1、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,National Thermal Power Corporation,NTPC ProfileB Technology Centre in Energy- The ImperativesC. The Roadmap for Technology CentreD. Net working with institutes,Synopsis,Part-A
2、 NTPC Profile,NTPC was set up in 1975 in the central sector to bridge the widening gap of demand and supply of power in India.,Genesis & Vision of NTPC,NTPC Vision“To be one of the worlds largest and best power utilities, powering Indias growth”,In addition, NTPC also manages Badarpur Thermal Power
3、Station (705 MW ) of GOI in Delhi.,Present Generation Capacity is 22,249 MW,NTPC-The Premier Power Company,13 Coal Stations7 Gas Stations,NTPC Today- Lighting 1/4th of India,The Business- BOO thermal plants Projects: Full in-house implementation O&M: Purchase fuel to bulk power sale Consulting: full
4、 electricity value chain,Sixth Among the Top Ten Global Thermal Generators,TWH 2001,Source: A.T. Kearney,Global Stature,Financial Performance,In summary, NTPC would be a leading power utility in the world by 2017, in line with its current vision,NTPC in 2017Fortune 500 companyAn Indian MNC with pres
5、ence in many countries Diversified utility with multiple businessesAmongst top five market capitalisation in the Indian marketGroup turnover1 of over Rs. 1,400 Bn with 30000+ employeesSetting benchmarks in project construction and availability and efficiencyHave a strong research and technology base
6、Loyal customer base in both bulk and retail supplyPreferred employer A leading corporate citizen with a keen focus on executing its social responsibility,NTPC - 2017,Part-B A Technology Centre in NTPC The Imperatives,Technology Development Pursuit- an enabler to sectoral reforms,Technology and India
7、n Power Sector- an Overview,The Origin & Growth of World Class Organizations,Fundamental Research (DDR) In Labs, Academics,Product Idea/ Conception,Technology Build up,Organization,Product improvement Process ImprovementNew Process DevelopmentNew Product Idea,Strong Operations, Finance, HR, Marketin
8、g Functions,Exponential Growth,Further R&D (MDR),Prime ExamplesGeneral ElectricDOWDuPont, Bayer,UOP Xytel,Hitherto NTPC Story,Fundamental Research In Labs, Academics,Product Idea/ Conception,Technology Build up,Organization,Product improvement Process ImprovementNew Process DevelopmentNew Product Id
9、ea,Strong Engg, Projects, O&M, Finance, HR Functions,Exponential Growth,Further R&D,?,Technology Implantation,The need is :Return to original ModelWhile maintaining strengths,This will require two pronged Approach,?,?,Electricity Sector, is today facing similar technology questions as it faced 50 ye
10、ars back,Sellers Market,Buyers Market,Paradigm Shift,The technology approach adopted to jump start capacity appears inadequate in the changing business scenario,Jump Start Capacity Addition,Industry Setup,Technology Status,Challenge,Rapid Capacity Addition,PLF Maximize,Efficiency Focus,Cost Focus,En
11、vironment Focus,Power Delivery,Jump Start Capacity Addition,Rapid Capacity Addition,PLF Maximize,Efficiency Focus,Cost Focus,Environment Focus,Power Delivery,Jump Start Capacity Addition,Rapid Capacity Addition,PLF Maximize,Efficiency Focus,Cost Focus,Environment Focus,Power Delivery,New Business En
12、vironment Drivers,Sellers Market,COG:Profits:,Worldwide the Technology Development and Engineering are two separate activities.,NTPC- Driven by Technology,Fundamental Research In-house, Labs, Academics,Product Idea/ Conception,Technology Build up,Organization,Product improvement, Process Improvement
13、 New Process Development, New Product Idea,Strong Engg, Projects, O&M,Exponential Growth,Development of Required Knowledge & Technology,Product improvement Process Improvement,New Process Development New Product Idea,Identification of Performance Gaps,Intensified Products & Processes,Integration of
14、Technology,Strong Finance, HR Functions,Cost Reduction,Technological Growth Engines,No new technology developmentPoor technology customizationWeak technology improvementHamstrung cost improvements,Inadequate system design improvementsInadequate equipment design interventionInadequate use of Project
15、Management techniquesEngg Services dormantNo cost rationalization instruments,Missing self improvement & correction instrumentsBloated and outdated maintenance approachHeavy InventoriesSluggish Procurement methodsInoptimal workforce utilizationInadequate focus on fuel componentO&M services market ly
16、ing 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,Emergence of Technology Implant Culture in India- so internalized that these are no longer viewed a
