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NTPC- KA W AS GAS POWER<br />
PROJECT<br />
FINANCIAL APPRAISAL OF<br />
R&M WORKS OF NTPC- KA W AS GAS POWER PROJECT<br />
ST AGE-I<br />
(656.20 MW)<br />
CONTENTS<br />
1.00 INTRODUCTION 2<br />
2.00 BACKGROUND OF NTPC LIMITED 4<br />
3.00 NTPC KAWAS GAS POWER PROJECT 13<br />
4.00 RENOV AnON & MODERNISA nON WORKS 25<br />
5.00 R&M WORKS FINANCIALS 35<br />
--00000--<br />
Appendices attached to this report<br />
Appendix 1: Projected Financial Statements<br />
Appendix II: Key Assumptions<br />
--00000-
1.00 INTRODUCTION<br />
1.01 A. F. Ferguson & Co. (AFF) have been engaged by NTPC Limited to carry out a<br />
<strong>financial</strong> <strong>appraisal</strong> <strong>of</strong> the proposed Renovation and Modernisation (R&M) Works <strong>of</strong> the Kawas<br />
Gas Power Project (KGPP-Stage I) (656.20 MW) at Kawas, Surat.<br />
1.02 This document contains the report on the <strong>financial</strong> <strong>appraisal</strong> <strong>of</strong> the above R&M Works.<br />
Obiective <strong>of</strong> the <strong>financial</strong> <strong>appraisal</strong><br />
1.03 As a part <strong>of</strong> NT PC's internal approval process, the R&M Works for the <strong>project</strong>s that are<br />
proposed to be undertaken by it are required to be appraised by an external agency. Accordingly,<br />
this report has been prepared for the internal use <strong>of</strong> NT pc.<br />
1.04 NTPC is proposing to seek investment approval from its Board for the above R&M<br />
Works.<br />
Scope <strong>of</strong> work<br />
1.05 The scope <strong>of</strong> work was to carry out a <strong>financial</strong> <strong>appraisal</strong> <strong>of</strong> the above <strong>project</strong> covering:<br />
• Reviewing the <strong>financial</strong> model and the related <strong>project</strong> information which involved:<br />
• Reviewing the basis <strong>of</strong> the assumptions made with a view to assessing their<br />
prima-facie adequacy<br />
• Reviewing the consistency <strong>of</strong> the assumptions made in the <strong>financial</strong> forecast<br />
• Commenting on the viability <strong>of</strong> the R&M Works based on the proposed financing<br />
plan, expected internal rate <strong>of</strong> return (IRR) and other relevant <strong>financial</strong> parameters<br />
• Based on the above review, assessing the overall <strong>financial</strong> viability <strong>of</strong> the R&M<br />
Works.<br />
1.06 The above review was to be carried out based on the <strong>project</strong> information, R&M Works<br />
<strong>financial</strong> forecast, assumptions, and other necessary details as prepared / provided by NTPC.<br />
A brief description <strong>of</strong>the approach and methodolo2V<br />
1.07 The <strong>financial</strong> <strong>appraisal</strong> has been carried out based on the information and explanation<br />
provided by NTPC. The main documents / information provide by NTPC included the following:<br />
• R&M Works details including the Capital cost and the implementation schedule<br />
• Details about the existing operations <strong>of</strong> the <strong>power</strong> plant including the past<br />
performance, beneficiaries, Bulk Supply Agreement, tariff, approvals etc.<br />
• Proposed funding <strong>of</strong> the R&M Works<br />
2
1.08 AFF has relied upon the 'documents and information and explanations provided by<br />
NTPC.<br />
Caveats<br />
1.09 AFF's engagement for the assignment did not constitute an audit or certification <strong>of</strong> the<br />
historical/ <strong>financial</strong> statements/ forecasts <strong>of</strong> the Company/ Project.<br />
1.10 AFF does not accept responsibility or liability for any loss that may be caused to NTPC/<br />
any other person through the investment decision taken based on this report.<br />
1.11 This report is confidential and prepared solely for the internal use <strong>of</strong> NTPC. No part <strong>of</strong><br />
this report can be published externally or used by any third party without AFF's prior written<br />
consent.<br />
3 .'
2.00 BACKGROUND OF NTPC LIMITED<br />
2.01. NTPC Limited (NTPC) was incorporated on November 7, 1975 as a wholly owned PSE<br />
by the Government <strong>of</strong> India with the objective <strong>of</strong> planning, promoting and organizing integrated<br />
development <strong>of</strong> thermal <strong>power</strong> plants to meet the <strong>power</strong> requirements <strong>of</strong> the country. Within a<br />
span <strong>of</strong>30 years, NTPC has emerged as a truly national <strong>power</strong> company, with <strong>power</strong> generating<br />
facilities in all the major regions <strong>of</strong> the country. NTPC became a 'public limited' company in<br />
September 1985.<br />
2.02. The Core business <strong>of</strong> NTPC is engineering, construction and operation <strong>of</strong> <strong>power</strong> plants<br />
and it also provides consultancy to <strong>power</strong> utilities in India and abroad.<br />
2.03. The corporation began its operation by undertaking four green field <strong>project</strong>s to install<br />
four thermal <strong>power</strong> stations in various locations. The locations comprise Korba (Chattisgarh),<br />
Farakka (West Bengal), Singrauli (Uttar Pradesh) and Ramagundam (Andhra Pradesh). The first<br />
Unit at Singrauli was synchronized in February 1982 and the unit commenced commercial<br />
operations from June 1982.<br />
2.04. Presently, NTPC is the largest thermal <strong>power</strong> generating company in India. As on March<br />
31, 2007, NTPC accounted for 20.18 % in the total installed capacity <strong>of</strong> the country and<br />
contributed 28.50 % <strong>of</strong>the total <strong>power</strong> generation <strong>of</strong> the country during 2006-07.<br />
2.05. The installed capacity <strong>of</strong> NTPC as on date is 27,904 MW through its 15 coal based<br />
(22895 MW), 7 <strong>gas</strong>/liquid (3955 MW) and 4 Joint Venture <strong>project</strong>s (1054 MW).<br />
NTPC Owned<br />
Coal<br />
GaslLiquid Fuel<br />
Total<br />
Owned by NCs<br />
Coal<br />
GaslLiquid Fuel<br />
Grand Total<br />
15<br />
07<br />
22<br />
3<br />
1<br />
26<br />
22,895<br />
3,955<br />
26,850<br />
* Captive Power Plant under Ns with SAIL<br />
** Power Plant under N with GAIL, FIs & MSEB<br />
(Source: www.<strong>ntpc</strong>.co.in)<br />
314*<br />
740**<br />
27,904<br />
4
2.06. The installed capacity <strong>of</strong> coal based and <strong>gas</strong> based <strong>power</strong> station is given below:<br />
Coal Based Power Stations<br />
SNo •.<br />
. ,.;?;~:r;~:,('; Commissioned<br />
..<br />
:':€ollihased State .<br />
.
Power Plants with Joint Ventures<br />
,<br />
,<br />
"<br />
, ,.. -,<br />
Coal Based" 'Stitll '! ',,-'~'.,- ' ...~..",-."" ., .....•.... '- " .....<br />
;<br />
FUel<br />
,', ,<br />
-<br />
J. ,~,Commissi()J1ed<br />
"'?, calr:~ihr:,<br />
" -<br />
"',' '~'.' ;-,',<br />
,/
NTPC OPERATING PERFOMANCE PLF<br />
OF NTPC STATION Vs ALL INDIA<br />
ISALlINDlA PLF .NTPC PLF I<br />
to<br />
87<br />
"<br />
15<br />
72<br />
69<br />
II<br />
IS<br />
60<br />
,",. 11911. 'H9. 2000. 200'. 2002. 200S. 201M. 2lM15- 2OIHI.<br />
Ie 9' 2000 2001 2002 2003 2004 2005 2_ 2007<br />
2.\ o. It may be observed from the above that NTPC has consistently outperformed the national<br />
average in terms <strong>of</strong> PLF.<br />
2.11. While the installed capacity has increased by 56.40% in the last nine years, the employee<br />
strength went up by only 3.34%. The % <strong>of</strong> increase in the generation per employee from year<br />
1997-98 to year 2006-07 id given in the table below:<br />
Installed Capacity MW 16,847 26,350 56.40<br />
Generation Mus 97,609 1,88,674 93.29<br />
No. <strong>of</strong> employees No. 23,585 24,375 3.34<br />
Generation/employee MUs 4.14 7.74 86.95<br />
2.12. The detailed operational performance <strong>of</strong> coal based stations over the years is given in the<br />
table below:<br />
~<br />
Generation BU 106.2 109.5 118.7 130.1 133.2 140.86 149.16 159.11 170.88 188.67<br />
PLF % 75.20 76.60 80.39 81.8 81.1 83.6 84.4 87.51 87.54 89.43<br />
Availability<br />
Factor<br />
% 85.03 89.36 90.06 88.54 81.8 88.7 88.8 91.20 89.91 90.09<br />
7
Gas based Stations<br />
2.13. The generation and availability <strong>of</strong> <strong>gas</strong> based stations <strong>of</strong> NTPC for the last five - year<br />
period ended March 31, 2006 is as under:<br />
Y~f:endeaMarcli'3l., '2002 2Q03·' 2004 . 2005 2006'<br />
Capacity (Gas) - MW 3955 3955 3955 3955 3955<br />
Generation (Billion units)<br />
Anta 3.06 2.75 2.77 2.78 2.81<br />
Auraiya 4.68 4.27 4.25 4.12 4.28<br />
Dadri 5.73 5.21 5.06 5.46 5.39<br />
Faridabad 2.86 2.70 2.79 3.16 2.95<br />
Total- North 16.33 14.93 14.87 15.52 15.44<br />
Kawas 3.75 4.20 3.89 2.82 2.88<br />
Gandhar 3.61 3.37 3.22 4.03 4.48<br />
Total- West 7.36 7.57 7.11 6.85 7.36<br />
RGCCPP 1.32 2.12 2.12 0.62 0.36<br />
Total- South 1.32 2.12 2.12 0.62 0.36<br />
Grand Total 25.01 24.62 24.10 22.99 23.16<br />
Availability (%)<br />
Anta 94.67 90.87 92.17 94.63 96.53<br />
Auraiya 92.94 89.51 90.08 87.87 94.7<br />
Dadri 91.68 89.97 91.63 94.85 95.41<br />
Kawas 84.14 90.67 88.75 95.53 97.19<br />
Gandhar 81.44 77.21 78.33 94.17 92.98<br />
