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A Presentation On SettingSetting-up of A World Class Energy Technology & Research Institute By: Dr R.R.Sonde Ph.D, FNAE On 3/8/2004
Synopsis A. NTPC Profile B Technology Centre in Energy-- The Imperatives Energy-C. The Roadmap for Technology Centre D. Net working with institutes
NTPC was set up in 1975 in the central sector to bridge the widening gap of demand and supply of power in India.
NTPC Vision To be one of the worlds largest and best power utilities, powering Indias growth
NTPC OWNED
COAL GAS / LIQ. FUEL TOTAL 13 7 20 17,980 3,955 21,935
OWNED BY JVCs
COAL GRAND TOTAL 3 23 314 22,249
In addition, NTPC also manages Badarpur Thermal Power Station (705 MW ) of GOI in Delhi.
NTPC Today- Lighting 1/4th of India TodayOne of the largest thermal generator in the World- Data Monitor UK
The Business- BOO thermal plants BusinessProjects: Full in-house implementation O&M: Purchase fuel to bulk power sale Consulting: full electricity value chain
NTPC- CAPACITY PROFILE (MW) Present Capacity Constrctn Active Fuel Mix Coal Gas 22,249 5,000 + 9,000 + 17,000 + 4000 + 80-150
CCPP-GT
NTPC is surging ahead to add another 20,000 MW and become 40,000 MW company by 2012
Global Stature
Sixth Among the Top Ten Global Thermal Generators
TWH 2001
600
500
501
400
300
175
200
152
146
141
133
128 126
102
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Rs. 25964.2
PROFIT
Rs. 5260.78
2 -9 3 -9 4 -9 5 -9 6 -9 7 -9 8 -9 9 -0 0 -0 1 -0 -0 02 20 3 20 -0 03 4
91
92
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93
94
95
96
97
98
99
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20
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Years
NTPC - 2017
In summary, NTPC would be a leading power utility in the world by 2017, in line with its current vision
NTPC in 2017
Fortune 500 company An Indian MNC with presence in many countries Diversified utility with multiple businesses Amongst top five market capitalisation in the Indian market Group turnover1 of over Rs. 1,400 Bn with 30000+ employees Setting benchmarks in project construction and availability and efficiency Have a strong research and technology base Loyal customer base in both bulk and retail supply Preferred employer A leading corporate citizen with a keen focus on executing its social responsibility
R&D Labs
Academia
Technology Build up
UOP Xytel
Prime Examples
Product Idea/ Conception Fundamental Research (DDR) In Labs, Academics
Further R&D
- Product improvement - Process Improvement - New Process Development - New Product Idea
The need is :
- Return to original Model - While maintaining strengths
Electricity Sector, is today facing similar technology questions as it faced 50 years back
120000
Total Capacity (MW)
Sellers Market
Paradigm Shift
Buyers Market
1950
Full Plant Import
1960
1970
Indigenous Manufacture
1980
Design Copy
1990
User Driven Customizations
2004
Design Replication
2010
2020
2030
Industry Setup
Monolithic SEBs
Central Utilities
Challenge
PLF Maximize
The technology approach adopted to jump start capacity appears inadequate in the changing business scenario
Regulatory Regime
Norms Tightened
COG: Profits:
Sellers Market
Power is Purchased Hand Holding By Govt. Making Power in Plenty & Also Make Money
Buyers Market
Paradigm Shift
Power Has to be sold Survival of the Fittest Making Plenty of Money Through Power
Worldwide the Technology Development and Engineering are two separate activities...
