.
1.4 Development of Coal Based Generation
3oal ased ther!al *o)er stations are *resently the !ainstay of *o)er de-elo*!ent and this is
li,ely to e so in the i!!ediate future also" considerin+ the *resent status of the *ro5ects and
-arious constraints in de-elo*!ent of hydro and nuclear *o)er. As *er the *resent esti!ates" the
coal reser-es in the country are the order of 202 illion tones )ith the ul, of the reser-es lyin+
in the Eastern Re+ion states of 4ihar" Orissa and 6est 4en+al. Of the coal *roduced aout 809
is consu!ed in the *o)er sector. Presently" aout 200 Million Tonnes of coal is consu!ed
yearly in the *o)er sector and this re:uire!ent )ould continue to increase in the co!in+ years.
The Plannin+ 3o!!ission in the 7th *lan docu!ent has *ro5ected a coal de!and in the country
for end of 11th *lan '2011-12( of 88$ MT and *roduction of A82 MT lea-in+ a +a* of aout
10& MT. It is esti!ated that the de!and for coal y the *o)er sector is li,ely to e sustantially
in e/cess of the *roduction y the end of Ninth and Tenth Plan *eriods. This de!and )ould
need to e !et y i!*ortin+ coal and au+!entin+ do!estic coal *roducin+ ca*aility. 4oth the
o*tions )ould re:uire s*ecial efforts and *olicy !easures. The =o-ern!ent had ta,en a !a5or
ste* in o*enin+ u* coal !inin+ to the *ri-ate sector. It is ho*ed that sustantial *ri-ate
*artici*ation )ould +i-e a oost to the do!estic *roduction. 4esides :uantity" the :uality of
Indian coal has een a !a5or *role! and concern for the *o)er su**ly industry. 6ith ash
content of coals ein+ in the ran+e of &0-$09" the eneficiation of coal assu!es s*ecial
si+nificance. Estalish!ent of )asheries therefore assu!es a +reat i!*ortance and country has t
o address this *role! seriously. So far the *o)er sector has relied *ri!arily on rail)ays for coal
trans*ortation. #o)e-er" there are considerale constraints in this area and other !odes of
trans*ort" -i<. shi**in+" rail-cu!-sea route for coastal *ro5ects )ill ha-e to e e/a!ined on case
to case asis. @ee*in+ in -ie) the *role!s of fly ash and the hi+h ash content coal" the
desirale o*tion )ould e to de-elo* lar+e *it head coal *ro5ects and trans!it the *o)er to the
load centers. Only 6ashed 3oal should e trans*orted to load centre stations and )ashery re5ects
!ay e utili<ed throu+h fluidi<ed ed oilers in *o)er stations at the *it head itself.
10
Chapter 2
WORKING OF THERMAL POWER PLANT
2.1 0ia+ra! of a ty*ical coal fired ther!al *o)er station
2.2 Block Diagram
11
Figure-
2.1
2.3 Working of Thermal power plant
1.&.1 Beed)ater heater
A feedwater heater is a *o)er *lant co!*onent used to *re-heat )ater deli-ered to
a stea! +eneratin+ oiler. Preheatin+ the feed )ater reduces the irre-ersiility in-ol-ed in stea!
+eneration and therefore i!*ro-es the ther!odyna!ic efficiency of the syste!.
H?I
This reduces
*lant o*eratin+ costs and also hel*s to a-oid ther!al shoc, to the oiler !etal )hen the feed
)ater is introduced ac, into the stea! cycle.
2.&.2 4oiler
A boiler is a closed -essel in )hich )ater or other fluid is heated. The heated or -a*ori<ed fluid
e/its the oiler for use in -arious *rocesses or heatin+ a**lications.
2.3.3 Steam condensing
The condenser condenses the stea! fro! the e/haust of the turine into li:uid to allo) it to e
*u!*ed. If the condenser can e !ade cooler" the *ressure of the e/haust stea! is reduced and
efficiency of the cycle increases.
2.&.? Electrical =enerator
In electricity +eneration" an electric generator is a de-ice that con-erts !echanical
ener+y to electrical ener+y.
12
Figure-2.2
2.&.$ Stea! Turine
A steam turbine is a !echanical de-ice that e/tracts ther!al ener+y fro! *ressuri<ed stea!"
and con-erts it into rotary !otion.
2.4 Advantages
1. The fuel used is :uite chea*.
2. 2ess initial cost as co!*ared to other +eneratin+ *lants.
&. It can e installed at any *lace irres*ecti-e of the e/istence of coal. The coal can e
trans*orted to the site of the *lant y rail or road.
?. It re:uires less s*ace as co!*ared to #ydro *o)er *lants.
$. 3ost of +eneration is less than that of diesel *o)er *lants.
A. They can e located -ery con-eniently near the load centers.
8. 0oes not re:uire shieldin+ li,e re:uired in nuclear *o)er *lant
%. 1nli,e nuclear *o)er *lants )hose *o)er *roduction !ethod is difficult" for ther!al
*o)er *lants it is easy.
7. Trans!ission costs are reduced as they can e set u* near the industry.
10. The *ortion of stea! +enerated can e used as *rocess stea! in different industries.
11. Stea! en+ines and turines can )or, under 2$9of o-erload ca*acity.
12. Ale to res*ond chan+in+ loads )ithout difficulty.
13
2.5 Disadvantages
1. It *ollutes the at!os*here due to *roduction of lar+e a!ount of s!o,e and fu!es.
2. 2ar+e a!ounts of )ater are re:uired.
&. Ta,es lon+ ti!e to e erected and *ut into action.
?. Maintenance and o*eratin+ costs are hi+h.
$. 6ith increase in *ressure and te!*erature" the cost of *lant increases.
A. Troules fro! s!o,e and heat fro! the *lant" dis*osal of ash.
Chapter-3
ENVIRONMENTAL IMPACT OF THERMAL POWER STATIONS
Ther!al Po)er Stations in India" )here *oor :uality of coal is used" add to en-iron!ental
de+radation *role!s throu+h +aseous e!issions" *articulate !atter" fly ash and otto! ash.
=ro)th of !anufacturin+ industries" in *ulic sector as )ell as in *ri-ate sector has further
a++ra-ated the situation y deterioratin+ the a!ient air :uality. Ash content ein+ in
aundance in Indian coal" *role! of fly ash and otto! ash dis*osal increase day y day. The
fly ash +enerated in ther!al *o)er station causes !any ha<ardous diseases li,e Asth!a"
Tuerculosis etc.