Combined * 87.74 87.74 88.97 93.49 95.82<br />
* Including Faridabad and RGCCPP<br />
2.14. During the FY 2006, NTPC generated 23.16 billion units from <strong>gas</strong> based plants as<br />
compared to 25.01 billion units in FY2002, while availability improved from 87.74% in FY2002<br />
to 95.82% in FY2006.<br />
;1<br />
8
Financial Performance<br />
2.15. The <strong>financial</strong> position and performance <strong>of</strong> NTPC during last four <strong>financial</strong> years is given<br />
below:<br />
Pr<strong>of</strong>it and Loss Account<br />
INCOME<br />
Sale <strong>of</strong> Energy 199810 190571 232415 266564<br />
Consultancy and Other income 4492 61816 24110 26806<br />
Operating Revenue 204302 252387 256525 293370<br />
EXPENSES<br />
Fuel expenses 110312 122150 137235 163947<br />
o & M expenses 20649 14835 14725 22739<br />
Operating Expenses 130961 136985 151960 186686<br />
PSIDT 73341 115402 104565 106684<br />
PBIDT/Operating Revenue 35.90% 45.72% 40.76%, 36.36%<br />
Interest 9916 33697 16955 17632<br />
Depreciation 15291 20232 19584 20477<br />
Operating Pr<strong>of</strong>it 48134 61473 68026 68575<br />
Operating Pr<strong>of</strong>it /Operating 23.56% 24.36% 26.52% 23.37%<br />
Revenue<br />
Prior Period Items (Net) 803 183 -102 2488<br />
PST 47331 61290 68128 66087<br />
Income Tax (net <strong>of</strong> Deferred 11256 8682 10058 7885<br />
Tax)<br />
PAT 36075 52608 58070 58202<br />
PAT/Gross Revenue 17.66% 20.84% 22.64% 19.84%<br />
9
•<br />
Balance<br />
Sheet<br />
SOURCES OF FUND<br />
Shareholders' Fund 315040 355501 417763 449587<br />
Deferred Revenue on account <strong>of</strong> 271 1591 3374 4408<br />
AAD<br />
Develo ment Surchar e Fund 3784<br />
Loan Funds 132157 154528 170878 201973<br />
Deferred Tax Liabili 1 1 1 1<br />
TOTAL 447469 515405 592016 655969<br />
APPLICATION OF FUNDS 0 0 0 0<br />
Fixed Assets 262513 287498 322433 367235<br />
Investments 36674 173380 207977 192891<br />
Current Assets 194132 135468 129073 157245<br />
Less: Current Liabilities 45850 80941 67467 61402<br />
Net Current Assets 148282 54527 61606 95843<br />
TOTAL 447469 515405 592016 655969<br />
2.16. The key <strong>financial</strong> ratios are given below.<br />
~, Pll '~'-.'--j~)_~" - ~-"·-".~.···.~I}:.{·-r-·"jJ'T1.?j~1~" '~I1i~ilh-':~~: - )J'
Joint Ventures (JV)<br />
2.18. The following Joint Ventures (JVs) have been formed by NTPC:<br />
• NTPC Alstom Power Services Pvt. Ltd: This JV formed in 1999 was formerly known<br />
as NTPC-ABB Alstom Power Services Pvt. Ltd. NTPC has formed this JV to Undertake<br />
Renovation & ModemisatiQn<strong>of</strong> <strong>power</strong> stations in India and other SAARC countries. The<br />
promoter's equity contribution is 50:50 in this JV.<br />
• Utility Power Tech Ltd: NTPC has formed a JV in 1996 with Reliance Energy Limited<br />
(formerly BSES Limited) a private sector Indian <strong>power</strong> company to undertake <strong>project</strong><br />
construction, erection and supervision in <strong>power</strong> sector and other sectors in India and<br />
abroad. The promoter's equity contribution is 50:50 in this JV.<br />
• PTC (India) Ltd: This JV has been promoted with Power Grid Corporation <strong>of</strong> India Ltd<br />
(POWERGRlD), a Government owned transmission major in India. Power Finance<br />
Corporation (PFC), a <strong>power</strong> sector finance company owned by the Government <strong>of</strong> India<br />
and National Hydro Electric Power Corporation Ltd. (NHPC), a Government owned<br />
hydro <strong>power</strong> utility. This JV was formed in 1998 to trade, import, export and purchase<br />
<strong>power</strong> from identified <strong>power</strong> <strong>project</strong>s and sell it to identified SEBs/others.<br />
• NTPC-SAIL Power Company (Pvt) Ltd (NSPCL): NTPC has formed a JV with SAIL<br />
in equal participation which later merged with Bhilai Electric Supply Co. Pvt Ltd to<br />
supply <strong>power</strong> to the Bhilai, Durgapur and Rourkela Steel Plant <strong>of</strong> Steel Authority <strong>of</strong> India<br />
Limited (SAIL) from its Coal based <strong>power</strong> stations at Bhilai (Chhattisgarh), Durgapur<br />
(West Bengal) and Rourkela (Orissa). For the purpose <strong>of</strong> its business development,<br />
NSPCL is carrying out the expansion <strong>of</strong> its installed capacity at Bhilai, by<br />
implementation <strong>of</strong> 500MW (2x250MW) <strong>power</strong> plant.<br />
• NTPC Tamil Nadu Energy Company Limited: This JV was incorporated on May 23,<br />
2003 with Tamil Nadu Electricity Board, a State run Electricity Board in the State <strong>of</strong><br />
Tamil Nadu engaged in generation, transmission and distribution <strong>of</strong> electricity. The JV<br />
was formed to set up a 1000 MW coal based <strong>power</strong> station at Ennore in Tamil Nadu<br />
utilising the existing infrastructure facility at Ennore and supply <strong>power</strong> mainly to Tamil<br />
Nadu and the states <strong>of</strong> Kerala, Kamataka and Pondicherry. NTPC has equal equity<br />
participation with TNEB in this JV.<br />
• Vaishali Power Generating Company Limited: This JV was incorporated on with<br />
Bihar State Electricity Board, a State run Electricity Board in the State <strong>of</strong> Bihar, engaged<br />
in generation, transmission and distribution <strong>of</strong> electricity to take over Muzaffarpur<br />
Thermal Power Station (2xllOMW), a coal based <strong>power</strong> station at Kanti, for carrying out<br />
11
estoration, R&M and supplying <strong>power</strong> mainly to the state <strong>of</strong> Bihar. The equity<br />
participation is NTPC: 51-74% and BSEB: 26-49%<br />
• Aravali Power Company Private Ltd: The Joint Venture Agreement was signed on<br />
December 14, 2006 among NTPC Ltd, Indrapastha Power Generation Company Ltd.<br />
(IPGCL) and Haryana Power Generation Company Ltd. (HPGCL).The Company was<br />
incorporated on December 21, 2006 to set up a coal-based <strong>power</strong> station <strong>of</strong> 1500MW<br />
capacity in Distt. Jhajjar, Haryana, in joint venture with IPGCL and HPGCL. The equity<br />
participation is NTPC-50%, IPGCL-25% and HPGCL-25%.<br />
To summarise<br />
2.19. NTPC has emerged as the largest <strong>power</strong> generating company in India. NTPC is a<br />
growing, pr<strong>of</strong>it making and a dividend paying company. NTPC's operating performance has<br />
been in line with! above the industry averages. NTPC has rich experience in the field <strong>of</strong> <strong>project</strong><br />
engineering, implementation and management, electricity generation and O&oM<strong>of</strong> <strong>power</strong> plants.<br />
12
'..:.<br />
3.00 NTPC KA WAS GAS POWER PROJECT<br />
3.01. This chapter briefly describes a background <strong>of</strong> the NTPC Kawas Gas Power Project<br />
(KGPP), including the existing facilities, past operating and <strong>financial</strong> performance <strong>of</strong> the plant,<br />
bulk sale agreement, tariff structure etc.<br />
3.02. The Project (Stage I) was sanctioned on August 19, 1988 and the main plant contract was<br />
awarded in March 1990. The commercial operation <strong>of</strong> the plant commenced in the year 1992-93.<br />
EXISTING<br />
FACILITIES<br />
Location<br />
and Land<br />
3.03. NTPC Kawas Gas Power Project (KGPP - 656.28 MW) is located near Mora village<br />
under Choryasi Tehsil in Surat district <strong>of</strong> Gujarat having latitude <strong>of</strong> 21°10' N and longitude <strong>of</strong><br />
72°41' E and is adjacent to the Surat-Hazira road. The site is bounded by KRIBHCO Fertilizer<br />
Plant towards East, Reliance Petro-Chemical Plant towards West and river Tapti towards South.<br />
The Plant is located at a distance <strong>of</strong> 23 Kms from Surat Railway station and is connected with<br />
Vadodara and Mumbai through NH- 8. The nearest airports are located at Surat and Vadodara.<br />
The detail <strong>of</strong> existing plant land is given below:<br />
Mau.-;~~~.~'d¥·62!'~;'\:···'· :',..~.~;;: ; /······.· ..fj~si~ls:t·~;;/.:·<br />
Stage-l 166.71<br />
Reservoir 127.37<br />
Stage-2 228.97<br />
Subtotal 523.05<br />
Aditya Nagar Township 45.10<br />
Total 568.15<br />
Capacity<br />
3.04. KGPP is a combined cycle duel fuel fired <strong>gas</strong> <strong>power</strong> plant. KGPP has two combined<br />
cycle modules, each comprising 2 <strong>gas</strong> turbines <strong>of</strong> capacity 106 MW each and I steam turbine <strong>of</strong><br />
capacity 116.10 MW. The Gas Turbines (Frame 9161E) were supplied and commissioned by<br />
EGT France. The details <strong>of</strong> the commissioning schedule is given below:<br />
Gas Turbine<br />
GT#lA<br />
GT#lB<br />
GT#2A<br />
24.05.1992<br />
22.03.1992<br />
30.06.1992<br />
01.08.1992<br />
01.06.1992<br />
01.11.1992<br />
98549<br />
100667<br />
100039<br />
13
Un.itNo~<br />
GT#2B<br />
Steam Turbine<br />
27.08.1992<br />
ST# 1C 23.02.1993 01.09.1993<br />
ST#2C 19.03.1993 01.09.1993<br />
* Gas turbines have a capacity <strong>of</strong> 106 MW each<br />
** Steam turbines have a capacity <strong>of</strong> 116.1MW each<br />
89085<br />
92513<br />
Technical<br />
facilities<br />
Gas Turbines<br />
3.05. The Stage-I, Kawas Gas Turbines are GE Frarne-9161- E design supplied by Mis EGT<br />