17、s problems.,The reason is late Indian entry to technology development arena. Affluent nations have had the advantage of SEQUENTIAL DEVELOPMENT facilitating knowledge systems development,Indian Entry,Missed OpportunityFew Technical Institutes establishedNo involvement in Engg. SciencesImport escapism
18、 culture establishedNo studies on domestic conditionsPoor industry quality consciousness,Systemic Distortions Focus on Equipment MultiplicationElectricity perceived as an inputAvailability of easy importsLow focus on T.D. developmentImported designs were implanted,Technology implants in the Electric
19、ity sector have had serious fall out on development of knowledge systems which are required for Technology Development,OEM Countries Scenario,Indian Industry Scenario,The effect entered even organisations set ups which do not differentiate between knowledge work, service functions and skill work,Pre
20、sence 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.,Typical Indian OrganizationMixed up knowledge and service f
21、unctionsNo education differentiation at entryAbsence of filters on Management LevelsUndifferentiated manpower movementNo separate specialist cadres,The sequential development in original technology countries resulted in evolution of country wide systems with “Knowledge and Technology” focus.,Equipme
22、nt Manufacturer,Power Technology Center,Universities,Labs,Power Knowledge Center,Equipment,Technology,Power Plant School,The differentiator and key enabler in such systems is the collaboration of industry-labs- academia- The GOLDEN TRIANGLE,Competition alone- which is one key objective of the new ta
23、rget framework - without the systemic enablers will have limited improvement potential,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,Power Technology Center,Universities,Labs,Powe
24、r Knowledge Center,Equipment,Utility,Design Copy,Power Plant School,Challenges For Enterprise Delivery,Critical SuccessFactors,Challenge,Dramatic Cost Reductions Required -Destination No.1,Strategic intervention for selective technology induction required,Required Shift,The new environment is creati
25、ng Paradigm Mismatches for the utilities,Cost Reductions- a quickly reachable destinationSystematic strategies are the only requirementSolvable in 5-10 years time Need to look at the bigger picture,The real challenge lies in the future - Dramatic changes are in the offing - Power sector has to shoul
26、der these,Changing Times- the real challenge,Indian society today stands on a cusp beyond which progress will telescopically expand,The power sector has to reorient itself to the new challenges for positive deliverance,World Energy Systems- getting electrified and decarbonized,The world is predicted
27、 to become more and more dependent on electricity,Global warming turnaround is not possible without developing countries participations,Destination No. 2 - Resolve Energy/ Carbon Challenge,Indian Energy Systems- rapidly changing scenario,India is changing in all spheres- population quality, infrastr
28、ucture, social fabric, govt. role,The question of sustainability of such mega development will naturally require a solution,Utility Company,wires,Pipes,Power will have to metamorph into a new role in the future electricity dependent society,Destination No.3 - Strengthen the power delivery system,The
29、 huge capacity will require a equally large, reliable and intelligent power delivery system,The emerging intelligent society will give rise to Customer Managed Service Networks,Destination No. 4 - Enable customer managed service networks,Destination No. 5,Power Distribution Technologies,Customer lev
30、el 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 & con
31、trol Power system controllers Operational strategies for maximising regional power transfer Wide area measurement & protection,Reduction in cost of power,Achieving the Energy-Environment Harmony,Strengthening the Power Delivery Infrastructure,Enabling Digital Society,Managing Global Sustainability,T
32、 I M E,Affordable PowerPower to all24x7 powerGreen PowerDigital Power Technological Growth EnginesSustainable DevelopmentNational Prosperity,KEY RESULTS,Destination Identification- infinity vision,An Infinity Vision for the future emerges .,Certain broad interventions for reaching the identified Des
33、tinations emerge from the Technology Driver-Destinations Matrix have been identified,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 “Te