&.1 Air *ollution
Initially" *erce*tions of o5ectionale effects of air *ollutants )ere li!ited to those easily
detected li,e odour" soilin+ of surfaces and s!o,e stac,s. 2ater" it )as the concern o-er lon+
ter!Jchronic effects that led to the identification of si/ criteria *ollutants. These si/ criteria
*ollutants are sul*hur di-o/ide 'SO2(" 3aron Mono-o/ide '3O(" Nitro+en o/ide 'NO2(" O<one
'O&(" sus*ended *articulates and non-!ethane hydrocarons 'NM#3( no) referred to as
-olatile or+anic co!*ounds 'FO3(. There is sustantial e-idence lin,in+ the! to health effects
at hi+h concentrations. Three of the! na!ely O&" SO2 and NO2 are also ,no)n *hytoto/icants
'to/ic to -e+etation(. In the later *art 2ead 'P( )as added to that list.
&.2 Nitro+en O/ide 'NO/(
Most of the NO/ is e!itted as NO )hich is o/idised to NO2 in the at!os*here. All
co!ustion *rocesses are sources of NO/ at the hi+h te!*erature +enerated in the co!ustion
*rocess. Bor!ation of NOK !ay e due to ther!al NO/ )hich is the result of o/idation of
nitro+en in the air due to fuel NO/ )hich is due to nitro+en *resent in the fuel. So!e of NO2
)ill e con-erted to NO& in the *resence of 02. In +eneral" hi+her the co!ustion te!*erature
14
the hi+her NO/ is *roduced. So!e of NO/is o/idised to NO&" an essential in+redient of acid
*reci*itation and fo+. In addition" NO2 asors -isile li+ht and in hi+h concentrations can
contriute to a ro)nish discoloration of the at!os*here.
&.& Sul*hur O/ide
The co!ustion of sul*hur containin+ fossil fuels" es*ecially coal is the *ri!ary source of SO/.
Aout 78 to 779 of SO/ e!itted fro! co!ustion sources is in the for! of Sul*hur 0i-o/ide
)hich is a criteria *ollutant" the re!ainder is !ostly SO&" )hich in the *resence of at!os*heric
)ater is transfor!ed into Sul*huric Acid at hi+her concentrations" *roduce deleterious effects on
the res*iratory syste!. In addition" SO2 is *hytoto/icant.
&.? 6ater *ollution
6ater *ollution refers to any chan+e in natural )aters that !ay i!*air further use of the )ater"
caused y the introduction of or+anic or inor+anic sustances or a chan+e in te!*erature of the
)ater. In ther!al *o)er stations the source of )ater is either ri-er" la,e" *ond or sea )here fro!
)ater is usually ta,en. There is *ossiility of )ater ein+ conta!inated fro! the source itself.
Burther conta!ination or *ollution could e added y the *ollutants of ther!al *o)er *lant )aste
as inor+anic or or+anic co!*ounds.
&.$ 2and de+radation
The ther!al *o)er stations are +enerally located on the non-forest land and do not in-ol-e !uch
Resettle!ent and Rehailitation *role!s. #o)e-er it>s effects due to stac, e!ission etc" on
flora and fauna" )ild life sanctuaries and hu!an life etc. ha-e to e studied for any ad-erse
effects. One of the serious effects of ther!al *o)er stations is land re:uire!ent for ash dis*osal
and ha<ardous ele!ents *ercolation to +round )ater throu+h ash dis*osal in ash *onds. 0ue to
enor!ous :uantity of ash content in India coal" a**ro/i!ately 1 Acre *er M6 of installed
ther!al ca*acity is re:uired for ash dis*osal. Accordin+ to the studies carried out y
International consultants if this trend continues" y the year 201? -201$" 1000 s:. ,! of land
should e re:uired for ash dis*osal only.
&.A Noise *ollution
So!e areas inside the *lant )ill ha-e noisy e:ui*!ents such as crushers" elt con-eyors" fans"
*u!*s" !illin+ *lant" co!*ressors" oiler" turine etc. Farious !easures ta,en to reduce the
15
noise +eneration and e/*osure of )or,ers to hi+h noise le-els in the *lant area )ill +enerally
includeL
i) Silencers of fans" co!*ressors" stea! safety -al-es etc.
ii) 1sin+ noise asorent !aterials.
iii) Pro-idin+ noise arriers for -arious areas.
iv) Noise *roof control roo!s.
v) Pro -ision of +reen elt around the *lant )ill further reduce noise le-els.
3.7 Technology up gradation:
&.8.1 3lean coal technolo+iesL
3lean coal technolo+ies offer the *otential for si+nificant reduction in the en-iron!ental
e!issions )hen used for *o)er +eneration. These technolo+ies !ay e utili<ed in ne) as )ell
as e/istin+ *lants and are therefore" an effecti-e )ay of reducin+ e!issions in the coal fired
+eneratin+ units. Se-eral of these syste!s are not only -ery effecti-e in reducin+ So/ and NO/
e!issions ut ecause of their hi+her efficiencies they also e!it lo)er a!ount of 3O2 *er unit of
*o)er *roduced. 33T>s can e used to reduce de*endence on forei+n oil and to !a,e use of a
)ide -ariety of coal a-ailale. 4lendin+ of -arious +rades of ra) coal alon+ )ith eneficiation
shall ensure consistency in :uality of coal to the utility oilers. This a**roach assu!es +reater
rele-ance in case of !ulti*le +rades of coals a-ailale in different *arts of the country and also
coals of different :ualities ein+ i!*orted y IPPs. Ministry of En-iron!ent and Borests -ide
their notification dated &0th Dune 177% had sti*ulated the use of ra) or lended or eneficiated
coal )ith ash content not !ore than &?9 on an annual a-era+e asis ). e. f. 1st Dune 2001.
3P34 has constituted a Steerin+ 3o!!ittee consistin+ re*resentati-e fro! so!e SE4s" 3P34"
Ministry of 3oal" Ministry of Po)er" 3EA and 6orld 4an, to carry out cost enefit analysis of
usin+ clean coal technolo+ies and assess and *rioriti<e technically feasile and econo!ically
-iale !easures to i!*ro-e coal :uality.