France. These Gas Turbines are capable <strong>of</strong> firing on Natural Gas and Liquid Fuels viz. Naphtha I<br />
NGL I HSD and mix fuel.<br />
Waste Heat Recovery Boilers<br />
3.06. The Waste Heat Recovery Boilers are <strong>of</strong> vertical type; double drum unfired and assisted<br />
circulation type. These were supplied by Mis. CMI, Belgium.<br />
Stearn Turbines<br />
3.07. The Stearn Turbines are <strong>of</strong> Impulse, tandem compound, double exhaust and condensing<br />
type. The HP Turbine is single flow horizontal 13 Stage and LP Turbine is <strong>of</strong> double flow<br />
horizontal having 5 stages.<br />
Generators<br />
3.08. The Generators are <strong>of</strong> 145 MY A for Stearn Turbine and 134 MY A for Gas Turbine. The<br />
rated terminal voltage is 11.5 KY ahd is <strong>of</strong> air-cooled type.<br />
Water Treatment Plant and other facilities<br />
3.09. Beside above facilities, Kawas has water treatment plant, fully equipped Workshop,<br />
NGLI Naphtha storage facility <strong>of</strong> 8000 KL and HSD storage tank having capacity <strong>of</strong>250 KL.<br />
Simulator<br />
3.10. Kawas has a combined cycle <strong>gas</strong> <strong>power</strong> plant simulator, one <strong>of</strong> its kind in Asia. It<br />
provides simulator training to NTPC as well as other <strong>power</strong> plant operation engineers for better<br />
operation <strong>of</strong> plant and real time simulation <strong>of</strong> various operation conditions.<br />
14
Inputs for Power Generation<br />
Fuel<br />
3.11. Natural Gas is supplied from Western <strong>of</strong>fshore <strong>gas</strong> fields through HBJ Pipe Line, while<br />
liquid fuel NGL / Naphtha is supplied by Mis HPCL through separate pipeline. HSD is obtained<br />
from open market from IOC / HPCL and is supplied to plant through road tankers.<br />
3.12. As informed by NTPC, from the very beginning, NTPC-Kawas was not able to get earlier<br />
committed supply <strong>of</strong> 2.25 million Standard Cubic Metres per day (MCMD) <strong>gas</strong> by the Ministry<br />
<strong>of</strong> Petroleum and Natural Gas, from the HBJ pipe line. The requirement <strong>of</strong> <strong>gas</strong> for KGPP at 80%<br />
PLF (approx 2.4 million Standard Cubic Metres per day) is higher than the minimum committed<br />
<strong>gas</strong> quantity available from GAIL (1.752 million Standard Cubic Metres per day) as per its<br />
agreement with NTPC dated July 14,1999 ..<br />
3.13. In order to overcome the situation, arrangements for the <strong>of</strong>f-base liquid fuel handling<br />
facility to make the plant operational on liquid fuel was decided. Ministry <strong>of</strong> Petroleum vide<br />
letter date 15.03.1995 allocated 0.7 MMTP A in favour <strong>of</strong> Mis HPCL to supply Naphtha to NTPC<br />
through a pipeline. The liquid fuel"facilities were commissioned for all the <strong>gas</strong> turbines units in<br />
December 1997.<br />
3.14. Further in the year 2000, mix fuel firing facilities was commissioned in all the <strong>gas</strong><br />
turbines to make the plant operational on mix fuels also. With this facility, Gas Turbine can be<br />
operated in any ratio <strong>of</strong> Gas and Liquid fuel.<br />
3.15. Since June 2006, KGPP has also switched over to LNG (a cheaper fuel than Naphtha). A<br />
separate pipeline has been laid in June 2006 to connect the GSPL (Gujarat State Petroleum<br />
Corporation) Mora Gas Terminal with the GAIL Gas pipe line. Now in case <strong>of</strong> spot purchase <strong>of</strong><br />
LNG, NTPC is getting <strong>gas</strong> through GSPLlHazira LNG also.<br />
Water System<br />
3.16. Make-up water was being drawn from Suvali minor canal Kakrapar right bank canal<br />
network, taking <strong>of</strong>f from Kakrapar .reservoir on river Tapti. As an alternative measure, all Hazira<br />
based industries jointly constructed a weir-cum causeway across river Tapti near Surat city.<br />
NTPC has its share for a reserved quantity <strong>of</strong>l5MGD water. Water is taken from Singanpur weir<br />
on Tapti River through an Underground pipeline <strong>of</strong> about 16 kIn length.<br />
15
-<br />
Status on the current available approvals/sanctions<br />
and their validity<br />
3.17. The Status on the available approvals/sanctions obtained for Kawas Gas Power Project<br />
and their validity (as provided by NTPC) is given below:<br />
S.No • 'J>~~n.pgq~}'.<br />
.. . .. . .,'<br />
:' ' ..<br />
.<br />
Y~!ldp,pto: .' LiccllSe No.<br />
(Date) ..•.•.<br />
. .. "<br />
,,,,},<br />
:.:'.' .<br />
1. Annual IBR inspection <strong>of</strong> WHRB-1 A 23,03,2008 GT-3069 (HP)<br />
(Waste Heat Recovery Boiler)<br />
GT-3070 (LP)<br />
2, Annual IBR inspection <strong>of</strong> WHRB-1 B 15.04.2008 GT-3071 (HP)<br />
GT-30n (LP)<br />
3. Annual IBR inspection <strong>of</strong>WHRB-2A 29.04.2008 GT-3103 (HP)<br />
GT-3104 (LP)<br />
4. Annual IBR inspection <strong>of</strong> WHRB-2B 30.08.2007 GT-3094 (HP)<br />
GT-3095 (LP)<br />
5. Storage <strong>of</strong> DiesellNGLlNaphtha 31.12.2008 P-12 (25)<br />
2999/GJ/SURl512<br />
6. Storage <strong>of</strong> Diesel in Black Start 31.12.2007 P-12(25)<br />
3383/GJ/SURl556<br />
7. Storage <strong>of</strong> Chlorine 31.03.2007 GJ/SUR/GC/S-29<br />
(sent for<br />
renewal)<br />
8. Storage <strong>of</strong> CO2 31.03.2009 PV/ (WC) S-<br />
312GJ/SURlPVC/35<br />
9. Storage <strong>of</strong> Naphtha (As per Gazette 29.10.2007 W1712000<br />
Notification)<br />
10 Air Consent Order 07.03.2010 13836<br />
II Water Consent Order 07.03.2010 3639<br />
12 Hazardous Waste Handling 07.03.2010 3264<br />
3.18. As per the above table nece~sary approvals are in place/ current at present<br />
SUPPLY OF POWER<br />
Bulk Supplv A2reement<br />
3.19. The Bulk Supply Agreement (BSA) was entered into on January 12, 1994 between<br />
National Thermal Power Corporation Limited (NTPC) and Madhya Pradesh Electricity Board<br />
(MPEB), Maharashtra State Electricity Board (MSEB), Gujarat Electricity Board (GEB),<br />
Electricity Department <strong>of</strong> Government <strong>of</strong> Goa (EDGG), Union Territory <strong>of</strong> Daman and Diu<br />
(UTDD), Union Territory <strong>of</strong> Dadra and Nagar Haveli (UTDNH) and Western regional<br />
Electricity Board (WREB) (Collectively referred as "Bulk Power Beneficiaries").<br />
16
3.20. The Bulk Supply Agreement pertains to selling <strong>of</strong> the bulk energy from NTPC's<br />
generating stations, wherein NTPC is desirous to sell to the bulk <strong>power</strong> customers, who are<br />
desirous <strong>of</strong> purchasing energy from NTPC at a mutually agreed terms and conditions.<br />
Allocation <strong>of</strong> Power<br />
3.21. The share <strong>of</strong> Power for the beneficiary states as per the Bulk Power Supply Agreement<br />
entered on January 12, 1994 is as follows:<br />
Beneficiary States·· MW··· .. %Share .<br />
MSEB 201 31.16%<br />
GEB 184 28.50%<br />
MPSEB 137 21.24%<br />
Goa 22 3.40%<br />
Dadra & Nagar 2 0.30%<br />
Haveli<br />
Daman & Diu 2 0.30%<br />
Unallocated 97 15.03 %<br />
Total 645 100.00%<br />
3.22. Presently, the <strong>power</strong> produced is fed to the Western grid and is shared by the<br />
beneficiaries. The current allocation <strong>of</strong> <strong>power</strong> to the beneficiary states is as under:<br />
,<br />
•<br />
~%~ot~Yr.e;, .<br />
-,' .' ..... " ~"<br />
BenetJcian> Stat~,.;:; .:',':~'~.MW~(,:~~:~;~;\~<br />
MSEB 238 36.28%<br />
GEB 191 29.12%<br />
MPSEB 158 24.09%<br />
CSEB 3 0.46%<br />
Daman & Diu 12 1.83%<br />
Dadar and Nagar<br />
Havelli 53 8.08%<br />
SEZ -Indore 1 0.15%<br />
Total 656 100.00%<br />
3.23. The Bulk Supply Agreement entered into with the beneficiary states in the year 1994 is<br />
valid upto year 1997. However, as per Clause 12 <strong>of</strong> this agreement, all terms and clauses <strong>of</strong> the<br />
agreement shaH be remain in force and shaH continue to be applicable unless the agreement is<br />
nullified or renewed. As informed by NTPC, currently, the <strong>power</strong> is supplied to the beneficiary<br />
states on the basis <strong>of</strong> this agreement and it shall continue to be valid for the extended life <strong>of</strong> the<br />
plant after the implementation <strong>of</strong> the R&M Works.<br />
17
Power Scenario in Beneficiarv<br />
States<br />
3.24. The beneficiary states have been facing <strong>power</strong> deficits <strong>of</strong> varying magnitude during the<br />
last 3 years. The <strong>power</strong> supply in the beneficiary states during the years 2003-04 to 2005-06 and<br />
during the period April<br />
illl.'.,~""'.;<br />
2006 to February 2007 is given below:<br />
.;~""E~,";;ir<br />
~til~~!i,;X.~r.<br />
' :-~bili' \D~'clti~ie}~ii ; "~'~iii' ~.\;- "niitl·.<br />
R~s~'n;',m':'1~'.<br />
".,...<br />
.<br />
"d"-"'~/., ... , "(l\t.W)'<br />
."=.1.i •..,,,.!" ......•...' """,.,,,....<br />
" -<br />
~JfitY.,.<br />
(MlJ)' ...... WlJ)."<br />
~"'<br />
:,'::.:-,y2",~;-:':' ;'-(o/~),(2,~'/;~~<br />
',' ;"'·;
StatelUTl Year Peak Peak };nergy~ Energy' Energy<br />
-·;}1~ - , ',' "- .,' :"_' r.-,· . ':<br />
Region A~iqability D~gCit<br />
•...,"'~#."", .."..... ',," ~~!ll~~!lt<br />
...~ .., . (MUr'~'•., ..,<br />
......<br />
~<br />
,.•..~/ •.::<br />
;~v~~~~~f$~~,<br />
.:;<br />
~..
