Report on US Aid/Eco-Asia organized Study Tour on “Clean Development and Climate Change Programme” in Central Europe (Poland, Czech Republic & Germany

Duration of stay in Poland, Czech Republic & Germany:

From 23.09.2009 to 01.10.2009

Participants of the Study Tour

1. Sri Debabrata Dey, Dy General Manager (Planning), & Sri Prasun Kumar Chakrabarty, Director (FM & HR), WBPDCL, India

2. Other Sixteen (16) Participants are from MoP (3), CEA (2), PGCIL (1), NTPC (1), DVC (2), Mahagenco (2), Eco-Asia (2), World Bank (3)

Foreword:

Leaving aside natural calamity like eruption of volcanoes, man made deforestation and burning of fossil fuel since mid 20^th Century for advancement in civilization including science & technology, rapid growth in power sector for massive industrialization and continual intensification of human comfort to a sky high level is identified as the root cause for abundance of CO₂ (GHG) on the surface of our planet leading to ecological imbalance and gradual adverse climate change over the decades. Roughly 72% of Green House Gases are made up of Carbon Dioxide out of which energy emissions from power, industry and transport sectors have their respective shares to the tune of 24%, 14% & 14%.

Global warming is a very slow process since mid 20^th Century and happened to be a most dreadful threat for mankind due to abundance of green house gas over the surface of the planet. Wise Men started thinking long back in 1992 at Reo-de-janerio, Brazil and subsequently in 1997 at Kyoto, Japan. In Kyoto Protocol, bench mark for reduction of GHG emission was set and respective targets were agreed to by developed countries to be achieved within 2012. Lucrative Carbon Credit coffer is in vogue till 2012 to encourage the Utilities in adopting CDM for less GHG emission within stipulated limits. Result is not at all optimistic. The journey of Wise Men at Reo and Kyoto failed to guarantee any comfort for 6.8 billion people; instead our Planet has now become 0.98 ⁰ C warmer [this global warming data was (0.74 ± 0.18) ⁰ C during the last Century and projected further rise during the 21^st Century may be 1.1 ⁰ C to 6.4 ⁰ C; a deadly threat for all of us]. Reduction of CO₂ could only arrest further warming of the planet and save our live. Perhaps, undeniable solutions to our liking are clean development philosophy i.e. either stop CO2 emission or reduce it to the maximum extent possible. Since a developing country like India cannot opt only for expensive nuclear/hydel power; there should be an optimum mix with more and cheaper coal based power with advanced energy efficient technology.

Report:

The undersigned reached Warsaw via Munich on 23.09.09 and boarded at Sport Hotel at Belchatow, Poland as per official itinerary and schedule.

Study Tour on “Clean Development & Climate Change Programme” started from the next day i.e. 24.09.09 and concluded on 30.09.09.

Objective:

An exposure to the power fraternity of Central Europe (Poland, Czech Republic & Germany) where Lignite Coal based old sub-critical Units (in the range of 200 to 360 MW) of sixties, seventies & eighties had been successfully undergone R & M including retrofits while switching over to much more energy efficient (from 32% to 38%) upgraded and uprated plants with improved parameters and extended life expectancy up to 2035. In tandem, they have already taken up ultra super-critical technology for higher capacity lignite coal based Units (660 MW and 858 MW) with commissioning target in 2011 and high efficiency level which is more than 43% (12% more compared to old sub-critical 150 MW Units of sixties and 7% more than 600 MW Units of seventies).

As an individual and being part and parcel of the society we should explore all possible avenues to cut down emission of green house gas even to an iota level.

Our prime objective which needs to be translated into action globally is:-

“Burn less coal – generate more power – release less CO₂”

Visit to Power Plants on 24/09, 26/09 & 30/09/09

The experts of Alstom Power Systems, Elblag, Poland gave a brief presentation on detailed R & M job of Belchatow Power Plant executed by them years back.

(1) Belchatow Power Plant: There were 12 Units each of capacity 360 MW installed long back during early eighties. Units (3 – 12) have undergone R&M; steam parameters/systems/C&I was upgraded during such R&M work and as a result capacity has now been uprated to 370 MW. Further uprating is planned to 380 MW through modification of turbine and auxiliaries including boiler. Life expectancy period has been extended from 160,000 Hours to 320,000 Hours. They have newly installed FGD Plant for respective Units within available space. Boiler feed pumps are combination of 1 (one) 100% steam driven pump along with a small capacity (30%) motor driven. As a result, Units are running in an energy efficient manner with less emission in compliance with latest European norm. All the Units are having NDCT through which flue gas with low emission level is leaving enroute FGD. R&M work for boiler & auxiliaries including installation of new FGD plant had been successfully done by one renowned manufacturer RAFACO and that for TG & auxiliaries by ALSTOM.