&.8.2 Refurish!ent of e/istin+ ther!al *o)er stationsL
3ontinuous deterioration in *erfor!ance of ther!al *o)er stations had een oser-ed durin+
early %0>s. Therefore" Reno-ation and Moderni<ation Sche!es'RMM Sche!es( )ere dra)n and
e/ecuted for i!*ro-in+ the *erfor!ance of e/istin+ ther!al *o)er stations. Pollution control
16
!easures in these *o)er stations ein+ a ca*ital-intensi-e acti-ity" it accounted for !a5or
*ortion-around ?09 of Rs. 12 4illion ,e*t for RMM sche!es under *hase-I. 0urin+ *hase-I" 1A&
units of &? ther!al *o)er stations )ere co-ered. As a result of RMM sche!es these achie-ed
10"000 !illion units of additional +eneration *er annu! a+ainst the tar+et of 8000 !illion units.
Encoura+ed y the results achie-ed" RMM *hase-II *ro+ra!!e is *resently under *ro+ress.
Total esti!ated cost of these )or,s is Rs. 2? 4illion. Most of the Electricity 4oards or other
+eneratin+ a+encies are facin+ financial constraints to carry out RMM acti-ities. Therefore" this
area has to e ta,en on *riority to arran+e financial assistance. Se-eral or+ani<ations ha-e
carried out Ener+y audits of ther!al *o)er *lants )ith a -ie) to su++est !easures to i!*ro-e
their o*erational efficiency and to identify areas ha-in+ )asteful use of ener+y. Ste*s ha-e een
su++ested to reduce ener+y losses and their i!*le!entation is ein+ !onitored -i+orously.
Chapter-4
ROLE OF NTPC AND POWER GENERATION
4.1 Overview:
India;s lar+est *o)er co!*any" NTP3 )as set u* in 178$ to accelerate *o)er de-elo*!ent in India.
NTP3 is e!er+in+ as a di-ersified *o)er !a5or )ith *resence in the entire -alue chain of the *o)er
+eneration usiness. A*art fro! *o)er +eneration" )hich is the !ainstay of the co!*any" NTP3 has
already -entured into consultancy" *o)er tradin+" ash utilisation and coal !inin+. NTP3 ran,ed &18
th
in
the N2007" Bores =loal 2000; ran,in+ of the 6orld;s i++est co!*anies. NTP3 eca!e a Maharatna
co!*any in May" 2010" one of the only four co!*anies to e a)arded this status.
The total installed ca*acity of the co!*any is &&"17? M6 )ith 1$ coal ased and 8 +as ased stations"
located across the country. In addition under DFs" $ stations are coal ased M another station uses
na*thaJ2N= as fuel. The co!*any has set a tar+et to ha-e an installed *o)er +eneratin+ ca*acity of
1"2%"000 M6 y the year 20&2. The ca*acity )ill ha-e a di-ersified fuel !i/ co!*risin+ $A9 coal" 1A9
=as" 119 Nuclear and 189 Rene)ale Ener+y Sources'RES( includin+ hydro. 4y 20&2" non fossil fuel
ased +eneration ca*acity shall !a,e u* nearly 2%9 of NTP3;s *ortfolio.
NTP3 has een o*eratin+ its *lants at hi+h efficiency le-els. Althou+h the co!*any has 1%.109 of the
total national ca*acity" it contriutes 2%.A09 of total *o)er +eneration due to its focus on hi+h efficiency.
?.2 Ash 1tilisation
=ainful and sustainale ash utili<ation is one of the ,ey concerns at NTP3. The Ash 1tili<ation
0i-ision" set u* in 1771" stri-es to deri-e !a/i!u! usa+e fro! the -ast :uantities of ash *roduced at its
17
coal ased stations. The 0i-ision *roacti-ely for!ulates *olicies" *lans and *ro+ra!!es for ash
utili<ation. It further !onitors the *ro+ress in these acti-ities and )or,s for de-elo*in+ ne) se+!ents of
ash utili<ation. At each station" its o)n Ash 1tili<ation cell handles ash utili<ation acti-ities and !a,es
efforts for +ainful and sustainale ash utili<ation.
The :uality of fly ash *roduced at NTP3;s stations is e/tre!ely +ood )ith res*ect to fineness" lo)
unurnt caron and has hi+h *o<<olanic acti-ity and confor!s to the re:uire!ents of IS &%12 G 200&-
Pul-eri<ed Buel Ash for use as Po<<olana in 3e!ent" 3e!ent Mortar and 3oncrete. The fly ash
+enerated at NTP3 stations is ideal for use in !anufacture of 3e!ent" 3oncrete" 3oncrete *roducts"
3ellular concrete *roducts" 4ric,sJloc,sJ tiles etc. To facilitate a-ailaility of dry ash to end G users" fly
ash e-acuation and stora+e syste! ha-e een set u* at coal ased stations. Burther" at NTP3-Rihand
facility for loadin+ fly ash into rail )a+ons has een *ro-ided so that fly ash can e trans*orted in ul,
:uantity throu+h rail)ay net)or,. Such facility is also ein+ *ro-ided at all ne) u*co!in+ ther!al
*o)er stations.
As the e!*hasis on +ainful utili<ation has increased" the usa+e o-er the years has also increased. O-er
the years" the Ash 1tili<ation le-el fro! !ea+er 0.& !illion tons in 1771 G 1772 has reached to roust
28.A1 !illion tons in 2007-10.
The -arious se+!ents of ash utili<ation currently include 3e!ent" Asestos G 3e!ent *roducts M
3oncrete !anufacturin+ industries" 2and de-elo*!ent" Road e!an,!ents construction" Ash 0y,e
Raisin+" 4uildin+ Products such as 4ric,sJ loc,sJtiles" Recla!ation of coal !ine and as a soil a!ender
and source of !icro Gnutrients in a+riculture.
Area wise break-up of utilisation for the year 2009-10 is as under:
Area of Utilisation
Quantity (in Million
Tons)
Land Development 8.8&
Cement manufacturing 8.20
Ready Mix Concrete and asbestos cement
products
0.?0
Roads embankments 1.&?
Ash Dyke Raising &.$1
Bricks and other building products 2.0?
Mine Filling 1.1&
Export 0.70
Others
&.&A
Total 27.61

1se of ash in a+riculture" as a soil !odifier and source of !icronutrient has een successfully
de!onstrated in the far!ers; fields at !any of NTP3 stations. Bor this Sho) case *ro5ectsOin
association )ith A+riculture Research Institutes ha-e een carried out in the far!ers; fields. Farious
cro*s of different seasons ha-e een +ro)n and har-ested and increase in cro*s yield is +i-en elo)L
18
Table-
4.1
Sl. No. Name of Crop Increase in Yields
1 Wheat 1A-229
2 Paddy 10-1$ 9
3 Sugarcane 20-2$9
4 Banana 2$-&09
5 Maize
More than &09
6 Vegetables 10-1$9
To de!onstrate use of ash in construction of rail)ay e!an,!ent research study )as carried out in
association )ith 3entral Road Research Institute '3RRI(" Ne) 0elhi. The desi+n of rail)ay
e!an,!ent de-elo*ed y 3RRI )as -alidated y conductin+ 3entrifu+e !odel tests at IIT" 4o!ay.