•<br />
section 43A(2) <strong>of</strong> Electricity Supply Act, 1948 (as amended). In case <strong>of</strong> any difference between<br />
the terms and conditions <strong>of</strong> the Bulk Power Supply Agreement and above notifications <strong>of</strong> Gol,<br />
the provisions <strong>of</strong> GoI shall prevail. For the tariff <strong>of</strong> Gas Power Station the prevailing<br />
arrangements <strong>of</strong> adhoc tariff would continue subject to adjustment as per the Notification to be<br />
issued by Gol.<br />
3.29. The revision <strong>of</strong> tariff and terms and conditions shall be in accordance with the<br />
notifications issued by GoI from time to time.<br />
Subsequently, CERC has notified the revised tariff for Kawas Gas Power Project on November<br />
16,2006 and has laid down the norms for tariff recovery till <strong>financial</strong> year 2008-09. The various<br />
tariff parameters that have been decided upon by CERC vide this order are as follows:<br />
D"'~~ ,",,;;-,-,' , '~',;',~::',"f> /':~ill>·",~<br />
·.J;Ju:ame.etC::·,;N: '~,>"<br />
Ca ital Base as on 1.4.2004<br />
Debt E uit Ratio<br />
Rate <strong>of</strong> Interest on Borrowings<br />
Interest on loan<br />
O&M Expenses<br />
Working Capital<br />
Interest on workin<br />
ca ital<br />
Year: 2004-05 - 6.43 %<br />
Year: 2005-06 - 8.09 %<br />
Year: 2006-07 - 8.09 %<br />
Year: 2007-08 - 8.11 %<br />
Year: 2008-09 - 9.58 %<br />
Since the loan has been repaid till the<br />
year 2004-05, there is no interest on<br />
loan from 2005 onwards.<br />
80%<br />
14% i.e. Rs 10598 lacs er annum<br />
Depreciable value <strong>of</strong> Rs 41504 lacs has<br />
been spread over the balance useful life<br />
<strong>of</strong> 8.39 years. (Depreciation per annum<br />
is Rs 4947 lacs<br />
Year: 2004-05 - Rs 3412 Lacs<br />
Year: 2005-06 - Rs 3550 Lacs<br />
Year: 2006-07 - Rs 3688 Lacs<br />
Year: 2007-08 - Rs 3839 Lacs<br />
Year: 2008-09 - Rs 3990 Lacs<br />
Fuel Cost (1 Month)<br />
Naphtha Stock (112 month)<br />
O&M expenses (1 month)<br />
Spares (1% <strong>of</strong> historical cost, escalated<br />
@ 6% p.a)<br />
Receivables (2 month<br />
10.25 % .a<br />
20
3.30. The operational norms for computing the variable cost for the period Year 2004 to Year<br />
2009 were fixed as follows:<br />
Des~,riIi~.YP<br />
- ,.;;.~:>-';~,:r,-<br />
Gas rice (Rs./I000 SCM)<br />
Gas GCV (kcaIlSCM)<br />
Price <strong>of</strong> Li uid Fuel (Rs./MT)<br />
GCV <strong>of</strong> Li uid Fuel (Kcal/K )<br />
·AS<br />
'-"""'"."<br />
considered<br />
4770.53<br />
9923.33<br />
20129.08<br />
11318.28<br />
3.31. The norms laid down by C~RC are till the year 2008-09.<br />
3.32. The break up <strong>of</strong> the existing applicable tariff is as under:<br />
2004-05 200S;.o(}<br />
11.09 11.09 11.09 11.09 11.09<br />
0.002 a 0 0 0<br />
23.76 23.76 23.76 23.76 23.76<br />
a a 0 a 0<br />
10.69 10.73 10.77 10.84 10.86<br />
7.65 7.96 8.27 8.61 8.95<br />
53.19 53.54 53.89 54.30 54.66<br />
25.72<br />
285.50<br />
25.72<br />
285.50<br />
25.72<br />
285.50<br />
25.72<br />
285.50<br />
25.72<br />
285.50<br />
364.41<br />
364.76<br />
365.11<br />
365.52<br />
365.88<br />
102.88 102.88 102.88 102.88 102.88<br />
0.00 0.00 0.00 0.00 0.00<br />
- Total Tariff under Scenario 2<br />
A+C 156.07 156.42 156.77 157.18 157.54<br />
3.33. It may be seen that the Energy Charges constitute the major component <strong>of</strong> cost in the<br />
existing tariff. This is because the KGPP has almost lived its life and there are no outstanding<br />
21
• '.~' y', .l'
.ParticullifslY ear'S 2003-04 2004-05 2005-P6 ..<br />
.' .. "." " .'<br />
Fixed Assets 413.45 316.36 210.61<br />
Investments - - -<br />
Current Assets 86.96 210.13 77.34<br />
Current Liabilities 219.07 256.76 111.07<br />
Net current Assets (132.10) (46.62) (33.73\<br />
Misc. Expenditures<br />
TOTAL 281.34 269.74 176.88<br />
Current Assets (no. <strong>of</strong> days <strong>of</strong> 24 52 23<br />
Sales)<br />
Current Liability (no. <strong>of</strong> days 61 63 33<br />
<strong>of</strong> Sales)<br />
3.39. As per the above Table, the' net current assets was negative / negligible. The gross current<br />
assets has been in the range <strong>of</strong> 15 to 24 days (except for 52 days in the year 2005-06).<br />
3.40. The summary <strong>financial</strong> performance <strong>of</strong> the unit for the past three years has been as<br />
under:<br />
."0 , •• •••,;:};".~'l~~e~::;?,o<br />
._e.~ ..•st~~.(~:~t'l~;,.";:*':··'<br />
- ,<br />
.. -,'<br />
'?'_~·~~ltS.i~;~:~;~:-~<br />
0<br />
;;"{::':iL-"\ , '"Sales'<br />
96.67%<br />
':?~Jt%'~?<strong>of</strong>;~
3.41. From the above table, it emerges that fuel is the major cost <strong>of</strong> <strong>power</strong> in KGPP as the plant<br />
has been almost fully depreciated and the there are no outstanding long term loans. The plant has<br />
been making pr<strong>of</strong>its since the plant availability had been well over 80 % resulting in full<br />
recovery <strong>of</strong> the fixed costs even though the PLF had been lower. As per the Tariff, the variable<br />
cost is a pass through cost.<br />
To summarise<br />
• Since KGPP is an existing plant, it already has the required land, approvals, input<br />
arrangements, bulk supply agreement, evacuation facility etc. in place. NTPC would need to<br />
get the approvals renewed if any, as and when required.<br />
• The tariff is governed by the CERC Tariff Order and the payment is secured as per the usual<br />
payment security mechanism <strong>of</strong> opening <strong>of</strong> LC by the beneficiary States. It is understood<br />
that the beneficiary states would continue to be governed by the existing Bulk Supply<br />
Agreement and CERC Tariff Order during the extended life <strong>of</strong> the Plant post implementation<br />
<strong>of</strong> the R&M Works.<br />
• The major cost component <strong>of</strong> tariff is the fuel cost as the Plant has been almost fully<br />
depreciated and there are no outstanding long term loans.<br />
• The <strong>gas</strong> availability is lesser than the quantum <strong>of</strong> <strong>gas</strong> required to operate the Plant at 80%<br />
PLF. The cost <strong>of</strong> fuel varies significantly depending upon the proportion <strong>of</strong> <strong>gas</strong> / Naphtha<br />
used. However as per the Tariff Order, the fuel cost is recoverable at the actual fuel used.<br />
• KGPP has maintained plant availability <strong>of</strong> over 90% in the past though the PLF had been<br />
lower due to the lesser supply <strong>of</strong> <strong>gas</strong> / costly alternate fuel (i.e. Naphtha) resulting in less<br />
energy requested by the beneficiary states.<br />
• KGPP has been making pr<strong>of</strong>its since the plant availability had been well over 80 % resulting<br />
in full recovery <strong>of</strong> the fixed costs and the fuel cost is a pass through cost.<br />
~<br />
'"•<br />
24
4.00 RENOV A.TION & MODERNISATION WORKS<br />
4.01. NTPC proposes to take up the Renovation and Modemisation work at its Kawas Gas<br />
Power Project (656.28 MW). As informed by NTPC, the need for the R&M Works has arisen<br />
mainly due to technological obsolescence and some change in the statutory requirements for<br />
environment and safety considerations. As per NTPC:<br />
• Each <strong>gas</strong> turbine has been in service for the last 15 years with an average operation <strong>of</strong><br />
6145 hrs to 6400 hrs per year (i.e. operating availability <strong>of</strong> 70% to 73%).<br />
• All components installed in the turbines and the spares available at the site have almost<br />
completed their recommended life and these components are beyond repair.<br />
• Further, due to degradation <strong>of</strong> the compressor blades, the compressor efficiency may<br />
come down resulting in the form <strong>of</strong> surging and thereby causing severe damage to the<br />
compressor blades due to high vibrations.<br />
4.02. In view <strong>of</strong> the above, NTPC has filed a proposal for investment in Renovation and<br />
Modemisation (R&M) Works <strong>of</strong> the KGPP to Central Electricity Authority (CEA) in Dec 06 for<br />
Techno Economic Clearance.<br />
4.03. CEA has awarded the Techno Economic Clearance to the KGPP R&M Works vide its<br />
letter No. 3/6/NTPC (Kawas)/TRM/CEA/2007/21 dated June 1, 2007. Further, on June 19,<br />
2007, CEA has accorded its recommendation for the implementation <strong>of</strong> the KGPP R&M Works<br />
at an estimated cost <strong>of</strong>Rs 51,604.30 Lacs.<br />
4.04. Through R&M Works <strong>of</strong>KGPP, NTPC plans to meet the following objectives:<br />
• Life extension <strong>of</strong> the units<br />
• Overcome Technological Obsolescence<br />
• Meet statutory norms related to Environment and Safety.<br />
• Sustain availability <strong>of</strong> the U.nits<br />
25
4.05. The R&M schemes are planned to be implemented by 2012-13 in a phased manner. A Summary <strong>of</strong> the R&M Works cost as<br />
provided by NTPC is given below:<br />
I<br />
GT Components<br />
Extension<br />
All the <strong>gas</strong><br />
components available<br />
have almost completed<br />
their recommended life.<br />
For another 80,000 EOH<br />
operation <strong>of</strong> GTs requires<br />