Technology Developer Manufacturer Industry License Tech Lab Development Academia Utility
Checks on Drawings and Documents System Plant Engineering Integration Manufacturer inspection shop, site tests
Exponential Growth
Organization
Cost Reduction Intensified Products & Processes Integration of Technology Development of Required Knowledge & Technology Identification of Performance Gaps
Product improvement Process Improvement
Product improvement, Process Improvement New Process Development, New Product Idea
Emergence of Technology Implant Culture in India- so internalized that these are no longer viewed as problems... Equipment Supply Industry
Collaborator
Engineering
Design Copy
Operations
Central Groups
Equipment Manufacturer
Equipment
Station
Station
Station
Station
Project
No new technology development Poor technology customization Weak technology improvement Hamstrung cost improvements
Inadequate system design improvements Inadequate equipment design intervention Inadequate use of Project Management techniques Engg Services dormant No cost rationalization instruments
Missing self improvement & correction instruments Bloated and outdated maintenance approach Heavy Inventories Sluggish Procurement methods Inoptimal workforce utilization Inadequate focus on fuel component O&M services market lying dormant
The weak links are a result of the technology import culture from the Colonial legacy- especially as Electricity was considered an input and not an end unlike Space and Nuclear sectors
The reason is late Indian entry to technology development arena. Affluent nations have had the advantage of SEQUENTIAL DEVELOPMENT facilitating knowledge systems development
UK Germany USA Russia Japan
Technology Multiplication
1800
1850
1900
1950
2000
Indian Entry
Missed Opportunity Few Technical Institutes established No involvement in Engg. Sciences Import escapism culture established No studies on domestic conditions Poor industry quality consciousness
Systemic Distortions Focus on Equipment Multiplication Electricity perceived as an input Availability of easy imports Low focus on T.D. development Imported designs were implanted
Technology implants in the Electricity sector have had serious fall out on development of knowledge systems which are required for Technology Development
The effect entered even organisations set ups which do not differentiate between knowledge work, service functions and skill work
Typical Indian Organization Mixed up knowledge and service functions No education differentiation at entry Absence of filters on Management Levels Undifferentiated manpower movement No separate specialist cadres
Presence of distinct knowledge groups in the company structure provides a robust framework which facilitates informed management decisions and provides internal resources for new programme conceptualisation, roll out and midcourse corrections.
The sequential development in original technology countries resulted in evolution of country wide systems with Knowledge and Technology focus...
The Originals
Equipment Manufacturer
UK Germany USA
Equipment
Russia Japan
Universities
Labs
The differentiator and key enabler in such systems is the collaboration of industry-labs- academia- The GOLDEN TRIANGLE
For the Indian Power Sector to grow on the competitive turf spread by the new Electricity Law it is necessary to establish the Golden Triangle...
Equipment Manufacturer
Industry
Equipment
Design Copy
Utility
Power Knowledge Center
R&D Labs
Academia
Competition alone- which is one key objective of the new target framework without the systemic enablers will have limited improvement potential
NEW BUILDS: Arrest and Reverse Increasing Trend in Capital Cost Without Compromising Quality
Dramatic Cost Reductions Required OPERATING STATIONS: -Destination No.1 Arrest and Reverse Increasing Trend of Maintenance
Cost Maximize Availability and Efficiency
Age
The new environment is creating Paradigm Mismatches for the utilities Commercial - Making Power - Maximize Generation New Build High End (VX)!!! O&M Strategies Low End (LX)
- Making Money
- Maximize Profit
- Predominantly
Replacement Based - Proactive Condition Based - High Spare Inventory R&M Strategies Predominantly Replacement Based
Required Shift
Risk Based
The real challenge lies in the future - Dramatic changes are in the offing - Power sector has to shoulder these
The power sector has to reorient itself to the new challenges for positive deliverance
The huge capacity will Destination No.3 require a equally large, reliable and intelligent - Strengthen the power delivery system power delivery
system
The emerging Destination No. intelligent 4 society will give rise to Customer - Enable Managed customer Service managed Networks service
networks
Utility Company
wires
Pipes Destination
No. 5
The question of sustainability of such mega development will naturally require a solution Power will have to metamorph into a new role in the future electricity dependent society
Power Distribution Technologies Customer level intelligent automation system to ensure harmonic detection, proper metering, identification & control on overloading feeders, CAD distribution transformers & data communication systems Custom power devices Distributed power generation software
Power Transmission
Voltage stability assessment & control Power system controllers Operational strategies for maximising regional power transfer Wide area measurement & protection
2010
2015
2020 2025 T I M E
2030
Certain broad interventions for reaching the identified Destinations emerge from the Technology Driver-Destinations Matrix have been identified
Knowledge and Technology Drivers Cost Reductions Managing Energy/Carbon Conflict StrengthenPower Delivery System Enabling Customer Managed Ser Networks Managing Sustainability Challenge
System Improvements Micro Technology Interventions Distributed Generation Advanced Coal Conversion
Studies are underway to identify Technology drivers for destinations like enabling customer managed service networks.