34、chnology Development”,New InitiativesRevisit Procurement needs & specificationsTechnology Options StudiesVillage specific technology solutionsAvailability StudiesReliability Studies Heat Rate InitiativesStations Modernization focusFuel Options StudiesFuel Price Reduction AdvocacyNew Ash utilization
35、InitiativeNew O&M Services InitiativeCentralized ProcurementShared Maintenance ServicesInventory Management FocusProductivity Enhancements,Knowledge Activity Consolidation Automate non-value added jobsCreate Knowledge PlatformsCreate Power Plant SchoolsCreate Technology PlatformsKnowledge Groups in
36、companiesKnowledge Worker SustenanceNetwork 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-
37、line Energy Intensification and Diagnostic Model (EIDM) Resource optimization & site integration technologies (water, ash, chemicals) Ageing Management Technologies- Corrosion/Erosion/ Fatigue, creep/ Coatings Robotized Maintenance Systems,Immediate Actions,TM-1.1: Low Grade Heat Utilization : Phase
38、 - III- Condensate Heating Using Flue Gas- Air Conditioning & CW Cooling Through Extra IP Exhaust Steam - Integration of Solar Power & Kalina Cycle,ID - A,ID - B,Chimney,Return,Part Condensate,Ammonia Absorption Chilling,Saved IP Exhaust Steam,Control Room Cooling,CW Cooling,Solar Heating,Ammonia Tu
39、rbine,Kalina Cycle,Stirling Engine,Solar Heating,Completion Schedule : Dec06,Additional Steam Turbine,ESP Technologies RT-EP,SPM Control Technologies: Flue Gas Conditioning Solutions,ESP Technologies RT-EP,SPM Control Technologies: Flue Gas Distribution System,Energization System,Back Corona Limitin
40、g System,Intermittent Energization System,Pulse Energization System,Minimum Voltage based System,Minimum Voltage based System,SPM Control Technologies: Energization & Back Corona Control Systems,Efficiency Intensification & Diagnostic Model: EIDM RT-EI,Plant Process Parameters,Advanced Instruments L
41、PT 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,Real Time Heatrate Real Time Heatrate Deviation breakup due to a) Key Process Parameters, b) Key Equipment Real Time Plant Equipm
42、ent Performance Real Time System Information Coal Properties & CV Condenser CW Flow Unburnt Carbon in Ash Gaseous Pollutant Flow LPT Exhaust Steam Quality,The Near & Medium Term Technologies,Power,Hydrogen,Liquid fuels,Power,Power,Coal& Alternatefuels,IGCC,Fuel Cell,LMMHD,New Energy Technologies,TAR
43、GET: BREAKING CARNOT EFFICIENCY BARRIER,SYSTEMATIC EFFICIENCY ENHANCEMENT PROGRAMME IN IGCC CYCLE,Case 1: Base Cycle Case 2: Base Cycle+Hot gas Case 3: Case 2 +Class H Case 4: Case 3 +OTM 5: Case 4 +MCFC Case 6: Case 5 +SOFC,Phase wise progression (2007-2015),Road Map on IGCC,Near & Medium Term Tech
44、nologies,TM- 2.1: IGCC Technologies,IG-FB: Design/ Scale-up/ Optimization of GasifierIG-GC: Design & Development of Gas Clean up systemIG-SI: System integration for a base cycle,IG-AC: Advanced cycle consisting of O2 Transport membraneCO2/ H2 SeparationGasifier/ Combustor design,IGCC Technologies Fl
45、udised Bed Gasifier Design & Development Gas Clean-upIGCC System IntegrationAdvanced Gasifier Cycles,Robotics CFD/ ANN Material sciences including corrosion & erosion Special Coatings,Ammonia Absorption Refrigeration system Ammonia Turbine Cycle are required,Cooperation with external agencies and co
46、llaborative development with be the focus of the new platform. Following areas for immediate cooperation have been identified,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
47、 Fuel Cell Systems Development of Solid Oxide Fuel Cell System,Distributed Generation Solar PV and Thermal Systems Ammonia Cycle Sterling Engines,Hydrogen Energy Research: Hydrogen Generation Through IGCC Route, HTTR Hydrogen Storage: Metal & Chemical Hydrides,Carbon Sequestration,SPECIFIC AREAS OF
48、RESEARCH,Nanotechnologies in the development of fuel cell catalysts, CO2 capture molecules etc Membrane science for air separation (oxyfuels), hydrogen purification Materials science for high temperature and hydrogen environment 9Oxide dispersed alloys, dual ferritic etc) Super conductors, cryogenic
49、s, optical fiber technologies for power grid control, transmission & distribution Biotechnological applications in the field of hydrogen generation, CO2 conversion etc,The Major Joint Collaborative Projects,Short listed R & D areas for collaboration Design and development of SO3 / NH3 reactor for FG
50、C ANN modelling of the major sub systems of the power station CFD modelling of the boiler and surface condensers Development of on-line sensors for unburnt carbon, coal properties, flue gas charcterisation Development of on-line flow visualisation systems FEM of the boiler and creep & fatigue analysis of critical systems,