replacement <strong>of</strong> the<br />
components along with<br />
the associated hardware.<br />
;EX·e&t!d~Dlte.·<br />
..~f.PI;H:,:;;··.·;<br />
·Colfifuis-Sioniil'<br />
First GT-<br />
November 2009<br />
Second GT- July<br />
2010<br />
Third<br />
2011<br />
GT- July<br />
Fourth GT-<br />
October 201 I<br />
II<br />
III<br />
Renovation<br />
and<br />
Modernization <strong>of</strong> Gas<br />
Turbine Control system<br />
Renovation<br />
and<br />
Modernization <strong>of</strong> Steam<br />
Turbine, WHRB and other<br />
combined<br />
cycle<br />
equipments control system<br />
up-gradation including<br />
Man Machine Interface<br />
(MMI , Vibration<br />
708.00<br />
2678.50<br />
Existing GE Mark - IV<br />
<strong>gas</strong> turbine contro'l<br />
system has become<br />
obsolete and phased out<br />
by manufacturer.<br />
Existing control system<br />
and MMI have become<br />
obsolete and phased out<br />
by manufacturer.<br />
Up gradation <strong>of</strong> the<br />
control system with the<br />
latest microprocessor<br />
based digital control<br />
system <strong>of</strong> Supertonics<br />
Mark - VI s stem <strong>of</strong> GE.<br />
Up gradation <strong>of</strong> existing<br />
control system with the<br />
latest microprocessor<br />
based digital control<br />
system ALSTOM<br />
ALSPA P320.<br />
Overcoming<br />
Obsolescence<br />
Overcoming<br />
Obsolescence<br />
Along with<br />
GT's<br />
Along with<br />
Second and<br />
Fourth GT's<br />
26
IV<br />
V<br />
Monitoring system, UPS<br />
s stem<br />
Up-gradation <strong>of</strong> Simulator<br />
Replacement <strong>of</strong> Halon<br />
System<br />
Total<br />
550.00<br />
275.00<br />
51604.30<br />
As the simulator<br />
hardware has become<br />
obsolete the spares<br />
support is not available.<br />
Statutory requirement to<br />
phase out Halon fire<br />
fighting system.<br />
Present simulator Overcoming<br />
hardware should be Obsolescence<br />
replaced with the same as<br />
main plant hardware so<br />
that system workability<br />
would not be affected.<br />
Replacement <strong>of</strong> Halon Environment<br />
fire fighting system with &<br />
Inert <strong>gas</strong> fire fighting Obsolescence<br />
system.<br />
Year 2009-10<br />
Year 2009- I0<br />
27
4.06. The description <strong>of</strong> the above proposed schemes as provided by NTPC is given in the<br />
subsequent paragraphs:<br />
l. Gas Turbine lGT) Components Life Extension<br />
I Area <strong>of</strong> pr'o})lem.<br />
At Kawas, there are 2 modules <strong>of</strong> 2 Gas Turbines (GT's) and 1 Steam Turbine (ST) each. The<br />
GTs are <strong>of</strong> GE USA make, model 9161 E and were supplied by EGT France. These are 3 stage<br />
impulse turbines, with 17 stage heavy duty axial flow compressor. The combustion section is<br />
multiple chamber cane annular type reverse flow design having 14 combustion chambers. All the<br />
four Gas Turbines were commissioned in the year 1991-92.<br />
As on August 1,2007, these turbines have clocked more than 90000 Equivalent Operating Hours<br />
(EOHs) each. The details <strong>of</strong> machine EOHs are as follows.<br />
• GT -1A<br />
• GT-IB<br />
•• GT - 2A<br />
GT - 2B<br />
98549 EOHs<br />
100667 EOHs<br />
100039 EOHs<br />
98284 EOHs<br />
These GT's operate on high temperatures. The temperature at turbine inlet is <strong>of</strong> the order <strong>of</strong><br />
1104 0 C. and the exhaust <strong>of</strong> the turbine is at 540 0 C. Further, there are various other operating<br />
factors like different type <strong>of</strong> fuels, loading and unloading cycles, water injection etc., combined<br />
effect <strong>of</strong> which results in corrosion, erosion and wear, creep deformation, out <strong>of</strong> dimension<br />
limits, cracks, thermal fatigue etc.<br />
To ensure GT availability at full potential performance and to avoid un-foreseen failures <strong>of</strong> the<br />
machine and taking into consideration all the operational limiting factors, Original Equipment<br />
Manufacturer (OEM) has recommended the Inspection intervals for the <strong>gas</strong> turbines which are as<br />
follows:<br />
• Combustion Inspection (CI) at every 8000 EOH: In this inspection, the combustion<br />
chambers and the associated components like Combustion Liners, Transition Pieces,<br />
Cross Fire Tubes, and Flow-Sleeves etc. are inspected and replaced, if required .<br />
• Hot Gas Path Inspection (HGPI) at 24000 EOH: In this type <strong>of</strong> inspection, apart from the<br />
combustion inspection portion, the turbine portion including the buckets, nozzles,<br />
shrouds are also inspected and replaced, if required.<br />
• Major Inspection (MI) at 48000 EOH: In this type <strong>of</strong> inspection, the whole <strong>gas</strong> turbine<br />
including the Compressor and the bearings is inspected.
Till date, the GTs have completed<br />
completed is as follows.<br />
II cycles <strong>of</strong> Inspection each. The detail <strong>of</strong> GT wise inspection<br />
Unit CI HGPI MI<br />
GT-IA 6 3 2<br />
GT -IB 6 4 I<br />
GT - 2A 6 3 2<br />
GT - 2B 6 3 2<br />
Due to the factors discussed above, every component <strong>of</strong> the GT has a limited life in comparison<br />
to the unit available life depending upon the type <strong>of</strong> component, its location in the turbine and its<br />
severity <strong>of</strong> service conditions. The OEM recommends service life <strong>of</strong> the component in the form<br />
<strong>of</strong> repair intervals and replacement intervals.<br />
S"N "<br />
1. Combustion Liner CI 5 CI<br />
2. Transition Piece CI 6CI<br />
3 Fuel Nozzle CI 3 CI<br />
4. Cross Fire Tube CI 3 CI<br />
5. Fuel Pump CI 3 CI<br />
6. Stage # I Nozzle HGPI 3 HGPI<br />
7. Stage # 2 Nozzle HGPI 3 HGPI<br />
8. Stage # 3 Nozzle HGPI 3 HGPI<br />
9. Stage # 1 Shroud HGPI 2 HGPI<br />
10. Stage # 2 Shroud HGPI 3 HGPI<br />
11. Stage # 3 Shroud HGPI 3 HOPI<br />
12. Stage # I Bucket HGPI 2 HGPI<br />
13. Stage # 2 Bucket HGPI 3 HGPI<br />
14. Stage # 3 Bucket HGPI 3 HGPI<br />
, .', .O~:'<br />
CODlP6'ii:enti ",/. " Repa(fPite~al't, 'Rep~emehfiiite".r,.'<br />
Thus, all the components installed in the turbines and the spares available at site have almost<br />
completed their recommended life.<br />
Axial Flow compressor deterioration is one <strong>of</strong> the major causes <strong>of</strong> loss in GT output and<br />
efficiency. As mentioned earlier, all the GT's have logged more than 90000 EOH (equivalent<br />
operating hours). Corrosion <strong>of</strong> compressor blades causes pitting in blade surface, which serves as<br />
potential site for fatigue crack initiation in addition to increasing surface roughness. These<br />
surface roughness and blade contour changes will decrease the compressor airflow and<br />
efficiency.<br />
29
I Effect <strong>of</strong>the problem onpfant operation and performance:<br />
The recommended life <strong>of</strong> turbine components has expired and the same are beyond repair. This<br />
will render the components and the turbine unavailable for operation.<br />
Due to degradation <strong>of</strong> the compressor Blades, the compressor efficiency may come down all <strong>of</strong> a<br />
sudden, resulting in the form <strong>of</strong> surging and thereby causing severe damage to compressor blades<br />
due to high vibrations. There are instances at Kawas <strong>of</strong> crack development at the root <strong>of</strong> the first<br />
stage stator blades which called for replacement <strong>of</strong>Stage#1 stator blades on three occasions.<br />
Problems have been faced by one <strong>of</strong> the NTPC <strong>gas</strong> stations due to failure <strong>of</strong> these vanes leading<br />
to loss <strong>of</strong> availability. Any such occurrence at Kawas may lead to generation loss and unit<br />
unavailability for long duration in absence <strong>of</strong> the safety stock <strong>of</strong> these spares.<br />
To replace the components with new components such that the life <strong>of</strong> the turbines are extended<br />
and the same are available for operation for another 80,000 operating hours.<br />
The life <strong>of</strong> the <strong>gas</strong> turbines will be extended by further approx. 80,000 hours and part<br />
performance recovery from existing levels is expected.<br />
II. Renovation and Modernization <strong>of</strong> Gas Turbine Control System<br />
The GT controls Mark IV installed presently have been phased out by GE due to up gradation <strong>of</strong><br />
technology and components. The control <strong>of</strong> GT is a very essential function <strong>of</strong> operation. Any<br />
unavailability <strong>of</strong> control system function may result in unavailability <strong>of</strong> machine and in the worst<br />
case may damage the equipment. As OEM support would not be available and spares<br />
requirement <strong>of</strong> the existing Controls would affect the safe running <strong>of</strong> the GT's.<br />
The solution <strong>of</strong> the above problem is the Up gradation <strong>of</strong> existing control system with the latest<br />
Microprocessor based Digital control system <strong>of</strong> Supertonics Mark VI system <strong>of</strong> GE (OEM <strong>of</strong><br />