3onstruction of rail)ay e!an,!ent of NTP3;s Merry =o-Round 'M=R( trac, for coal trans*ortation
is *lanned at @ahal+aon and Talcher G@aniha.
1se of fly ash in the !anufacture of *re-stressed rail)ay concrete slee*er de!onstrated in association
)ith IIT @an*ur. Research Studies also ha-e een ta,en u* to e/*lore use of ash in #0PE and
Poly*ro*ylene *roducts.
Bro! ti!e to ti!e" NTP3 Ash 1tili<ation 0i-ision is rin+in+ out literature on use of ash in -arious
a**lications in the for! of oo,s M *ro!otional rochures and docu!entary fil!s to create a)areness
a!on+ the *ros*ecti-e users M entre*reneurs for use of ash.
In Octoer 200?" NTP3 launched its Initial Pulic Offerin+ 'IPO( consistin+ of $.2$9 as fresh issue and
$.2$9 as offer for sale y =o-ern!ent of India. NTP3 thus eca!e a listed co!*any in No-e!er 200?
19
Figure-4.1
Table-4.2
)ith the =o-ern!ent holdin+ %7.$9 of the e:uity share ca*ital. In Beruary 2010" the Shareholdin+ of
=o-ern!ent of India )as reduced fro! %7.$9 to %?.$9 throu+h Burther Pulic Offer. The rest is held y
Institutional In-estors and the Pulic.

At NTP3" People before Plant #oad $a!tor is the !antra that +uides all #R related *olicies. NTP3 has
een a)arded No.1" 4est 6or,*lace in India a!on+ lar+e or+anisations and the est PS1 for the year
2007" y the =reat Places to 6or, Institute" India 3ha*ter in collaoration )ith The Econo!ic Ti!es.
The conce*t of 3or*orate Social Res*onsiility is dee*ly in+rained in NTP3>s culture. Throu+h its
e/*ansi-e 3SR initiati-es" NTP3 stri-es to de-elo* !utual trust )ith the co!!unities that surround its
*o)er stations.
?.& 3enPEEP - 3entre for Po)er Efficiency M En-iron!ental Protection
To)ards the reduction of =reenhouse =as '=#=( e!ission fro! Indian ther!al *o)er *lants" NTP3
has een *ro!otin+ and de*loyin+ efficient *o)er +eneration technolo+ies and *ractices fro! desi+n
sta+e to o*eration sta+e and uildin+ local institutional ca*acities for continuously stri-in+ for eco-
friendly technolo+ies.
NTP3 estalished 3entre for Po)er Efficiency M En-iron!ental Protection '3enPEEP( in collaoration
)ith 1SAI0 )ith a !andate to reduce =#= e!issions *er unit of electricity +enerated y i!*ro-in+ the
o-erall *erfor!ance of coal-fired *o)er *lants. The centre functions as a resource centre for ac:uisition"
de!onstration and disse!ination of state-of-the-art technolo+ies and *ractices for *erfor!ance
20
Figure 4.2
i!*ro-e!ent of coal fired *o)er *lants for the entire *o)er sector of India.
Win-win Approach for Global Climate Change
NTP3 has ado*ted a )in-)in strate+y at 3enPEEP y achie-in+ syner+y et)een en-iron!ental
concerns and utility needs. 6e ha-e initiated the 3o!*rehensi-e Perfor!ance O*ti!isation Pro+ra!!e
therey successfully alancin+ the dual o5ecti-es of reducin+ caron-di-o/ide e!issions that contriute
to cli!ate chan+e and facilitatin+ hi+her efficiency of *o)er +eneration.
1nder NTP3;s effort for etter!ent of Indian Po)er Sector" 3enPEEP is also assistin+ -arious state
electricity utilities in India y de!onstration and disse!ination of i!*ro-ed technolo+ies and *ractices.
To increase outreach to SE4s" 2 re+ional centres of 3enPEEP ha-e also een estalished in the
Northern Re+ion '2uc,no)( and Eastern Re+ion 'Patna(.This a**roach has rou+ht si+nificant enefits
to the *o)er *lants and hel*ed in the reduction of e!issions.
4.4 Technological Interventions
Bor +reater acce*taility and assi!ilation of eco-friendly technolo+ies and *ractices" !ethodolo+y of
NTechnolo+y Ac:uisition" 0e!onstration and 0isse!ination; has een ado*ted. Bocus has een on lo)
cost hi+h enefit o*tions. Also in-ol-e *eo*le fro! local *o)er stations durin+ de!onstration and
)ides*read disse!ination.
Methodology & Reach
4oiler Perfor!ance O*ti!isation Predicti-e !aintenance syste! and technolo+ies
for dia+nostics
4est *ractices for air-*reheater" etc. condenser
)ater *ressure cleaner
Reliaility 3entred Maintenance'R3M(
3ondenser heliu! lea, detection Ther!odyna!ic !odelin+L A tool for
*erfor!ance analysis
Stea! turine *erfor!ance assess!ent M Ther!al audit forL- accurate assess!ent of
21
Figure 4.3
o*ti!isation de+radations
Real ti!e !easure!ents M alancin+ of air-fuel
ratio
Ris, E-aluation M Prioritisation 'REAP(
3oolin+ to)er" condenser *erfor!ance
o*ti!isation
Ne) o-erhaul *ractices
Tale ?.&
?.$ Afforestation:
Maintenance of ecolo+ical alance and a *erfect en-iron!ent has een
of ut!ost i!*ortance at NTP3. En-iron!ent *lannin+ and *reser-ation
is an inte+ral *art of its *ro5ect acti-ities. NTP3 underta,es afforestation
*ro+ra!!es co-erin+ -ast tracts of land in and around its *ro5ects in a
concerted id to counter the +ro)in+ ecolo+ical threat.
The crucial need for conser-ation and restoration of the de+raded
ecosyste! and *reser-ation of +enetic resources of the country led to
the enact!ent of the N6ild 2ife Protection Act; '178?( and NBorest Act;
'17%0( in addition to le+al acts of air" )ater and en-iron!ent.
4.6 NTPC's Approach:
It has een *ossile to achie-e a satisfactory co!ination of en-iron!ental :uality and techno-
econo!ics throu+h deter!ined efforts at NTP3. 3ontinuous -i+ilance is !aintained to !ini!ise
*ollution. This is o-er and ao-e the other en-iron!ent !ana+e!ent *ro+ra!!es that start
si!ultaneously )ith start of construction acti-ities.
