Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
A
Presentation
On
Setting-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
Part-A
NTPC Profile
NTPC Vision
To be one of the worlds largest and best
CAPACITY (MW)
NTPC OWNED
COAL
GAS / LIQ. FUEL
TOTAL
13
17,980
3,955
20
21,935
3
23
314
22,249
OWNED BY JVCs
COAL
GRAND TOTAL
Fuel Mix
Present
22,249
Constrctn
5,000 +
Active
9,000 +
Coal
17,000 +
Gas
4000 +
13 Coal Stations
7 Gas Stations
CCPP-GT
80-150
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
501
500
400
300
175
152
200
146
141
133
128 126
102
94
100
EL
(I
TA
)
TE
PC
O
(J
AP
)
TV
A
(U
S)
RW
E
(G
ER
)
EN
TP
C
N
AE
P
So
(U
ut
S)
he
rn
Co
(U
S)
(S
KR
)
CO
KE
P
M
ES
KO
RA
O
-U
ES
(R
US
)
(S
AF
)
Financial Performance
Rs. Crores
30000
TURNOVER
25000
Rs. 25964.2
PROFIT
20000
15000
10000
5000
Rs. 5260.78
01
20
01
-0
2
20
02
-0
3
20
03
-0
4
00
-
00
99
-
99
98
-
98
97
-
97
96
-
96
95
-
95
94
-
94
93
-
93
92
-
91
-
92
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
Preferred employer
Part-B
A Technology Centre in NTPC
The Imperatives
R&D Labs
Academia
Exponential
Growth
Organization
Further R&D
(MDR)
Strong
Operations,
Finance, HR,
Marketing
Functions
- Product improvement
- Process Improvement
- New Process Development
- New Product Idea
Technology Build
up
Prime Examples
UOP
Xytel
Product Idea/
Conception
- General Electric
- DOW
Fundamental Research
(DDR)
In Labs, Academics
- DuPont,
- Bayer
Organization
Strong Engg,
Projects, O&M,
Finance, HR
Functions
Technology
Implantation
Further R&D
- Product improvement
- Process Improvement
- New Process Development
- New Product Idea
Technology Build
up
Product Idea/
Conception
The need is :
Fundamental Research
In Labs, Academics
Electricity Sector, is today facing similar technology questions as it faced 50 years back
120000
Sellers Market
90000
Buyers Market
Paradigm Shift
60000
30000
0
1940
1950
Technology Status
Industry Setup
Monolithic SEBs
Challenge
1960
1970
Indigenous
Manufacture
1980
Design Copy
1990
User Driven
Customizations
2010
2020
2030
Design
Replication
Central Utilities
2004
PLF Maximize
The technology approach adopted to jump start capacity appears inadequate in the
changing business scenario
Regulatory
Regime
Norms Tightened
No Norms
Market Forces
COG POG
COG:
Profits:
Deregulation
Price Cost > 0
Sellers Market
Power is Purchased
Hand Holding By Govt.
Making Power in
Plenty & Also Make Money
Paradigm
Shift
Buyers Market
Power Has to be sold
Survival of the Fittest
Making Plenty of Money
Through Power
Technology Developer
Checks on Drawings
and Documents
Industry
System
Tech
Lab Development
Academia
Utility
License
Manufacturer
Technology Development
- USP of developed world
Plant
Engineering
Integration
Manufacturer inspection
shop, site tests
Exponential
Growth
Strong Finance,
HR Functions
Organization
Cost Reduction
Technology Build
up
Integration of Technology
Development of Required
Knowledge & Technology
Identification of
Performance Gaps
Product improvement
Process Improvement
Product Idea/
Conception
Fundamental Research
In-house, Labs, Academics
Emergence of Technology Implant Culture in India- so internalized that these are no longer viewed
as problems...