They have also taken up implementation of Unit # 13 of capacity 858 MW with ultra super-critical steam parameters; commissioning is expected by 2011. Apart from SO₂ removal they have envisaged de-NO_x and carbon capture schemes too.

(2) PGE Turow Power Plant: It is situated ay Bogatynia. There were 9 Units each of capacity 210 MW installed long back during early seventies; boilers were supplied by Foster &Wheeler and turbine by LMZ. Units 1 – 6 have undergone R&M; steam parameters/systems/equipment/C&I was upgraded during such R&M/Retrofits/Replacement programme and as a result capacity has now been uprated to 235 MW for Units (1 – 3) and 260 MW for Units (4 – 6). However, old Units (7 – 9) are going to retire soon. They have newly installed FGD Plant for respective Units (1 – 6) within available space. Boiler feed pumps are combination of 1 (one) 100% steam driven pump along with 80% motor driven. As a result, Units are running in an energy efficient manner with less emission in compliance with latest European norm. There are 7 NDCT and 2 Chimneys for 9 Units. 1^st chimney contains 6 flues whereas 2^nd contains other 3 flues through which flue gas with low emission level is leaving enroute FGD. R&M work (1994 – 2001) for boiler & auxiliaries including installation of new FGD plant had been done by RAFACO and that for TG & auxiliaries by ALSTOM.

During a brief presentation before plant visit Rafaco informed that PGE desire to implement one 500 MW extension Unit with super-critical steam parameters.

(3) Tusimice Czech Republic Power Plant: There were 4 Units each of capacity 200 MW commissioned long back in 1975; boilers were supplied by a Czech Boiler supplier and TG by Skoda. Units 1 – 4 are undergoing R&M in two phases (Phase I - Units 3&4 and Phase II - Units 1&2); it is a complete Replacement/Retrofit programme with latest advanced technology. They had taken up and completed the massive demolition work of boiler drums including structures, recasting of TG foundation including power house structures within six (6) months. It was learnt that the common Chimney [multi-flue (quadruple)] will be demolished after construction is over and commissioning of all four Units. Steam parameters/systems/equipment/C&I was upgraded during such R&M and as a result capacity has now been uprated to 210 MW with much higher efficiency (from 32% to 38%). They have newly installed FGD Plant for respective Units (1 – 4) within available space. Boiler feed pumps are combination of 2 (two) 50% steam driven pumps along with a 50% motor driven pump. As a result, Units are running in an energy efficient manner with less emission in compliance with latest European norm. There are 4 NDCT; one each for 4 Units. Old chimneys are, now, stand abandoned. Flue gas at the outlet of ESP with low emission level is leaving respective NDCT enroute FGD. Phase-I reconstruction job had started on June 2007 and commissioning is expected by December 2009 (210 MW Unit # 3 already synchronized on July 2009) whereas Phase-II reconstruction job has started on June 2009 and commissioning is expected by September 2011. R&M work for boiler & auxiliaries including installation of new FGD plant had been successfully done by a Czech boiler manufacturer and that for TG & auxiliaries done by Skoda. Generator and C & I procured from Siemens; turbine and TSI from Skoda Power. Overall guarantee is given by the EPC Contractor M/s Skoda Praha Invest. Life expectancy of the said four 210 MW Units is up to 2035. No major job done with existing 4 NDCT.

They have also informed that they are planning to take up implementation of extension Units each of capacity 660 MW with USC steam parameters.

Normally, pit head (2-3 KM from power plant), Lignite Coal from open cast mine with 40-50% moisture, 0.5-1.0% Sulphur, 5-10% ash having GCV around 2000 Kcal/kg is used in most of the power plants in Poland, Czech & Germany.

Visit to Workshops of

RAFACO & ALSTOM on 25/09 & SKODA on 29/09/09

(1) Manufacturing Shop of Rafaco: It is a very big boiler manufacturing Unit established in the sixties at the city Raciborz, Poland. It started its journey long back with small capacity boilers of 150 TPH. Now, it is equipped with latest designed automatic machines for manufacturing of boiler pressure parts including drum for sub-critical boilers and super-critical boilers. During visit, the manufacturing of spiral wound furnace wall tubes, super heater/reheater tubes etc. of 660 MW super-critical boilers and a 12 M long boiler drum for 500 MW sub-critical boilers was witnessed. The Man-hour utilisation in this shop is around 2 million per annum, it was learnt. Rafaco is the biggest boiler manufacturer in Poland. They procure raw materials from Germany, Italy, Japan, USA etc. In continuation with R&M work they have booked adequate orders from EU Countries till September 2009 for new Units. Rafaco experts gave a presentation on sub/super critical 200 MW/500 MW/660 MW boilers.

