R M in Japan and Our Experiences under the

R&M in Japan and Our Experiences under the CEA-JCOAL Cooperation Japan Coal Energy Center (JCOAL) at Round Table Meeting on Thermal Power Energy Efficient Rehabilitation and Modernization (EER&M) by WBPDCL, Kolkata April 4, 2016 1

Overview 1. 2. 3. Philosophy and practices of coal fired power station management in Japan Our experiences in India Summary 2

1. Philosophy and practices of coal fired power station management in Japan 3

Concept of full plant economic life in Japan Source: Kyushu Electric Power

Maintaining the designed efficiency over 45 years 　　　　　　 a crucial key to excellent and sustainable efficiency O & M is management of power station throughout its lifetime. 　　　 Comparison of an old power plant in Japan with its counterpart power plant in country X Thermal efficiency (%, HHV) 40 39 TAKASAGO coal fired power plant No. 1/ No. 2 38 X国の石炭火力発電所 37 36 Designed thermal efficiency 35 30 出典: 電事連 20 Coal fired power station of country X 0 10 20 Source: J-POWER 30 40 5 5

Takasago coal-fired power plant (250 MW X 2 units) : Working efficiently over 45 years Gross Output Net Output 250, 000 k. W× 2 MW 233, 000 k. W× 2 MW Fuel Coal (Heavy Oil) (Start-up only 　light oil) Boiler　Manufacturer Boiler Type Mitsubishi, CE Forced Circulation, subcritical pressure Drum Type Boiler & Corner Firing System ※ＭＣＲ＝maximum continuous rating 　825 t/h SH out 17. 2 MPa SH out 571℃　RH out 543℃ Boiler　output(※MCR) Steam. Flow Pressure Temperature Turbine Manufacturer Turbine Type Main steam　Pressure Main steam Temperature Reheat steam Temperature Mitsubishii, Westinghouse Regenerative, reheat, condenser 16. 6 MPa 　566℃ 　538℃ Source: J-POWER Unit 1: COD in Jul 1968 Unit 2: COD in Jan 1969

Plant management timeline Ash processing unit improvement Boiler dust collector improvement Turbine performance upgrading Steam condenser ball washing Super heater tube restoration Mill moisture trouble prevention Superannuation measures FY: Fiscal Year, EY: Elapsed Year Step voltage regulator replacement Generator mending Electric Precipitator improvement Low NOx boiler/bu rner Boiler automatic controller improvement Economizer replacement Main block valve restoration Improving cooling water intake Super heater tube restoration LP feed water heaters replacement Boiler partition wall tube restoration Generator mending Re-heater mending FY 91 92 93 94 95 96 97 98 99 00 01 02 03 04 05 06 07 08 09 10 11 12 13 EY 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 In-house coal transportatio n facilities replacement Turbine: Motor operated valves installation HP feed water heaters replacement Reheated steam stop valve restoration HP rotor replacement Boiler: super heater outlet tube restoration Milling equipment restoration 7

2. Our experiences in India under the CEA-JCOAL Cooperation 8

Japan Coal Energy Center (JCOAL) • • Established as a foundation in 1990, with its origin back to 1948 Covers all coal related issues from upstream to downstream of the coal value chain Members: 119 incl. major public-listed companies and main players in energy and relevant sectors Supervision by METI (Ministry of Economy, Trade and Industry of Japan) Facilitation and promotion of cleaner utilization of coal Mining & Preparation Exploration Coal utilization technology development 9

Our major partner institutions Provincial Government of Saskachewan Government of Ukraine IEA-Clean Coal Energy Centre. A IEA-GHGA China Electricity Councila Government of Poland Government of Canada CEA, Government of India State Mining Exploration Company of Mozambique ASEAN Centre for Energy Government of Australia Government of Indonesia *Indicated are JCOAL’s major partners only. State Government of Queensland State Government of Victoria

Diagnostic studies for R&M üJCOAL conducted diagnostic studies for R&M implementation at 3 (three) state power stations and at 5 (five) NTPC power stations. üAt Dr. NTTPS of APGENCO the study was done at the time of shut-down and cost-benefit analysis was made. 2015 Dadri 2012 Unchahar 2012 Badarpur 2011 Kahalgaon 2012 Durgapur 2010, 2011 Wanakbori 2010 Ramagundam 2010, 2011, 2012 Dr. Narla Tata Rao (Vijayawada)