Equipment Supply Industry
Collaborator
Operations
Engineering
Design Copy
Central Groups
Equipment
Manufacturer
Station
Station
Station
Station
Equipment
Project
No new technology
development
Poor technology
customization
Weak technology
improvement
Hamstrung cost
improvements
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
OEM
Countries
Scenario
Technology Multiplication
1800
1850
1900
1950
2000
Indian Entry
Indian
Industry
Scenario
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
Equipment
Manufacturer
Equipment
Russia
Japan
Power
Knowledge
Center
Power
Plant
School
Power
Technology
Center
Universities
Labs
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
Power
Plant
School
Power
Technology
Center
R&D Labs
Academia
Labs
Competition alone- which is one key objective of the new target framework without the systemic enablers will have limited improvement potential
Critical Success
Factors
Challenge
Cost/ MW
NEW BUILDS:
Arrest and Reverse Increasing Trend in Capital
Cost Without Compromising Quality
Strategic
intervention for
selective technology
Years
induction
required
Dramatic Cost
Reductions Required
OPERATING STATIONS:
-Destination
Arrest and Reverse Increasing
Trend ofNo.1
Maintenance
Availability
Maint. Cost
Cost
Maximize Availability and Efficiency
Age
Challenge
- Making Money
- Maximize Generation
- Maximize Profit
New Build
High End (VX)!!!
O&M Strategies
- Predominantly
Replacement Based
- Proactive Condition Based
- High Spare Inventory
Required
Shift
- Risk Based
Maintenance
- Spares: Just In Time
Philosophy
R&M Strategies
Predominantly
Replacement Based
Risk Based
2000
2020
2050
Population (billion)
6.2
10
10
13
17
0.38
0.5
0.7
13
28
60
10
10
Destination No. 2
- Resolve Energy/
Carbon Challenge
system
The emerging
Destination No.
intelligent
4
society will give
rise to Customer - Enable
Managed
customer
Service
managed
Networks
service
networks
Utility Company
wires
Destination
No. 5
Pipes
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 Transmission
power transfer
Wide area measurement & protection
Green Power
Digital Power
Destination4
Destination3
Destination1
Reduction
in cost of
power
2010
Destination2
Achieving the
EnergyEnvironment
Harmony
2015
Strengthening
the Power
Delivery
Infrastructure
Managing
Global
Sustainability
Enabling
Digital
Society
2020
2025
T I M E
Technological
Growth Engines
Sustainable
Development
National
Prosperity
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
Hybrid Power
Systems
Studies are underway to identify Technology drivers for destinations like enabling
customer managed service networks.
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
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
TM-1.1: Low Grade Heat Utilization : Phase - III
- Condensate Heating Using Flue Gas
- Air Conditioning & CW Cooling Through Extra IP Exhaust Steam
Part Condensate
Return
Solar Heating
ID - A
Chimney
ID - B
Solar Heating
Additional Steam
Turbine
Ammonia Turbine
Saved IP
Exhaust Steam
Kalina Cycle
Stirling Engine
Ammonia
Absorption
Chilling
Control Room
Cooling
CW Cooling
Ammonia
based FGC
SO3
based FGC
Dual FGC
Humidification
System
Hybrid
Aqueous
Ammonia FGC
Molten Sulfur
FGC
Water Fogging
System
Anhydrous
Ammonia FGC
Granular Sulfur
FGC
Water Mist
System
Urea based
Ammonia FGC
Native SO2
Conversion
System
Steam Injection
System
FGC
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
Expected Date
March2K5
Sept2K5
March2K6
Dec2K5
March2K5
Dec2K5
Target SPM
100 mg/Nm3
75 mg/Nm3
75 mg/Nm3
50 mg/Nm3
< 50 mg/Nm3
Anti
Sneakage System
Expected Date
Target Bypass FG %
March2K5
Dec2K5
March2K6
0%
Back Corona
Limiting
System
Minimum
Voltage based
System
Minimum
Voltage based
System
Intermittent
Energization
System
Pulse
Energization
System
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
Plant Simulation
Tool
What-If Analysis
Phase-IV, [Mar05]
Phase-II, [Nov04]
Expert System, for
Operator Guidance
Interface with plant
controls
Artificial Intelligence
Artificial Neural
Network
Phase-III, [Jan05]
Phase-I, [Sept04]
IGCC
Power
Hydrogen
Coal
Liquid fuels
&
Alter
nate
Fuel Cell
Power
LMMHD
Power
fuels
90
80
70
60
50
40
Case 2: Base
Cycle+Hot gas
Case
30
20
10
0
Case 3: Case 2
+Class H
Case 4: Case 3
+OTM
C1
C2
C3
C4
C5
C6
5: Case 4
+MCFC
Case 6: Case 5
+SOFC
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
- Ammonia Absorption
Refrigeration system
- Ammonia Turbine Cycle
are required
Carbon Sequestration
2.