Actualization of the technology initiatives calls both for Systemic Improvements as well as Technology Development
New Initiatives Revisit Procurement needs & specifications Technology Options Studies Village specific technology solutions Availability Studies Reliability Studies Heat Rate Initiatives Stations Modernization focus Fuel Options Studies Fuel Price Reduction Advocacy New Ash utilization Initiative New O&M Services Initiative Centralized Procurement Shared Maintenance Services Inventory Management Focus Productivity Enhancements
Knowledge Activity Consolidation Automate non-value added jobs Create Knowledge Platforms Create Power Plant Schools Create Technology Platforms Knowledge Groups in companies Knowledge Worker Sustenance Network with external agencies
Technology Initiatives IGCC development for Indian coal Hybrid power system development Distributed Generation Options Carbon Sequestration Technologies Fuel Cell technologies Low grade heat utilization SPM reduction technologies On-line Energy Intensification and Diagnostic Model (EIDM) Resource optimization & site integration technologies (water, ash, chemicals) Ageing Management TechnologiesCorrosion/Erosion/ Fatigue, creep/ Coatings Robotized Maintenance Systems
Immediate Actions
TMTM-1.1: Low Grade Heat Utilization : Phase - III - Condensate Heating Using Flue Gas - Air Conditioning & CW Cooling Through Extra IP Exhaust Steam - Integration of Solar Power & Kalina Cycle
Part Condensate
Return
ID - A
Solar Heating
Chimney
ID - B
Solar Heating
Additional Steam Turbine Ammonia Turbine Saved IP Exhaust Steam Kalina Cycle Stirling Engine Control Room Cooling
CW Cooling
Dual FGC
Humidification System
Hybrid
FGC
Aqueous Ammonia FGC Anhydrous Ammonia FGC Urea based Ammonia FGC
Molten Sulfur FGC Granular Sulfur FGC Native SO2 Conversion System In-Line SO2 Conversion System
FGC Technology Ammonia based FGC External SO3 injection based FGC Internal SO2 conversion based FGC Dual FGC System Humidification FGC System Hybrid FGC System
Flue Gas Distribution System CFD Modeling of Gas Distribution inside ESP Flow Model Test facilities of ESP Proto-Type Gas Distribution Solutions
Target Bypass FG % 0%
EIDM
Advanced Instruments LPT Exhaust Steam Dryness Fraction Meter On-Line LOI Measurement Real Time FG Flow meter Real Time Condenser CW Flow measurement On-Line FG Analyzer On-Line Moisture Meter
Phase-III, [Jan05]
Power Hydrogen
Liquid fuels
IGCC
Case 3: Case 2 +Class H Case 4: Case 3 +OTM 5: Case 4 +MCFC Case 6: Case 5 +SOFC
IG-FB: Design/ Scale-up/ Optimization of Gasifier IG-GC: Design & Development of Gas Clean up system IG-SI: System integration for a base cycle
IG-AC: Advanced cycle consisting of -O2 Transport membrane - CO2/ H2 Separation - Gasifier/ Combustor design
Cooperation with external agencies and collaborative development with be the focus of the new platform. Following areas for immediate cooperation have been identified
Hydrogen Energy Research: Hydrogen Generation Through IGCC Route, HTTR Hydrogen Storage: Metal & Chemical Hydrides Design & Development of IGCC Gasifier Design Hot Gas Clean up System- Ceramic Filters High Efficiency, Rugged, Matching Gas Turbine Fuel Cells Development of Molten Carbonate Fuel Cell Systems Development of Solid Oxide Fuel Cell System Distributed Generation Solar PV and Thermal Systems Ammonia Cycle Sterling Engines
Robotics CFD/ ANN Material sciences including corrosion & erosion Special Coatings
Carbon Sequestration
The Major Joint Collaborative Projects Short listed R & D areas for collaboration 1. Design and development of SO3 / NH3 reactor for FGC 2. ANN modelling of the major sub systems of the power station 3. CFD modelling of the boiler and surface condensers 4. Development of on-line sensors for unburnt carbon, coal properties, flue gas charcterisation 5. Development of on-line flow visualisation systems 6. FEM of the boiler and creep & fatigue analysis of critical systems
The Major Joint Collaborative Projects Short listed R & D areas for collaboration 6. Low grade heat utilisation projects 7. Water chemistry and water networking 8. Ash utilisation technologies
1. IGCC Gasifier design and development, gas clean up system, combined cycle development 2. Hydrogen energy research 3. Solar energy integration (low grade, stirling engines, PVs ) 4. Carbon capture technologies (Membranes, PSA, nano materials etc) 5. Energy and bio technologies
Functional Groups
To carry out the technology development in a smooth, faster and most economical manner, the Energy Technology shall have: A no. of Centers of Excellence (App. 37)- concentrating on fundamental research App 25 Technology Missions A Strategic Planning Group for Networking etc. A Prototype Division Other Essential Enabling Functions shall be: Knowledge Centre IPR Division Human Resource Finance Contracts & Materials Information Technology Other Facilities
NTPC Management Eminent Scientist Eminent Academic Providing overall direction Supporting in selecting functional heads Projects approvals
ED (ET)
Retrofit Technologies
New Technologies
ESP Performance Enhancement Energy Optimisation & Diagnostic Model EIDM Ash Utilization Ageing Management Advanced Controls/ ANN Alternate Fuels & Fuel Beneficiation
Finance
Knowledge Centre
Human Resource
Information Technology
Architect
Gasification & Hydrogen Fuel Cell Technologies Carbon Capture Technologies Solar Energy Technologies Bio Energy Technologies Power Delivery System Technologies
SMART Technologies
Technology Advocacy Group Legend: Special Analysis, Computing and Simulation Centre CoE: Centre of Excellence CoC: Centre of Competence
Mechanical
Mechanical
Electrical
DT / NDT
Electrical
Instrumentation
Civil
Business Development
When you really want something to happen, the whole universe conspires to help you to achieve your dreams .. The Alchemist by Paulo Coelho
Study leave up to a period of 3 years after 3 years of service Membership of a Professional body. Very liberal medical facilities without any contributions. Reimbursement of OPD & hospitalization charges. Number of good hospitals, including super specialty hospitals on the Company s panel. Well equipped hospitals at projects with state of the art facilities and equipments.