Proposed options of R&M (1) r ve on Boile r C COAL Stack Feed　Water Heater ye r Plan-A: LE　Replacement of worn parts only Plan-B: R&M Circuit Breaker Transformer Replacement of worn Cooling Tower parts + Reuse of Steam Turbine casing, replacement of SH Steam Generator HP, IP, LP turbine, DEHC improvement RH and ESP Steam Coal rehabilitation Bunke Condenser Feed Pump Mill Air Pre. Heater ESP IDF ※ Coal Yard ※ Bottom Ash PA F FD F P Air S Air Fly Ash　Pond Plan-C: R&M Plan-B+ generator improvement Plan-D: R&M Plan-C+ condensor and feedwater heater improvement 12

Proposed options of R&M (2) Plan　 Policy （Effect） Specification Upper: Capacity(MW)/ Lower: Heat rate(Kcal/k. Wh) Design Actual A (LE only) Keep the status quo with 20 years LE Replacement of worn parts only B Keep rated capacity 210 MW with heat consumption rate improvement by 5% and 20 years LE Reuse of casing, replacement of HP, IP, LP turbine, D-EHC improvement and ESP rehabilitation C Uprate of rated capacity to 225 MW Plan B＋generator heat consumption rate improvement by 5% and 20 years LE D Uprate of rated Plan C＋condensor and capacity to 225 MW heat consumption rate feedwater heater improvement by 5% and 20 year LE Analysis After R&M ← ← Required cost for 20 years LE +10 210 -120 2300 210 2350 High FIRR with environmental improvement +25 2300 -120 Good FIRR with environmental improvement even with LE +25 2280 -140 Environmental improvement and low FIRR with current price level of electricity 200 2420 R&M proposal of Plan B, C and D are found to be effective for efficiency and environmental improvement as well as economically beneficial. 13

Environmental Improvement by ESP Rehabilitation A 1 Dust Concentration (mg/Nm 3) A 3 A 4 A 5 B 1 B 2 B 3 B 4 B 5 C 1 C 2 C 3 C 4 C 5 D 1 Gas Flow A 2 D 3 D 4 D 5 IDF Stack IDF Expected Outcome by ESP Rehabilitation Moving electrode Discharge electrode Br ush NTPC has introduced MEEP at two units of Rihand TPS. 14

manufacturers-how it works to enhance economy of a unit Maritsa East III Bulgaria (210 MW x 4 units, age 20 -30 yrs) increased the capacities Liddell PS turbines with increased capacities 210 MW Renovation 500 MW Renovation (1) Original LP turbine(GEC) 520 MW 〇improved section (2) Retrofitted by Hitachi (now MHPS) Capacity uprate by 10% (225 -245 MW) with 15 -20 yrs life extension • Modernization of LMZ(K-200 -130) to 226 -230 MW with the same heat rate (By Toshiba) • Rehabilitation of boiler, generator & auxiliaries incl. transformers and ESP • BOP was also in the scope • Newly added equipment– FGD (By IHI) De-NOx s 15

Efforts for HELE (High Efficiency Low Emmissions) application through R&M: Feasibility Study on Replacement of Badarpur TPS, NTPC Ultra Super Critical, Efficiency = 45% Sub-Critical, Efficiency = 40% Old Isogo COD in 1967 Current Badarpur TPS New Isogo COD: Unit 1 in 2002, Unit 2 in 2009 Efficiency Improvement Cleaner Environment Capacity Increasing Power supply 530 MW （265 MW× 2 ） t y nc men ie ffic rove E p Im SO x Unit 1 Unit 2 NO CO 2 PM x Unit 1 Capacity Unit 2 Unit 1 1, 200 MW （600 MW× 2 ） g ly sin upp a cre er s In ow P Unit 2 Cleaner Environment 16

Outline of Combustion Test of Indian Coal Background Purpose • At the time of the commencement, new environmental norms were under discussion by the Government of India. • The Test was deemed to be a key to achieve low emissions of dust, SOx and NOx to be compliant with the new norms once they are in place. • Acquisition of data about performances of the emission control system • Feasibility study • Low emissions to be attained through the integrated system of SCR low-temperature EP and FGD system • The system has been proved to be effective on Indian coal. Outcome • Basic design for the demonstration at a station is ready. Source：MHPS 17

HRD Activities through CCT Transfer Program 18

High Efficiency Coal Washery Plant (NEDO) High efficiency coal preparation plant in Odisha ü High efficiency coal preparation plant was commissioned on July 25 th, 2014 in Angul, Odisha using latest vari-wave jig technology with processing capacity of 350 t/h. Source: NEDO website 19

Summary 20

We look forward to working with you Website: http: //www. jcoal. or. jp/index-en. html Contacts: Mr. K. Murakami (kzmurakami@jcoal. or. jp) Ms. Yamada, F. (fyamada@jcoal. or. jp) 21