(2) Manufacturing Shop of Alstom: It is a unique, huge and latest state-of-the- art Generator Manufacturing Unit established at the city Wroclaw, Poland after 2^nd World War during rebuilding of Poland. This is a European Centre for the production of TG Stators in Alstom Group. In this Wroclaw of Alstom factory air-cooled, hydrogen-cooled and water-hydrogen-cooled generator stators are manufactured; capacity ranging from over 120 MVA up to 1333 MVA. They have multifarious facilities capable to offer services relating to large size machining, laser cutting, and production of welded construction and diagnostics of generators. Reduction of cost and production cycle is the main objective of the factory. By virtue of technological development in recent years they are now capable to manufacture more than 40 Units of power up to 1400 MVA every year. They are continuously evolving solutions by using TVPI technology for stator winding bar to reduce production impact on environment. Generators of Wroclaw are used in steam/gas/combined cycle/nuclear plants. They have a consistent European market share of 40% including 12% in Poland. Against a specific question regarding possibility of switching over from existing water-hydrogen-cooled generator to totally hydrogen-cooled generator during carrying out R&M of Bandel 5^th Unit (210 MW); the reply was affirmative.

(3) Manufacturing Shop of Skoda: It is a very big turbine factory at Plzen aided by most advanced CNC machines, lathes, welding machines, forming/bending machines, heat treatment facility, balancing facility, NDT, 3-D measuring facility. First steam turbine produced by Skoda works was in 1904; own design turbine manufactured in 1911. Apart from 1000 MW turboset for nuclear power plant produced in 1992, the range of steam turbines manufactured during 1932 and till date by Skoda varies from 23 MW (sub-critical) to 660 MW (ultra super-critical). Since 2^nd World War they have installed 50,000 MW across Europe. They have also successfully executed a good number of replacement/retrofit/ R&M jobs. At present, they are executing the R&M of Tusimice Power Plant.

Prior to visit of their factory at Plzen, Czech Republic the experts of SKODA POWER A.S. gave a brief presentation on detailed R & M job of Tusimice Czech Republic Power Plant which is under execution by them since June 2007. They have also covered the design/operational details of 660 MW USC Units.

Visit to RWE Power In. Head Quarter

at Cologne, Germany on 28/09/09

RWE Power International is a world renowned Consultant, 2^nd in Germany, capable to extend engineering services, implementation support, maintenance support for thermal and nuclear power plants. RWE has given a day long presentation on “Power Plant Maintenance and Modernisation” assisted by Babcock Borsig on “Environment Management” and BHR Engineering Construction on “Advanced Concept of Heat Recovery”. They happened to be a big Utility also operating in Germany and U.K. and owner of a good number of generating stations. RWE carried out R & D on optimization studies of USC thermal Units and could reach an unbelievable efficiency level more than 43% in 2002 (12% more compared to an old designed 150 MW Unit of 1957) at the world’s most advanced technology oriented 1000 MW capacity BoA Power Plant at Rhineland, Germany. The unique feature and most important achievement of this state-of-the-art lignite fired ultra super-critical (USC) Power Plant is:-

Ø Higher Efficiency (> 43%, 12% more compared to an 150 MW Unit of 1957)

Ø Less Specific Coal Consumption (0.87 against 1.27 kg/kwh of 150 MW Unit)

Ø CO₂ , NO_X , SO₂ and SPM (– 30%/kwh less compared to an 150 MW Unit)

Ø Specific CO₂ Reduction – 3 million ton/year compared to an 150 MW Unit

Ø Construction Time – 4 years (August 1998 to August 2002)

They are continually in the process of expediting R & D work for more advanced technology with higher steam parameters and are quite optimistic in achieving 52% efficiency by 2020 with a target to reduce CO₂ emission by 40%.

Hard coal is costly in Germany and such mines are going to be closed due to its high mining cost about 150 Euro per ton, it was learnt from the experts of RWE.

There is a move in European Union to reduce GHG as maximum as possible. Accordingly, algae cell culture and CO₂ fixation schemes have been taken up.

Visit to Indian Embassy at

Prague, Czech Republic on 30/09/09

On the way back from Tusimice Power Plant, we, the team of 18 delegates visited Indian Embassy around 5.30 PM. Mr. D. P. Srivastava, Ambassador of India in Czech welcomed all the Participants of the Study Tour. There was exchange of views and opinion regarding capacity addition programme in India during 11^th Plan (78,000 MW) and 12^th Plan (1, 00,000 MW) and the unlimited opportunity of foreign BTG suppliers in India for their business promotion till 2017. The meeting ended with a sweet note and vote of thanks. However, prior to departure, cold drinks and hand made SAMOSA (oil cake) was served to all.

REPORT PREPARED BY DEBABRATA DEY, DGM, WBPDCL ON 13.10.2009