present control system) or equivalent. The control system shall be Operator work station based<br />
for control from local control room level as well at the Central Control Room level. Further the<br />
system shall open architecture for communication for integrating with the ST and WHRB control<br />
system so as to achieve Integrated Man Machine Interface from the CCR. The systt'm shall have<br />
provision for Historical data storage and retrieval capability. The associated systems/equipments<br />
requiring upgrade / compatibility with the new system shall also be upgraded. This shall include<br />
30
systems like <strong>power</strong> supply system, flame monitoring, hydraulic converters, speed detection ,<br />
vibration monitoring, cables etc.<br />
The SPEEDTRONIC Mark VI is Triple Modular Redundant (TMR) having Intel 300 MHz CPU<br />
with built in flash memory. The CPU and I/O modules are triplex configuration. Mark VI<br />
controller is single slot VME module housing. CPU board communicates with I/O boards<br />
through VME bus. The operating system is QNX which is real time, multitasking OS designed<br />
for high speed industrial application system. Mark VI diagnostics includes <strong>power</strong> up, background<br />
and manually initiated diagnostic routines capable <strong>of</strong> identifying both control panel, sensor and<br />
output fault. Mark VI is using two communication networks namely I/O Net and UDH. Both are<br />
Ethernet based.<br />
New digital control system shall provide many benefits including faster response and better<br />
regulation. This new system has improved diagnostic capability and better reliability. This<br />
system provides better protective features, safe and reliable operation <strong>of</strong> the GTs. The mark VI<br />
Human Machine Interface (HMI) is <strong>power</strong>ful, flexible and user friendly operator interface. It<br />
provides all display which are needed for real time control. The Alarm Viewer provides the<br />
alarm management functions for HMI system. The system is having facility to store the historical<br />
data. Historian is client -server based data archival system, designed to support plant data<br />
collection, storage and presentation <strong>of</strong> it. Historian's fast data access can significantly reduce the<br />
time required to analyze the process. This also helps to run the GT for optimum performance and<br />
enhances the troubleshooting. SIMPLICITY s<strong>of</strong>tware allows configuration <strong>of</strong> the system users<br />
to control access and privileges. Each user is assigned identity with password. In addition to the<br />
identity <strong>of</strong> user, each user is assigned a role and each role has certain privilege levels.<br />
III. Renovation and Modernization Steam Turbine. WHRB and other Combined Cvcle<br />
EQuipments Control System includine: Man Machine Interface (MMI). Vibration<br />
Monitorine:System<br />
Steam Turbine control system (REC 920), T 20 and Micro Z system for WHRB and other<br />
combined cycle equipments and Man Machine Interface (MMI), Vibration Monitoring System <strong>of</strong><br />
Block-l and Block-2<br />
Steam Turbine, Block Control System<br />
The present block control system namely T 20 (open loop control system), Micro Z system<br />
(Closed loop control system) and Steam Turbine REC 920 controls system and Centralog system<br />
(HMI) would not have OEM support and the system is obsolete in nature.<br />
31
The existing Block#l and Block#2 Man/Machine interface "Centralog System" was installed in<br />
the 1992 along with the main plant. Centralog system facilitates the centralized operation <strong>of</strong> the<br />
plant from CCR. Due to revolution and fast upgradation in the field <strong>of</strong> computer system, various<br />
components <strong>of</strong> Centralog systems have gone in obsolescence. These components are serial<br />
interface cards, Ethernet cards, keyboards, Hard disks, graphic control cards etc.<br />
As the Control system is obsolete in nature, the spares would not be available, thereby affecting<br />
the system availability. As a result the combined cycle availability would reduce.<br />
Up gradation <strong>of</strong> existing control system with the latest Microprocessor based Digital control<br />
system ALSTOM ALSP A P320 (QEM) <strong>of</strong> present system or equivalent for both the blocks. The<br />
control system shall control two WHRB, one ST along with the HP and LP Bypass system in one<br />
block with Open loop controls and closed loop controls <strong>of</strong> various systems. The control system<br />
shall have Operator work station and Large Video screen based HMI system for control at the<br />
CCR level. The HMI shall be integrated to achieve control <strong>of</strong> entire block including GT and<br />
common system drives. The system shall have provision for Historical data storage and retrieval<br />
capability. The control system <strong>of</strong> both the blocks shall be linked to the plant level LAN for<br />
collection and dissemination <strong>of</strong> information to the plant operation and management personnel.<br />
The associated systemsJequipments needing upgrade / compatibility with the new system shall<br />
also be upgraded, this shall include systems like UPS and DC <strong>power</strong> supply system, vibration<br />
monitoring and Analysis system and, cables etc.<br />
Better availability <strong>of</strong> the control system would ensure safe and reliable operation <strong>of</strong> the<br />
combined cycle plant.<br />
IV. UDl!radation <strong>of</strong> Simulator<br />
Present simulator hardware was supplied with main plant package which is exactly same as main<br />
plant hardware. This has become obsolete. The HP Computer has also become obsolete which<br />
actually simulates the processes. So the simulator needs up gradation for better workability.<br />
As the simulator hardware has become obsolete, the spares support is also not available. Present<br />
Simulator is to be up graded with main plant system so that system workability would not be<br />
affected.<br />
Present simulator System should be replaced with the operator interface same as that <strong>of</strong> main<br />
plant hardware.<br />
32
I Effedot:Upgradation<br />
The up gradation <strong>of</strong> the simulator will give better workability with the system.<br />
V. Replacement <strong>of</strong> Halon Fire Protection System in Central Control Room and Adiacent<br />
Relav Room, Gas Turbine Local Control Rooms, UPS Rooms<br />
,', ", ': I<br />
Fire fighting system <strong>of</strong> stage-l covering CCR, adjacent Relay rooms to the CCR, Gas Turbines<br />
Local Control Rooms and UPS Rooms for Module I & II.<br />
As per International norms and ISO 14001 norms, the Halon <strong>gas</strong> used as the extinguishing<br />
medium is to be replaced by the Non-ODS (Ozone Depleting substances) <strong>gas</strong>. This is essential as<br />
per Montreal Protocol as well as Gazette notification by GOL<br />
The existing fire fighting system IS around 16 years old. KGPP is facing frequent problems due<br />
to obsolescence & deterioration. The electronic boards, output modules for alarm and release and<br />
the existing sensors are <strong>of</strong> the imported origin. The sensors are old conventional type. The<br />
problem faced is due to:<br />
• Non-availability <strong>of</strong> the spares<br />
• Non-availability <strong>of</strong> the technical support.<br />
The fire protection system for the CCR, LCR and UPS rooms is very critical system. In case <strong>of</strong><br />
any non-availability or spurious functioning <strong>of</strong> old fire protection/fire fighting system it poses<br />
following problems:<br />
• Unsafe working condition.<br />
• Non-conformance to safety norms .<br />
• Environment deterioration due to use <strong>of</strong> Halon <strong>gas</strong> .<br />
• Any eventuality will affect the entire generation from the station.<br />
It is proposed to upgrade the present system with the state <strong>of</strong> art; fully addressable fire fighting<br />
system with the addressable detectors in place <strong>of</strong> the conventional detectors. This will involve<br />
replacing the existing sensors, detection system and the actuation system. hpart from this, the<br />
existing Halon <strong>gas</strong> is to be replaced by the Non-ODS (Ozone Depleting substances) <strong>gas</strong>.<br />
33
I Benefits Qnperformance 1generation as the result Qfrenovation<br />
Reliable and trouble free fire detection and actuation system with the facility <strong>of</strong> pin-pointing the<br />
location <strong>of</strong> fire / false call will ensure the safety and security <strong>of</strong> the switchyard building and<br />
hence entire station. It will ensure the following:<br />
• Safer working environment.<br />
• Adherence to environmental and safety norms.<br />
• Reduction in insurance premium.<br />
• Saving on account <strong>of</strong> equipments, machines and human lives.<br />
Conclusion<br />
4.07. With the implementation <strong>of</strong> the R&M proposals, NTPC envisage that:<br />
• The Gas Turbines life will be extended for about 80,000 - 100,000 hrs and<br />