The a**ro*riate afforestation *ro+ra!!e for *lant" to)nshi*" +reen-elt and other sites are desi+ned
accordin+ to the +eo+ra*hical features. S*ecies are selected on the asis of their ada*taility and
+rou*ed )ith local re*resentati-es. The +ro)th characteristics" flo)erin+ *attern and cano*y 's*readin+
nature( are e-aluated in their distriution o-er these sites of afforestation. These considerations not only
contriute to the aesthetics ut also +o a lon+ )ay in ser-in+ as NSin,s; for the *ollutant e!ission of the
*o)er *lant. At ti!es" they e-en co!at *ollution fro! other industries in the surroundin+ area.
NTP3 has de-elo*ed inde*endent #orticulture 0e*art!ent at its *ro5ects headed y e/*erienced
horticulture officers J su*er-isors.
Sa-in+ e/istin+ trees" *lantin+ ri+ht at the e+innin+ of construction *hase" *reser-ation of trees and
ad-ice fro! State Borest 0e*art!ents and a+ricultural uni-ersities are a fe) +eneral +uidelines
22
Figure 4.4
follo)ed y NTP3.
Chapter-5
ULTRA MEGA POWER PRO1ECTS
1ltra Me+a Po)er *ro5ects '1MPP( are a series of a!itious *o)er *ro5ects *lanned y the
=o-ern!ent of India. 6ith India ein+ a country of chronic *o)er deficits" the =o-ern!ent of
India has *lanned to *ro-ide >*o)er for all> y the end of the ele-enth *lan 'y 2012(. This )ould
entail the creation of an additional ca*acity of at least 100"000 M6 y 2012. The 1ltra Me+a
Po)er *ro5ects" each )ith a ca*acity of ?000 !e+a)atts or ao-e" are ein+ de-elo*ed )ith the
ai! of rid+in+ this +a*.
The 1MPPs are seen as an e/*ansion of the MPP 'Me+a Po)er Pro5ects( *ro5ects that the
=o-ern!ent of India undertoo, in the 1770s" ut !et )ith li!ited success. The Ministry of
Po)er" in association )ith the 3entral Electricity Authority and Po)er Binance 3or*oration 2td."
has launched an initiati-e for the de-elo*!ent of coal-ased 1MPP>s in India. These *ro5ects
)ill e a)arded to de-elo*ers on the asis of co!*etiti-e iddin+.
The =o-ern!ent has a tar+et of Po)er for AllO y 2012. To !eet the ca*acity addition tar+ets
re:uired to achie-e this o5ecti-e" the Ministry of Po)er launched an initiati-e facilitatin+ the
de-elo*!ent of coal-ased 1MPPs. 0e-elo*!ent of lar+e *o)er *ro5ects can result in chea*er
*o)er throu+h econo!ies of scale. Reco+ni<in+ this" the =o-ern!ent en-isa+es a series of
*ro5ects of at least ?"000 !e+a)atts 'M6( each. These *ro5ects )ill e a)arded to de-elo*ers
identified and selected throu+h international co!*etiti-e tariff-ased iddin+ *rocesses. The
*ro5ects )ill e de-elo*ed on a uild-o)n-o*erate asis. 4ased on su*ercritical technolo+y" these
*ro5ects are also e/*ected to e !ore en-iron!ent friendly than con-entional sucritical
+eneratin+ units. India )ill e de*endent u*on coal as a fuel for a lar+e *ortion of its *o)er
+eneration for the foreseeale future as it has no other *ractical alternati-es. Thus the issue is
ho) to +enerate *o)er fro! coal as cleanly as *ossile. The Pro5ect )ill e one of the ne)
+enerations of cleaner coal *ro5ects and thus !erits A04>s acti-e su**ort. The Pro5ect )ill
contriute si+nificantly to reducin+ *o)er shorta+es in the country.
5.1 The Sasan Ultra Mega Power Project RelianceL
Reliance Po)er;s Sasan 1MPP is a &"7A0 M6 'A units of AA0 M6 each( su*er-critical
technolo+y ased *it-head coal-fired *o)er +eneratin+ *lant at Sasan" in Madhya Pradesh" India.
this is the first of the three 1MPPs a)arded to Reliance Po)er. It in-ol-es de-elo*!ent of
associated ca*ti-e coal !ines allotted to the 3o!*any" )hich ensures fuel security. Sasan Po)er
has entered into a 2$-year Po)er Purchase A+ree!ent 'PPA( )ith off-ta,ers of *o)er for its
23
entire ca*acity at a co!*etiti-e tariff of P 1.17 *er ,6h. The Pro5ect )ould su**ly *o)er to 1?
off-ta,ers in se-en states enefittin+ o-er &$ crore Indians. The esti!ated Pro5ect 3ost of the
Po)er Pro5ect 'e/cludin+ coal !ines( is aout 1A"000 crore. The construction of the Pro5ect is
*ro+ressin+ at a fast *ace )ith the e/*ected co!!issionin+ in 2012-1&. Reliance Po)er
Reliance Po)er 2i!ited" a *art of Reliance Anil 0hiruhai A!ani =rou*" is India>s leadin+
*ri-ate sector *o)er +eneration 3o!*any. Reliance Po)er is i!*le!entin+ *o)er *ro5ects )ith
a++re+ate ca*acity of o-er &8"000 M6" y far the lar+est de-elo*!ent *ortfolio in the country.
