Renovation Modernization & Up Rating of Hydro Power Plants Presentation

Renovation Modernization
& Up rating of Hydro Power Plants

Presentation
About UJVN Ltd.

UJVN Ltd. is a part of erstwhile UPSEB
After bifurcation of Uttar Pradesh,
Uttarakhand came into existence in year
2000
Due to above bifurcation Uttarakhand Jal
Vidyut Nigam (now known as UJVN Ltd.)
came into existence in Year 2001
Core Business of UJVN Ltd.

UJVN Ltd operates into the following areas:
Generation of Power from Hydro Power Plants
Construction of New Hydro Power Station
(LHP & SHP)
UJVN Ltd. has intended to diversify its business

in the following areas also:
Solar
Gas
Thermal
UJVNL is a wholly owned Corporation of the

Government of Uttarakhand set up for managing
hydro power generation from existing power
stations and development, promotions of new
hydro projects with the purpose of harnessing
potential hydro power resources of the State
UJVNL operates hydropower plants ranging in
capacity from 0.2 MW to 304 MW, totaling up to
1306 MW
PROBLEMS: CONSTRUCTION OF NEW

PROJECTS
Inaccessible Sites
Obtaining techno-economic clearances from
CEA/CWC
Environment & Forest Clearance.
Defence clearance
Land Acquisition & Rehabilitation
Geological Risks
Inter state aspects
Renovation Modernization &

Upgradation
In the present scenario of resource
constraint and to tide over the shortage of
electricity, Renovation, Modernization &
Up rating (RM&U) of the existing/old
hydro electric power projects is considered
as one of the best options, as this is cost
effective and quicker to achieve than
setting up of new green field power
projects.
In order to augment the

hydropower generation and to
improve the availability of existing
hydro
power
projects,
Government of India also placed
emphasis on RM&U of various
existing old power projects in the
country.
Govt. of India constituted a
National Committee in 1987 and a
Standing Committee in 1998.
Reasons for RM&U
No or Minimum clearances required

Less Gestation Period up to 3 to 4 years
Less Risk
Less cost as against equivalent new project
Easy Financing
Technological Advancement
Exploration of Safety Margins and Overload
Margins in the Old design
Life Extension of Existing Facilities
Stages of RMU
Identification of the Project for RMU.
RLA & LE Studies (Residual
Assessment & Life Extension).
Detailed Project Report.
Tendering & Award of work.
Execution
Life
RLA & LE Studies

Systematic way of checking health of
every component of the old hydro power
station is done by Residual Life
Assessment and Life Extension (RLA &
LE) studies. This study helps in assessing
the uprating of the existing facilities of the
plants. RLA studies are helpful in
determining which component of the plant
to retain and which one to discard and
replace.
Technical Parameters of UJVN Ltd

Projects under RM&U
Sl.
No.
Name of Power
Station
Commiss
ioning
Year
River
Insta
lled
Capa
city
(MW)
Type of
Runner
Number
of Unit
1.
Chibro
1975
Tons
240
Francis
2.
Khodri
1984
Tons
120
Francis
3.
Dhakrani
1965
Yamuna
33.75 Kaplan
4.
Dhalipur
1965
Yamuna
51
Kaplan
5.
Kulhal
1975
Yamuna
30
Francis
6.
Tiloth
1984
Bhagirithi
90
Francis
7.
Chilla
1980
Ganga
144
Kaplan
8.
Ramganga
1975
Ramganga
198
Francis
9.
Khatima
1955
Sharda
41.4
Kaplan
10.
Pathri
1955
Ganga
20.4
Kaplan
11.
Mohammapur
1952
Ganga
9.3
Kaplan
Generation Details
Sl.
No.
Name of Power
Station
Average Generation
of last 10 years
(in MU)
Expected
Generation
after RMU
(in MU)
Additional
Generation
(in MU)
1.
Chibro
865
942
77
2.
Khodri
406
444
38
3.
Dhakrani
161
184
23
4.
Dhalipur
240
276
36
5.
Kulhal
145
183
38
6.
Tiloth
446
484
38
7.
Chilla
684
1074
390
8.
Ramganga
283
450
167
9.
Khatima
163
10.
Pathri
95
235
155
72
60
11.
Mohammapur
35
65
30
Total Gain = 970 MU
Financial Details
Sl.
No.
Name of Power Station
Total Project Cost

(in Crore)
Debt
Equity
Ratio
Financial Tie Up
1.
Chibro
185
80:20
KfW
2.
Khodri
170
80:20
KfW
3.
Dhakrani
117
80:20
KfW
4.
Dhalipur
117
80:20
KfW
5.
Kulhal
119
80:20
KfW
6.
Tiloth
127
80:20
KfW
7.
Chilla
337
80:20
CCC
8.
Ramganga
451
70:30
9.
Khatima
126
10.
Pathri
104
70:30
70:30
PFC
PNB
11.
Mohammapur
68
90:10
NABARD
Major Problems encountered in old Power Stations

Most of the Projects have already outlived its normal useful
life (30 to 55 yrs).
Excessive wear & tear of under water parts, resulting
inefficient operation of the power plant and consequently derating of the machine (s).
No mechanism for measurement of flow through turbines.
Old and obsolete Governors.
Old and obsolete Excitation system.
Automation system of the power house is defunct ional. It
takes more time to start / stop the units.
Old and non functional Control & Protection system. Most of
the controls of the Power Station are under manual operation.
Unavailability of spare parts of outdated systems and
equipment.
Pathri HEP
Average annual energy generation
Proposed annual energy generation
after M&U
Expected gain in energy
Project Cost
Project Cost (Including IDC)
Debt Equity ratio
Tariff (Rs/kWH)
First Year Tariff
Tariff after repayment of loan
Levelized Tariff
89.91 MU
155.6MU
65.69 MU
Rs. 70.86 Crore