Advances
[At low rates of Simple Interest-reducing balance method)
HBA
Maximum of 7.5 lacs, after 5 years of service
Conveyance Advance
Car advance Max Rs.1,80,872/- (as per today s price) Motor Cycle Max. Rs. 33,291/- structure)
PC Advance
Rs.40,000/-
Accommodation
Full fledged, excellently maintained township amidst lush green environment with all facilities like clubs, recreation centers, movie theatres, marketing complexes, parks etc. to ensure a superior quality of life.
Education Of Children
Schools of repute like DPS, Kendriya Vidyalaya, DAV and other convent schools upto Class XII to ensure education standards for children
Growth Opportunities
ELIGIBILITY FOR PROMOTION (IN YEARS)
3 1 3 3 3 4 4 4 2 3 -
POSITION
ASSTT. ENGINEER SR. ASSTT. ENGINEER ENGINEER SR. ENGINEER DY. MANAGER MANAGER SR. MANAGER DY. GENERAL MANAGER Asst. GENERAL MANAGER GENERAL MANAGER EXECUTIVE DIRECTOR
LEVEL
E1 E2 E2A E3 E4 E5 E6 E7 E7A E8 E9
PAY SCALE
10750 4% - 16750 11225 12000 13750 16000 17500 18500 19000 19500 20500 23750 4% - 17250 4% - 17500 4% - 18700 4% - 20800 4% - 22300 4% - 23900 4% - 24750 4% - 25600 4% - 26500 4% - 28550
M Tech
01.
Chemical/ Mechanical
Chemical/ Mechanical
Thermal design, equipment design, Heat Exchanger network, computer aided design tools
Development of Heat exchanger networks, design of new type of heat exchangers (viz. plate & fine type) Development of Control & instrumentation based on model prediction controls in the existing plants to improve their performance, development of C&I for new technologies.
02.
Control& Instrumentatio n
Process control, Process analysis, Advanced control system, Model predictive controls, etc
03.
Mechanical
Mechanical
04.
Chemical
Chemical
Reaction Engg., Kinetics, design of reactor, mass transfer with RXN, catalyst, nano systems ,etc
Design of reactor system for removal of contaminants, mini SO3 reactors, carbon capture technologies, Conversion of coal into chemicals.
05.
Chemical
Chemical
Separation sciences , Adsorbent design pressure swing adsorption etc, membrane design Power grid control, Power evacuation system design, optical fiber, etc Bio-chemical Engg. In the field of bio-mass conversion into hydrogen and fuels
Design of gas cleanup system adsorbent, gas separation through membrane, etc
06.
Electrical/E lectronics
Power Systems
07.
Chemical
Bio-energy technologies
08.
Metallurgy
Metallurgy
Material science, Physical metallurgy ceramics, high temperature materials, development of nano particle systems. Solar energy systems, design of collectors, photovoltaic cells,etc
High temperature ceramic filters, membrane design, high temperature material design.
09.
Mechanica l/Electrical
Mechanical/E lectrical
Smart Energy Meter Technologies Remote Monitoring Technologies Embedded Fiber Optic Technologies Distribution Network Layout Technologies Intelligent Connecting Device Technologies
High Performance Polymeric Cable Technology High Temperature Superconductor Technology Low Cost Underground Transmission Intelligent On-Line Analysis & Control Technologies Secure Power Transmission Technologies
Compressed Air Storage Technologies Pumped Hydro Technologies Hydrogen Based Fuel Cell Technologies Super conducting Magnetic Energy Storage Efficient Battery Technologies