The 3o!*any also has the lar+est coal reser-es in the *ri-ate sector esti!ated at !ore than t)o
illion tones
5.2 Ultra Mega Power Project Tata Power
The Mundra 1MPP )as a)arded to Tata Po)er and as *er the share *urchase a+ree!ent Tata
Po)er ac:uired 3=P2 on 22 A*ril 2008.The *ro5ect )ill ha-e fi-e units of %00 M6 each"
+eneratin+ a total of ?"000 M6 usin+ su*ercritical technolo+y and ?0"000 MT Jday i!*orted
coal.Po)er )ill e e-acuated throu+h si/ ?00,F lines" to e installed y Po)er =rid" to
ulti!ately enefit the States of =u5arat" Maharastra" Pun5a" #aryana and Ra5asthan
5.3 Ultra Mega Power Project NTPC
The ?"000-M) @uda+i 1ltra Me+a Po)er Plant *ro*osed to e set u* y the National Ther!al
Po)er 3or*oration 'NTP3( at @uda+i in 4asa-ana 4a+e)adi talu, of 4i5a*ur district"
24
Figure 5.1
Chapter-6
ADVANCED TECHNOLOGIES OF PREVENTIVE MAINTENANCE FOR
THERMAL POWER PLANTS
A.1 OverviewL
Althou+h ther!al *o)er +eneratin+ facilities are a+in+" fle/ile o*eration in res*onse to
chan+es in the de!and for electrical *o)er is re:uired. To e/tend the life and !ana+e the
!aintenance of those facilities" ad-anced *re-enti-e !aintenance technolo+y is i!*ortant. Bor
that reason" #itachi has een +ra**lin+ )ith nondestructi-e ins*ection" life assess!ent
technolo+y" rationali<ation technolo+y for scheduled ins*ections of the oilers" stea! turines"
+as turines and other !achinery used in ther!al *o)er +eneration to stren+then *re-enti-e
!aintenance and increase the efficiency of !aintenance. Recently" they ha-e een de-elo*in+
*roducts and ser-ices for ad-anced su**ort for !aintenance and *reser-ation throu+h the use of
IT 'infor!ation technolo+y( and net)or, technolo+y" +oin+ eyond )hat has *re-iously een
a-ailale.
A.2 IntroductionL
In recent years" startu* and shutdo)n o*erations ha-e eco!e fre:uent in a+in+ ther!al *o)er
+eneration facilities" and *re-enti-e !aintenance technolo+y has steadily een increasin+ in
i!*ortance fro! the -ie)*oints of e/tendin+ the scheduled ins*ection inter-al and stren+thenin+
the inde*endent !ana+e!ent of facilities. Burther!ore" concernin+ *reser-ation of the +loal
en-iron!ent as )ell" there is also a stron+ de!and for the reduction of 3O2 e!issions throu+h
i!*ro-ed +eneration efficiency and fuel con-ersion in e/istin+ facilities.
1nder such circu!stances" #itachi is +oin+ eyond the a**lication of ne) technolo+y that has
25
Figure 5.2
een de-elo*ed for ne) *o)er *lants to old facilities" and has ta,en u* the challen+e of
de-elo*in+ our o)n *re-enti-e !aintenance technolo+y. To+ether )ith these ad-anced
technolo+ies and *roducts" #itachi is !a,in+ use of IT" )hich has de-elo*ed ra*idly in recent
years" to *ro-ide +loal ser-ices that contriute to life-cycle cost !ini!i<ation for *o)er
+eneration facilities 'see Bi+. 1(.

A.& Application of IT to Preventive
Maintenance of Thermal Power PlantsL
#itachi is *roceedin+ to add intelli+ence in a )ide ran+e of fields y !a,in+ use of IT and the
*ro*rietary ,no)led+e )e ha-e accu!ulated in -arious industrial areas )ith the o5ecti-e of
ein+ the custo!ers; 4est Solutions PartnerO y offerin+ ne) solutions.
In the field of *re-enti-e !aintenance for ther!al *o)er *lants" too" they ha-e ta,en u* the
challen+e of usin+ IT and net)or, technolo+y to *ro-ide ser-ices for the su**ort of ad-anced
!aintenance and *reser-ation that +o eyond )hat has een a-ailale to the custo!er in the *ast.
6ith the increasin+ly se-ere de!ands on the o*eration of a+in+ ther!al *o)er *lants" ty*ified
y e/tension of the *eriod for scheduled ins*ections and 0SS 'daily start-u* and shut-do)n(
o*erations" there is increasin+ need to ,no) the :uantitati-e state of the facilities" such as y
!onitorin+ o*eration at ti!es of transition and ,no)in+ the deterioration state of e:ui*!ent" in
addition to the re+ular !onitorin+ of o*eration. There is also a de!and for the *ro-ision of
*erfor!ance e-aluation technolo+y for life-cycle cost !ini!i<ation" as )ell as the *ro-ision of
26
Figure
6.1
o*eration !ethods that use such technolo+y to o*ti!i<e efficiency and the *ro-ision of o*eration
data !ana+e!ent ser-ices. To !eet that de!and" #itachi is de-elo*in+ ser-ices )hich !a,e use
of IT" such as *lant !onitorin+ ser-ices and en+ineerin+ ser-ices.
6.4 Preventive Maintenance Technology for Boilers Application of the Latest
Development TechnologyL
The con-entional techni:ues for nondestructi-e ins*ection of oiler !aterials and *arts
include PT 'li:uid *enetrant testin+(" MT '!a+netic *article testin+(" and 1T 'ultrasonic
testin+(" a!on+ others.
These ty*es of ins*ection" ho)e-er" ha-e *role!s such asL
'1( difficulty of ins*ectin+ narro) +a**ed areas"
'2( re:uirin+ a lar+e a!ount of associated )or," and
'&( difficulty of lifeti!e dia+nosis or can *redict :uantitati-e da!a+e *ro+ress.
To co*e )ith these *role!s" #itachi has een de-elo*in+ -arious ,inds of scheduled
ins*ection rationali<ation technolo+y to achie-e lo)er-cost" ti!ely ins*ection y reducin+ the
*re*aration )or, and to achie-e fast" hi+hly accurate ins*ection y e!*loyin+ ad-anced
ins*ection e:ui*!ent )ithout direct contact. The !ain dia+nostic *oints and dia+nosis
technolo+y are sho)n in Bi+. &. These rationali<ed technolo+ies are already ein+ a**lied in
actual *lants.
Of these technolo+ies" E2BOSS 1T 'electronic focus sector scan ultrasonic testin+(" )hich
can e-aluate internal defects in the )elds of !ain *i*es" is descried elo)L
E2BOSS 1T can e-aluate defects contained in )elds and in narro) no<<le stus y electronic
focusin+ and sector scannin+ techni:ues. A !a5or feature of this de-ice is that the scannin+
27
Figure 6.2
ran+e of the 1T *roe is s!aller than that used in the con-entional 1T !ethod" so the defect
si<e and location can e deter!ined accurately. The results of E2BOSS 1T ins*ection of a
*late '100-!! thic,( utt )eld that contains an artificial defect are sho)n in Bi+. ?. The
defect detected y the nondestructi-e !ethod !atches )ell )ith the defect as confir!ed y
cross-section e/a!ination. 6ith such an e/cellent defect detection ca*aility" this e:ui*!ent
is ein+ a**lied to *recise ins*ection of i!*ortant areas" such as the )elds of !ain *i*es.