performance will be maintained to the design level. As per NTPC, the plant should<br />
have an extended life <strong>of</strong> 15 years post implementation R&M Works.<br />
• The new digital control system would provide safe and reliable operation <strong>of</strong> the <strong>gas</strong><br />
turbines.<br />
• The new Halon-free fire protection would provide reliable and trouble free fire<br />
detection and actuation system with the facility <strong>of</strong> pin pointing the location <strong>of</strong><br />
fire/false call and ensure the safety and security <strong>of</strong> the station.<br />
34
5.00 R&M WORKS FINANCIALS<br />
Estimation <strong>of</strong> Renovation and Modernisation (R&M) cost<br />
5.01 The estimate <strong>of</strong> the R&M Works cost is as follows:<br />
Estimation<br />
<strong>of</strong> R&M cost<br />
Head<br />
NTPC Estimates<br />
(Rs. in Lacs<br />
R&M Cost<br />
% <strong>of</strong> Total<br />
HGP Components 47392.80 79.32%<br />
Other R&M Cost 4211.50 7.05%<br />
Total (as approved by CEA) 51604.30 86.37%<br />
Contingency 2580.22 4.32%<br />
R&M cost (including contingency) 54184.52 90.69%<br />
Interest During Construction Period 5355.37 8.96%<br />
(IDC)<br />
Financing charges 209.12 0.35%<br />
Total 59749.01 100.00%<br />
Cost per MW 91.05<br />
5.02 NTPC has determined the R&M cost estimates essentially based on the following:<br />
• Most <strong>of</strong> the above mentioned cost estimates are based on either the budgetary<br />
<strong>of</strong>fers/purchase order or quotations invited during the year 2004 and 2005.<br />
• NTPC has considered the exchange rate <strong>of</strong> Rs. 45 /- per USD and Rs. 60 /- per Euro<br />
while computing the cost <strong>of</strong> the R&M Works.<br />
• A provision <strong>of</strong> 5% has been made towards the physical contingency for the costs<br />
estimates provided by NTPC.<br />
5.03 As mentioned earlier, CEA has awarded the Techno Economic Clearance to the KGPP<br />
R&M Works vide its letter No. 3/6/NTPC (Kawas)/TRMlCEA/2007/21 dated June 1,2007.<br />
Further, On June 19,2007, CEA has accorded its recommendation for the implementation <strong>of</strong> the<br />
KGPP R&M Works at an estimated cost <strong>of</strong>Rs 51,604.30 Lacs.<br />
5.04 It should be noted that the above CEA approval is before taking into account the<br />
contingency and IDC. CEA's clearance <strong>of</strong> R&M proposals are normally accorded excluding<br />
35
Contingency & IDC. It is understood that NTPC will obtain CERe's approval for the revised<br />
R&M Works cost based on the actual costs incurred on implementation.<br />
Means <strong>of</strong> Financinl!.<br />
5.05 The R&M cost is proposed to be financed with a debt equity ratio <strong>of</strong> 70:30. Based nn<br />
this, the means <strong>of</strong> financing works out as follows:<br />
(Rs. in Lacs)<br />
PartiCular . Amount % <strong>of</strong>R&M cost<br />
Equitv 17,924.70 30%<br />
Domestic commercial borrowings 41,824.30 70%<br />
Total 59,749.01 100%<br />
Equity<br />
5.06 The equity funding component <strong>of</strong> the R&M Works is Rs. 17,924.70 lacs, being 30% <strong>of</strong><br />
the R&M cost including IDC and finance charges. The rate <strong>of</strong> return on equity has been taken as<br />
14%.<br />
Borrowings<br />
5.07 Domestic commercial borrowings <strong>of</strong> Rs. 41,824.30 lacs would be raised from the<br />
<strong>financial</strong> institutions/ banks. The interest rate is assumed at 10 % p.a. A provision has been made<br />
for financing charges at the rate <strong>of</strong> 0.5% <strong>of</strong> loan amount. The loan will be repayable in 10 equal<br />
annual installments from the next year from the completion <strong>of</strong> the R&M Works.<br />
5.0& The adequacy <strong>of</strong> <strong>project</strong>ed cash flows <strong>of</strong> the R&M Works to fund the above repayment<br />
obligations has been evaluated later in this chapter. However it is understood that NTPC would<br />
be raising funds based on its balance sheet and therefore debt servicing is not dependent only<br />
upon the R&M Works cash flows.<br />
Tariff and R&M Works Pr<strong>of</strong>itability<br />
5.09 The <strong>project</strong>ed pr<strong>of</strong>it and loss account, balance sheet, cash flow statement and the key<br />
<strong>financial</strong> indicators <strong>of</strong> the R&M W9rks are given in Appendix - I.<br />
5.10 The key assumptions underlying the pr<strong>of</strong>itability estimates for the proposed R&M Works<br />
are given in Appendix II.<br />
5.11 The commissioning date <strong>of</strong> the units has been taken as follows:<br />
First GT 30 November, 2009<br />
- Second GT 31 July, 2010<br />
- Third GT 31 July, 2011<br />
- Fourth GT 31 October, 2011<br />
36
5.12 The <strong>financial</strong> <strong>appraisal</strong> <strong>of</strong> the R&M Works has been assessed assuming that the <strong>power</strong><br />
shall be continued to be sold by NTPC Kawas based on the existing Bulk Supply Agreement<br />
entered into with the beneficiary states and the existing tariff notification issued by CERC for the<br />
central <strong>power</strong> utilities shall continue to be applicable to the KGPP post R&M Works.<br />
5.13 It is understood that the Bulk Supply agreement entered into with the beneficiary stMes<br />
will continue to contain the existing provisions and safeguard for ensuring timely payment by the<br />
beneficiary states. Accordingly, timely payments have been assumed in the R&M Works<br />
<strong>financial</strong> s.<br />
5.14 The R&M Works would lead to increase in the Fixed Charges component <strong>of</strong> the Tariff<br />
for KGPP, covering the following costs items as per the CERC tariff norms:<br />
• Depreciation on R&M Works cost, including advance against depreciation.<br />
• Interest on loan for R&M Works<br />
• Return on Equity funding<br />
• Interest on incremental working capital (additional debtors due to increased tariff<br />
and maintenance spares)<br />
5.15 The other components <strong>of</strong> the fixed charge i.e. the O&M expenses will remain as before<br />
since these are recoverable at the flat rate per MW. Thus, there will be no incremental revenue<br />
on this account. The tariff norms provide for return on equity on post tax rates basis. Hence the<br />
incremental income tax liability shall also be recoverable from the beneficiaries.<br />
5.16 The existing fixed costs which form part <strong>of</strong> the Tariff shall remain unchanged with the<br />
implementation <strong>of</strong> R&M Works except that there could be decapitalisation <strong>of</strong> <strong>project</strong> cost on<br />
account <strong>of</strong> replacement <strong>of</strong> existing plant and machinery under the R&M Works. This may reduce<br />
the existing fixed costs recovery.<br />
5.17 As far as the variable charges (i.e. the fuel cost) are concerned, these shall continue to be<br />
recovered at actuals as per the Tariff norms.<br />
5.18 The incremental recovery <strong>of</strong> the fixed tariff shall form the incremental Sales Revenue for<br />
the R&M Works.<br />
5.19 In view <strong>of</strong> the above, the fmandal viability <strong>of</strong> the R&M Works has been evaluated based<br />
on the incremental revenue and incremental costs to KGPP.<br />
5.20 The life extension <strong>of</strong> GTs has been considered for 15 years. The levelised tariff for 15<br />
years has been worked out taking full capacity <strong>of</strong> the KGPP i.e. GTs (4*106 MW) and STs<br />
(2* 116.1 MW) throughout the life extension period. This would imply that the Steam Turbines<br />
and other components <strong>of</strong> the plant shall also be available for the extended period <strong>of</strong> the <strong>project</strong>.<br />
In this regard, it is assumed that if and whenever additional expenditure L required to be incurred<br />
on the Steam Turbines and other components, KGPP will get compensated by way <strong>of</strong> appropriate<br />
increase in tariff accordingly at that point <strong>of</strong> time in future.<br />
37
5.21 The <strong>power</strong> station's performance in the year on completion <strong>of</strong> the full phase <strong>of</strong> R&M<br />
Works (i.e. during the year 2012-13) is given below:<br />
656.20<br />
80%<br />
4598.65<br />
4460.69<br />
9871.57<br />
9871.57<br />
2091.73<br />
22.13<br />
5.22 The key <strong>financial</strong> indicators <strong>of</strong> the R&M Works are given below:<br />
Impact on Tariff<br />
Parameters<br />
Key Indicators<br />
IRR 11.41 %<br />
Average DSCR 1.38<br />
Maximum DSCR 2.44<br />
Minimum DSCR 1.18<br />
Project Payback Period from the 8.17 years<br />
year <strong>of</strong> commissioning <strong>of</strong> the first<br />
GT i.e. FY 2009-10 (based on cash<br />
accruals before interest on long term<br />
loan)<br />
Incremental Levelised Tariff 21.41<br />
(paisalkwh) - l.e. Fixed Ch:rrges<br />
(based on CERC tariff norms and<br />
taking discount rate <strong>of</strong> 12% p.a.)<br />
5.23 As per the details provided in the earlier chapter the break up <strong>of</strong> the existing tariff is as<br />
under:<br />
(FiJ[ures in PaisaIKwh)<br />
Particulars·;··.'''/:-;;;'~:... , ';
Particulars<br />
Auxiliary Power<br />
Consum tion (%)<br />
Gross Station Heat rate<br />