Rs.105.62 Crore
70:30
Rs 1.4
Rs 0.54
Rs 1.03
Mohammadpur HEP
Average annual energy generation
Proposed annual energy generation after M&U
Expected gain in energy
Project Cost
Project Cost (Including IDC)
Debt Equity ratio
Tariff (Rs/kWH)
First Year Tariff
Tariff after repayment of loan
Levelized Tariff
35 MU
64.92 MU
29.92 MU
Rs. 53.66 Crore

Rs. 64.35 Crore
90:10
Rs 2.03
Rs 0.74
Rs 1.78
Proposed RMU Works

Replacement of turbines and associated
accessories with the provision of new
runner/runner blade of improved design
having higher efficiency.
Provision of new sets of guide vane and
replacement of grease lubricated bearings
by self lubricated bushes.
Replacement of new digital governor
system.
Provision of new static excitation system.

Installation of monitoring system for
turbine and generator.
Replacement of Control, Protection and
Instrumentation System by the state-of- art
technology.
Refurbishment of generator with provision
of new class F insulated rotor windings
,cooling water system, CO2 system and
common auxiliaries .
Phasing of RMU Schemes

In the first phase following two plants have
been taken up for RMU in year 2010 and
execution is under progress:
Pathri (3 X 6.8 MW)
Mohammadpur ( 3 X 3.1 MW)
Methodology for Execution of RM&U

Two different mode has been adopted for RM&U
of Pathri & Mohammadpur Power Stations:
For Pathri Power Station 1 month shutdown of unit
was given to the firm for Reverse Engineering.
Thereafter prolonged shutdown of Ist unit was given
after detailed engineering.
Thus schedule of shutdown of units are as follows:
Unit # 1
Unit # 2
Unit # 3
:
:
1 month for reverse engineering and

12 months thereafter
10 months
10 months
After Reverse Engineering the scope of the

Contract changed and based on this change
the Schedule & Cost of the Project also
changed;
After acceptance of changes the schedule of
shutdown changes as follows:
Unit # 1
Unit # 2
Unit # 3
:
:
1 month for reverse engineering and

18 months thereafter
9 months
9 months
Shutdown of the units is planned only after

availability of supplies at site for the last two
units;
Problems During Execution

Mohammadpur & Pathri Power Station are
under execution. Following issues were
noticed till date:
It has been noticed that the scope of the Project
got exceed due to replacement of the items which
are to be repaired as per scope.
Main reason which has been noticed is non-accessibility
of items during RLA & LE studies, which is the basis for
scope preparation;
Due to these changes in the scope the time schedule
and cost also got affected.
Execution of Mohammadpur
Contract for extensive RM&U of this plant was awarded
on 6th April 2010;
Work started from 6th June 2010;
Total Contractual Period is 36 months;
Time allocated for three unit as per contract was:
Unit # 1
Unit # 2
Unit # 3
:
:
:
18 months
9 months
9 months
Due to change in scope the first unit is commissioned

after 22 months. Efforts are being to compensate this by
reducing the execution time of other units.
Overall Benefit from RMU

After completion of Pathri & Mohammadpur
R&M, UJVNL shall have a addition of about
90 MU.
Life extension of about 30-35 years of the
existing old plants.
Better efficiency of plant & machines;
Better know-how of employees;
Centralized monitoring of all the plants.
One Unit of Mohammadpur Power Station

has been commissioned on 30th April 2012
after extensive RM&U.
Switchyard & Control Room has been
commissioned;
All common works associated with the Units
have been completed;
New unit has generated additional 2.546

MU from May 2012 to August 2012 (7.614
MU) as compared to its generation in
same months of 2009 (5.068MU).
Issues & Challenges

Due to demand supply gap it is very difficult to undertake the RMU
of plants;
Not much of expertise is available in the Indian market for Scope
determination of RMU Project:
It is not possible to engage any manufacture for RLA & LE studies,
since such action shall debar him from participation in tender for
execution.
There is a dearth of good consultancy firm / agency for conducting tests
required in RLA & LE studies.
Owner of the plant does not give the unit for complete dismantling,
which results in wrong assessment of scope.
No standard benchmark for such projects;

Non availability of initial documents of the Projects;
Issues related to copy right of the original manufacturer;
Employees reluctance to accept the change;
Thank You

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Renovation Modernization

& Up rating of Hydro Power Plants

About UJVN Ltd.

Core Business of UJVN Ltd.

UJVN Ltd. has intended to diversify its business

UJVNL is a wholly owned Corporation of the

PROBLEMS: CONSTRUCTION OF NEW

Renovation Modernization &

In order to augment the

Reasons for RM&U

No or Minimum clearances required

RLA & LE Studies

Technical Parameters of UJVN Ltd

Total Gain = 970 MU

Name of Power Station

Total Project Cost

Major Problems encountered in old Power Stations

Rs. 70.86 Crore

Rs. 53.66 Crore

Proposed RMU Works

Provision of new static excitation system.

Phasing of RMU Schemes

Methodology for Execution of RM&U

1 month for reverse engineering and

After Reverse Engineering the scope of the

1 month for reverse engineering and

Shutdown of the units is planned only after

Problems During Execution

Due to change in scope the first unit is commissioned

Overall Benefit from RMU

One Unit of Mohammadpur Power Station

New unit has generated additional 2.546

Issues & Challenges

No standard benchmark for such projects;

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