6.5 Scheduled Inspection Rationalization Technology:
The -arious ty*es of nondestructi-e ins*ection e:ui*!ent sho)n in Bi+. & are all ca*ale of
:uantitati-e e-aluation of defects" and can also e called rationali<ed technolo+ies )ith
res*ect to shortenin+ ins*ection ti!e for schedule ins*ections.
In addition to such hi+her *erfor!ance of the ins*ection e:ui*!ent itself" rationali<ation
technolo+y such as for shortenin+ the *re*aration ti!e for ins*ection is also desired.
Bor e/a!*le" in the furnace of coal-fired oilers" fused ash adheres to *laces such as the ends
in the heat e/chan+e *i*es that are sus*ended fro! the to* of the furnace. Such ash !ay +ro)
to for! hard clin,ers. 4ecause it is -ery dan+erous if those clin,ers fall inside the furnace"
they should e re!o-ed efore installin+ the scaffoldin+ and *erfor!in+ the ins*ection and
re*air )or, at the ti!e of scheduled ins*ections. The re!o-al of the clin,ers in this )ay
re:uires !uch ti!e and laor. Bor that reason" hitachi turned attention to 6D ')ater 5et(
technolo+y" and de-elo*ed a s*ecial no<<le that *roduces se-eral ti!es the force of the
con-entional no<<le. 1sin+ this no<<le reduces the ti!e re:uired for clin,er re!o-al
si+nificantly" and the ti!e fro! the shutdo)n of a *lant to the e+innin+ of ins*ection and
re*air can e +reatly reduced.
28
6.6 Preventive Maintenance Technology for Steam
Turbines:
Bor hi+h-te!*erature co!*onents of a+in+ stea! turines" accurate *re-enti-e !aintenance
and e/tension of !achine life is eco!in+ estalished.On the other hand" for lo)-te!*erature
co!*onents" of )hich lo)-*ressure turines are a ty*ical e/a!*le" da!a+e related to
corrosion has een a**earin+ in recent years. In !ost of those cases" corrosion fati+ue
crac,in+ or S33 'stress corrosion crac,in+( is seen in the se-erely corrosi-e *hase transition
<one en-iron!ent. To deal )ith these *role!s" hitachi estalishin+ hi+hly accurate lifeti!e
e-aluation technolo+y deri-ed fro! an understandin+ of actual o*eration in ser-ice. That
technolo+y is ased on analysis of the -iratory res*onse in +rou*ed lades in the lo)
*ressure sta+e and accu!ulatin+ data on the occurrence and +ro)th of corrosion *ittin+ in the
actual en-iron!ent. As a result" it is tryin+ to !aintain the reliaility of lo)-te!*erature *arts
in a corrosi-e en-iron!ent y reco!!endin+ the o-erhaul of lo)-*ressure turines that ha-e
29
Figure 6.3
een in ser-ice for 20 years or !ore y re!o-al of the uc,et.

6.7 Development of Scheduled Inspection Technology for Improving In
Efficiency:
6ith the continuin+ rela/ation of re+ulation" there is an e-en stron+er de!and for i!*ro-e!ent
in the o*eratin+ efficiency of facilities as )ell as the lo)erin+ of !aintenance costs. Bor those
reasons" )e are endea-orin+ to raise the efficiency of )or, in-ol-ed in the scheduled ins*ection
of turines and to de-elo* -arious ty*es of technolo+y for increasin+ efficiency and conser-in+
ener+y. The technolo+y for rationali<in+ scheduled ins*ection )or, not only i!*ro-es that
)or, directly" ut also includes technolo+ies" such as facility dia+nosis technolo+y" that
!ini!i<es that )or, and asset !ana+e!ent technolo+y that in turn increases the efficiency of
!ana+in+ the scheduled ins*ection data.
30
Figure 6.4
6.7.1 Rationalization Technology For Scheduled
Inspections:
To shorten the scheduled ins*ection *rocess" )e ha-e de-elo*ed ta*ered slee-e ty*e oltin+
e:ui*!ent for the uc,et cou*lin+ and oil flushin+ reduction e:ui*!ent. The ta*ered slee-e ty*e
oltin+ e:ui*!ent allo)s s!ooth olt e/traction" so the olt loosenin+ ti!e can e reduced to
half a day *er cou*lin+. Pre-iously" fi-e to se-en days )ere re:uired to flush the oil for cleanin+
the earin+s and earin+ o/ after co!*letin+ the asse!ly of the turine and +enerator. The oil
flushin+ reduction e:ui*!ent" ho)e-er" achie-ed results that fully satisfy the s*ecified earin+
oil cleanness re:uire!ent in only three days" as )ell as reducin+ the test o*eration ti!e.
6.7.2 Facility Diagnosis Technology :
Bor facility dia+nosis" )e de-elo*ed lea, dia+nosis technolo+y that !a,es use of AE 'acoustic
e!ission(. 1* to no)" AE dia+nosis has een a**lied to anor!ality detection in rotatin+ *arts
such as turines and *u!*s. No) )e ha-e de-elo*ed technolo+y for a**lyin+ this !ethod to
stea! lea,s in sto* -al-es as )ell. An a**lication e/a!*le is sho)n in Bi+. $.
6.7.3 Asset Management Technology:
As an asset !ana+e!ent technolo+y" )e ha-e de-elo*ed a scheduled ins*ection record and
history !ana+e!ent a**lication syste!. Ra*id and *a*erless recordin+ of data fro! the ti!e of
!easure!ent to data !ana+e!ent is !ade *ossile y usin+ a net)or, to connect the ins*ection
site and the *ersons res*onsile for data a**ro-al and !ana+e!ent. This ins*ection recordin+
a**lication is lin,ed to a history !ana+e!ent syste!" and ser-es to *ro-ide data for the history
!ana+e!ent of assets. In this )ay" the -arious ty*es of infor!ation fro! the ins*ections is data
ased for each asset so that the deterioration trend of each asset can e ,no)n. Burther!ore" data
!inin+ is done easily y ti!e series of the !aintenance data for each asset or y *heno!enon. A
sa!*le )indo) fro! the turine history !ana+e!ent a**lication is sho)n in Bi+. A. Introducin+
the -arious ty*es of rationali<ation e:ui*!ent that ha-e een de-elo*ed can shorten the standard
*rocess for a A00-M6 turine to aout fi-e days and a 10 to 1$9 sa-in+ in ener+y can e
e/*ected.