3.
4.
5.
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
NTPC Management
Eminent Scientist
Eminent Academic
ED (ET)
Retrofit
Technologies
New
Technologies
Fundamental
Research
Division
Strategic
Business
Division
ESP Performance
Enhancement
Energy Optimisation &
Diagnostic Model EIDM
Ash Utilization
Ageing Management
Advanced Controls/ ANN
Alternate Fuels & Fuel
Beneficiation
Finance
Knowledge
Centre
Contracts
& Materials
Advanced Conventional
Power System Technologies
Human
Resource
Information
Technology
Architect
CoE-CO[Corrosion Science]
CoE-MS[Material Science]
CoE-FM[Fracture Mechanics]
CoE-SE[Solar Energy]
CoE-FEM
CoE-FS[Fluidization]
CoE-SD[Sensors / Detectors]
CoE-RF[Refractory Design]
CoE-RC[Catalyst / Reactors]
CoE-ED[Equipment Design]
CoE-AC[Analytical Chemistry]
CoE-CS[Catalyst]
CoE-MB [Membranes]
CoE-CE[Ceramics]
CoE-BT[Bio-Technology]
CoE-AD[Adsorbents]
CoE-PC[Process Control]
CoE-IS[Instrumentation]
CoE-SX[Solvent Extraction]
SMART Technologies
Mechanical
Electrical
Mechanical
DT
/
NDT
Electrical
Instrumentation
Civil
Business Development
.. The Alchemist
by Paulo Coelho
Part-E
Human Resource
12000
DA
6500
FCA
561
1820
Shift Allowance
900
175
Washing Allowance
126
490
2806
587
167
300
LTC
1198
2058
PF
1897
Gratuity
Post-retirement Medical Scheme
Electricity subsidy
760
4216
750
Advances
HBA
Conveyance Advance
Accommodation
Education Of Children
Growth Opportunities
POSITION
LEVEL
ASSTT. ENGINEER
E1
ELIGIBILITY
FOR
PROMOTION
(IN YEARS)
PAY SCALE
10750 4% - 16750
E2
11225 4% - 17250
E2A
12000 4% - 17500
SR. ENGINEER
E3
13750 4% - 18700
DY. MANAGER
E4
16000 4% - 20800
MANAGER
E5
17500 4% - 22300
SR. MANAGER
E6
18500 4% - 23900
E7
19000 4% - 24750
E7A
19500 4% - 25600
GENERAL MANAGER
E8
20500 4% - 26500
EXECUTIVE DIRECTOR
E9
23750 4% - 28550
ENGINEER
Discipline
Specialization
Nature of work
B Tech
M Tech
01.
Chemical/
Mechanical
Chemical/
Mechanical
02.
Electronics/
Instrumenta
tion/Chemic
al
Control&
Instrumentatio
n
03.
Mechanical
Mechanical
04.
Chemical
Chemical
Discipline
Specialisation
Nature of work
05.
Chemical
Chemical
06.
Electrical/E
lectronics
Power
Systems
07.
Chemical
Chemical/Bio
-chemical
Engg.
Bio-energy technologies
08.
Metallurgy
Metallurgy
09.
Mechanica
l/Electrical
Mechanical/E
lectrical
Smart Power
Delivery
Technologies
Higher
Capability &
Reliability of
Transmission
Grid
Electricity
Storage
Technologies
Strengthened
Copper Plate
Power Delivery
Infrastructure
Part-D
The Road Map for
Technology Centre