31
6.8 Preventive Maintenance Technology for Gas
Turbines:
The load conditions are -ery se-ere for +as turines" )hich use hi+h-te!*erature co!ustion
+ases as the )or,in+ fluid. Bor that reason" differently fro! stea! turines" the hot +as *ath
co!*onents that are *laced in the *ath of the co!ustion +ases ha-e a relati-ely short
o*eratin+ ti!e and are re*aired re*eatedly durin+ the course of use. Maintenance costs for
re*air" reconditionin+ and *art u*datin+ are a lar+e *ro*ortion of the cost of +eneratin+
electricity" so the ad-ance!ent of *re-enti-e !aintenance technolo+y is i!*ortant in ter!s of
econo!y as )ell as reliaility.
6.9 Lifetime Management and Repair of Hot Gas Path
Components:
The life of hot +as *ath co!*onents is shortened y cree*" arasion" o/idation and other
such da!a+e that is related to o*eratin+ ti!e and y da!a+e that occurs as the result of
re*eated startu*s and shutdo)ns" such as lo)-cycle fati+ue. Accordin+ly" lifeti!e
!ana+e!ent e!*loys the e:ui-alent o*eratin+ ti!e !ethod" )hich ta,es into account the
effects of the nu!er of startu*s shutdo)ns and sudden chan+es in load" etc. as )ell as the
32
Figure 6.5
actual o*eratin+ ti!e. 6hen the e:ui-alent o*eratin+ ti!e reaches the s*ecified lifeti!e"
that co!*onent is considered to ha-e reached the end of its o*eratin+ life. 3oncernin+ the
hot +as *ath co!*onents" if the ins*ection result e/ceeds the 5ud+e!ent criteria" the
co!*onent is re*aired. See Tale 1 for a descri*tion of the re*airs. Of those" the latest re*air
technolo+y that is currently ein+ used in actual *lants is descried elo).
6.10 Gas Turbine Bucket Recoating Repair:
=as turine uc,ets are su5ected to se-ere conditions of centrifu+al force and hi+h ther!al
stress load in the hi+h-te!*erature and hi+h-*ressure co!ustion +ases. Bor that reason" Ni-
ased su*er-alloys are used and an o/idation resistance coatin+ is a**lied to the uc,et
surface to *rotect the ase !aterial. 6ith lon+-ter! use of the uc,ets" the coatin+ suffers
da!a+e y deterioration" so it is necessary to stri* the old coatin+ and recoat the uc,ets
efore the ase !aterial is da!a+ed. Measures are also ta,en a+ainst erosion of the uc,et
ti*s y hi+h-te!*erature o/idation. #ot tearin+ fro! )eldin+ heat flu/ usually occurs in Ni-
ased su*er-alloys )ith hi+h Ti or Al content" so it is a difficult !aterial to )eld. In recent
years" ho)e-er" lo)-current )eldin+ !ethods ha-e een de-elo*ed" so re*air y uild-u*
)eldin+ has eco!e *ractical for the lo)-stress uc,et ti*s.
6.11 Gas Turbine Nozzle Blade Diffusion Brazing Repair:
=as turine no<<le lades suffer ther!al fati+ue crac,in+ due the ther!al stress caused y
start-u* and shut-do)n. Those crac,s !ust e re*aired y )eldin+ durin+ the course of
no<<le lade use. There is a tendency for !ulti*le ther!al stress crac,s to a**ear o-er a
)ide area of the no<<le lades" so re*airin+ the! ta,es a +reat deal of ti!e and effort.
Burther!ore" defor!ation of the no<<le lades occurs in *ro*ortion to the a!ount of heat
a**lied durin+ the )eldin+. 0iffusion ra<in+ re*air a-oids that *role! y usin+ a ra<in+
filler !etal that has aout the sa!e co!*osition as the ase !etal" ut )ith a lo) !eltin+
*oint !etal added. This !ethod in-ol-es cleanin+ the surfaces of the crac,s" flo)in+ the
filler !etal into the crac,s and then diffusin+ the filler !etal into the lade !etal )ith a heat
treat!ent. This !ethod reduces laor for the re*air and *re-ents defor!ation of the lades.
4y usin+ oth )eldin+ re*air and diffusion ra<in+ re*air" )e are reducin+ laor and
e/tendin+ the life of no<<le lades.
33
Comparison
Table- 6.1
34
CONCLUSION
1. There is a hu+e increase in de!and for *o)er" due to *o*ulation increase" econo!ic
de-elo*!ent" ra*id industriali<ation and +ro)th of IT ser-ices industry. #o)e-er
shorta+e of *o)er is not only incon-eniencin+ the citi<ens of the country ut also
ad-ersely affectin+ the industrial *roduction and studies of the students durin+ the
e/a!ination ti!e
2. The *ossiility of increasin+ *o)er *roduction throu+h hydro-electric route is -ery
li!ited. There is -ery hu+e resistance to uild nuclear *o)er *lants due to the ris, of
radiation and its ad-erse effect on the *o*ulation around the *o)er *lants. The recent
tra+edy at Bu,ushi!a in Da*an has only co!*licated the nuclear ener+y situation.
&. The final conclusions of this *a*er are-
I. Presently India has sustantial ther!al *o)er *roduction infrastructure. The
technolo+ical inno-ations introduced y #itachi as e/*lained ao-e should e
ado*ted y the -arious ther!al *lants.
II. NTP3 is doin+ a yeo!an ser-ice in the field of ther!al *o)er in India. All
encoura+e!ent should e +i-en to it" to not only increase the ca*acity ut also the
efficiency of *o)er *roduction. =o-ern!ent of India should *ro-ide it )ith
ade:uate ca*ital su**ort.
III. The recent decision of the =o-ern!ent of India to a)ard 1MPP to -arious *ri-ate
sector *arties is a -ery )elco!e decision. More and !ore locations suitale for
1MPP should e identified y the =o-ern!ent and the *ro5ects should e
a)arded to the *ri-ate sector e/*editiously.
35
REFERENCES
E-BOOKS & 1OURNALS
NTP3 =uide for 1sers of 3oal Ash
Bly Ash 4ric,s G Modern 4uildin+ MaterialC To)ards 3leaner En-iron!ent
Bly Ash for 3e!ent 3oncrete G A Resource for #i+h Stren+th and 0uraility of Structure
at 2o)er 3ost
Ritish Electricity International '1771(. Modern Power Station Pra!ti!e% in!orporating
modern power system pra!ti!e '&rd Edition '12 -olu!e set( ed(. Per+a!on. IS4N 0-0%-
0?0$10-2&.
WEB LINKS
))).air-dis*ersion.co!
))).nt*c.co.in
))).e!t-india.netJPowerPlant 3o!*onent
))).Sciencedirect.co!
36