(kcallk Wh)<br />
2004-05 2005;.()6 2006-07<br />
3% Normative<br />
2008;.()9<br />
25.72<br />
285.50<br />
25.72<br />
285.50<br />
25.72<br />
285.50<br />
25.72<br />
285.50<br />
25.72<br />
285.50<br />
364.41 364.76 365.11 365.52 365.88<br />
102.88<br />
0.00<br />
102.88<br />
0.00<br />
102.88<br />
0.00<br />
102.88<br />
0.00<br />
102.88<br />
0.00<br />
Total Tariff under<br />
Scenario 2 A+C 156.08 156.42 156.77 157.18 157.54<br />
5.24 From the above Table, it may be seen that the fixed charges are in the range <strong>of</strong> Paisa 53<br />
to 54 per Kwh. The fixed charges are low at present sinc~ the plant has depreciated to a large<br />
extent and the loans have been fully repaid. With the R&M Works, the fixed charges would<br />
increase by around Paisa 21.41 (i.e. estimated incremental levelised tariff). Thus the revised<br />
fixed charges shall be around Paisa 75 per Kwh (based on 80% PLF). This is before taking into<br />
account reduction in fixed charges due to decapitalisation, if any, <strong>of</strong> the existing plant being<br />
replaced under the R&M Works. The revised fixed charges are understood to be lower than that<br />
<strong>of</strong> a green field <strong>gas</strong> plant.<br />
5.25 The total tariff cost is dependent upon the actual input scenario i.e. <strong>gas</strong> / Naphtha and can<br />
vary significantly depending upon the proportion <strong>of</strong> <strong>gas</strong> / Naphtha used. Further, in case the<br />
actual PLF is lower than 80% with availability remaining high the average tariff to the<br />
beneficiary states would be further higher (as the fixed charges would be recovered by NTPC on<br />
availability basis but for the beneficiary, it would be apportioned over lower energy sold!<br />
purchased as compared to at 80% PLF).<br />
5.26 However, under the CERC Tariff norms, the above costs are pass through and it is<br />
assumed that the beneficiary states would continue to bear the additional cost due to the higher<br />
input costs/ lower PLF. (In case NTPC was to sell the <strong>power</strong> as a Merchant Plant, these<br />
additional costs may have impacted the competitiveness <strong>of</strong> the <strong>power</strong> produced).<br />
39
••• , •••. , , ; ~ • - , ". q \ '" ( '" •<br />
Sensitivity Analvsis<br />
5.27 A sensitivity analysis <strong>of</strong> the R&M Works <strong>financial</strong>s is carried out on the following key<br />
parameters:<br />
~~~~ H'~~"; ~'r'-,_,_rt~'JC':I' . ]i::, ._ ,":"(~'l't,~ .. 1'.~"<br />
!"" . " ~.~;- I'''' ,,,,. .... l - '<br />
" ," '" ~'(_1I'''1'~<br />
..... '''.. --;~~,:,.<br />
~~ ~<br />
Base Case 11.41% 1.38 21.41<br />
Increase in R&M works cost (5%)- 11.41% 1.38 22.48<br />
pass through<br />
Increase in R&M works cost (10%) 11.38% 1.38 23.55<br />
- pass through<br />
Decrease in R&M works cost (5%) 11.41% 1.38 20.34<br />
- pass through<br />
Decrease 10 R&M works cost 11.41% 1.38 19.27<br />
(10%) - pass through<br />
Decrease in PLF (5%) (i,e. PLF at 11.41% 1.38 22.84<br />
75%) - Though full recovery <strong>of</strong><br />
fixed cost at PAF 80%, but higher<br />
average fixed cost per unit sold<br />
Decrease in PLF (10%) (i.e. PLF at ] ].41% 1.38 24.47<br />
70%) - Though full recovery. <strong>of</strong><br />
fixed cost at PAF 80%, but higher<br />
average fixed cost per unit sold<br />
Lesser capitalisation <strong>of</strong> the R&M 10.56% 1.31 20.33<br />
Cost allowed by CERC (95%)<br />
Lesser capitalisation <strong>of</strong> the R&M 9.70% 1.24 19.32<br />
Cost allowed by CERC (90%)<br />
Increase in R&M works cost (I 0%) 9.80% 1.26 21.40<br />
- not pass through<br />
Increase in Rate <strong>of</strong> Interest on long 12.02% 1.36 22.26<br />
term loan (1% p.a.) - pass through<br />
cost<br />
Decrease in Rate <strong>of</strong>Interest on long ]0.81% 1040 20.58<br />
term loan (1% p.a.) - pass through<br />
cost<br />
40
Overall analysis<br />
5.n From the above tinancial analysis, the following aspects emerge:<br />
• The incremental levelised fixed charge as per the sensitivity analysis would increase!<br />
decrease due to the changes in R&M Works costlPLF!interest rate etc. (though with<br />
varying impact) as compared to the base case. However, if these are pass through<br />
costs, there is no impact on IRR to NTPC.<br />
• In case, CERC does not allow capitalization <strong>of</strong> full R&M Works cost to NTPC, there<br />
would be under recovery to NTPC leading to lower IRR. However, it is assumed that<br />
with NTPC's considerable experience in <strong>project</strong> management and R&M Works, the<br />
probability <strong>of</strong> such an event should be low.<br />
• It is understood that NTPC would continue to supply <strong>power</strong> to the beneficiary states<br />
during the extended life <strong>of</strong> 15 years as per the Bulk Sale Agreement and the CERC<br />
Tariff norms. Thus NTPC should be able to recover full fixed charges, considering<br />
NTPC's consistent past performance in achieving over 80% plant availability.<br />
Further, the Energy Charges shall be a pass through cost.<br />
• In view <strong>of</strong> the existing Payment Security Mechanism and NTPC's past experience, it<br />
is expected that KGPP should be able to collect sales revenue as per the payment<br />
terms.<br />
• The R&M Works IRR <strong>of</strong> 11.41 % is higher than the weighted average cost <strong>of</strong> capital<br />
(i.e. 11.20 % based on 14% p.a. post tax return on equity and 10% p.a. interest rate on<br />
long term loan and Debt Equity ratio <strong>of</strong> 70:30). The CERC tariff computation<br />
provides for reimbursement <strong>of</strong> actual interest cost and post tax return on equity @<br />
14% p.a. at the Debt Equity ratio <strong>of</strong>70:30.<br />
• The DSCR is ranging between 1.18 and 2.44 which is within the normally acceptable<br />
norms by the banks! <strong>financial</strong> institutions. The depreciation charge @ 6% p.a. as per<br />
the CERC tariff has facilitated enough cash flows for the R&M Works to achieve this<br />
level <strong>of</strong> DSCR.<br />
5.29 Based on the above <strong>project</strong>ed <strong>financial</strong>s, assumptions and the <strong>project</strong> evaluation<br />
parameters, the R&M Works appears to be <strong>financial</strong>ly viable.<br />
41
S.LN3:W'JUV.LS '1VDNVNU
NT<br />
• w••<br />
• o- ro • w.•••<br />
Pr<strong>of</strong>lt.llbll ectlon.<br />
0.00 0.00 1.00 2.00 '.00 '.00 '.00 •. 00 1.00 •.00 '.00<br />
For the .ar ended March 31 31-M.r.41 31-Mcr.ot 3t-Mar·1o. 31-Mar-i1 31-M.r-12 31-M.r.13 3100M.r-1. 31-M.r-iS 31·Mar-ia 31·Mar-11 31-Mar-18<br />
l<br />
851.20 658.20- '58.20 156.20 154.20 151.20 856.20 656.20 656.20 656.20 656.20<br />
rotJon<br />
0.00 0.00 12.00<br />
0.00 0.00 12.00<br />
0.00 0.00 12.00<br />
0.00 0.00 12.00<br />
0." 0." 12.00<br />
•••• ••••<br />
• 0%<br />
Million Units 0.00 .598.6<br />
MOOon UnIta O. 137.00<br />
MfUfon Un 0." 4480..6<br />
.• 8760. 8760 .<br />
MNIlonUnllo O. 4460 .•<br />
P.fMIKwfw 0.00 19.60<br />
Ib. In lacs 0.00 8742.5<br />
Ex: enditure<br />
O&Me nse' RS./nt.ac:t. 0.00 0.00 0.00 0.00<br />
Total Ex ndfture R.I. In lAct: 0.00 0.00 0." 0.00 0.00 0.00<br />
P8DIT 0.00 0.00 1137.3 5305.0<br />
De redation Rs. in lacs 0.00 0.00 38656 1847.8<br />
Advance A .ins' De "!ltion Rs.lnUtc:::s 0.00 0.00 0.00 0.00<br />
Interett on lotn R'./n 0.00 O. '50 2155.<br />
Inton~n a 'tal Loan R •. In L..es 0.00 3e.43 1".<br />
PST fts. Inucs 0.00 0.00 .u ..(1 1ft .1<br />
Groa. Cuh Accru." Ra.ln UCI 0.00 O.<br />
•••• •••••<br />
Gross Pr<strong>of</strong>it M GPM% 100% 100% 100o/e '00% 100% 100% 100% 100% 100%<br />
PST % 23.16% 22.57% 21.06% 21.19% 22.55% 24.02% 2562% 27.38% 29 26%
Kawai u •_r ..,t. &<br />
••••<br />
rontallbll P<br />
••••<br />
10.00 11.00 12.00 13.00 14.00 16.00 16.00 17.00 18.00<br />
For the If ended Man:h :U 31-Ma,-1. S1-Ma,·20 31-Ma,·21 31-M.,-22 31·Ma,-2) S,-Ma,·2. 31-M.,-2S :)1-M.,-26 31·»&r-27<br />
.ratlon<br />
MW<br />
'''.20<br />
116.20 "'.20 1'1.20 156.20 151.20 656.20 866.20 656.20<br />
aratlon<br />
MllliorlUflfta<br />
au 'on MilliooUnita<br />
MlllionUnIlt<br />
•<br />
Million Units<br />
Pa'se/K¥ffU'<br />
Ra. in '.Ie.<br />
Ex ndltun<br />
O&Me Rt. In lacs 0.00 O. 0.00 0.00 O.<br />
Tot.IEx ndllure Rs. In Laes 0.00 0.00 0.00 0.00 0.00<br />
PBOlT 6096.41 6085.' 5,"".1 3008.7 1189 .• 1<br />
aliOn Rs. in lacs 3584.91 3534.91 1737.2 643<br />
Advance A ainlt De 'abon Rs. in lacs -214.33 -214 -125.03 -491<br />
Interest on loan RI. in Lacs 0.00 0.00 0.00 0.00<br />
1m on \\b1d C L•••• RI. In laC! 162.31 154.21 135.2 108.6<br />
PBT lb. J" Ltc. 2683 .• 2660.' 1261.2 486.1<br />
Gro•• Ca." Accruals R•• In Lac.<br />
,_ ,_<br />
5913.7 6023.5 6215.' $722.71 5934.1 $931.4 2873.4 10$1.1<br />
GrossPr<strong>of</strong>ttMa n GPM% 100% 100% 100% 100% 100% 100% 100%<br />
per % 31.35% 33.66% ~.18% 35.77% 42.05% 42.08% 42.06% 41.92% 40.91%
RIM<br />
NTPC LTC<br />
Klwa. ~. Power P ect # WOt1ls<br />
ealance Sheet<br />
RS.ln lacs<br />
Forthe ar ended March 31 31-Ma,-oa 31oMa'"," 31-M.,·10 31-Mar·11 31·M.r·12 31-Ma,·13 31-Mar.104 31·Ma,·15 31·Ma,·16 31·Mc,·17 31·Ma,·18<br />
Assets<br />
Gross Block 0.00 59748..4 59748.4 59748.4<br />
Less: De tttCiabon 0.00 19515.21 23100.1 26685.0<br />
Net glad< o. 4023J.2 38648.3 33003..4<br />
ca laIwmlnPr 7893. 0.00 0.00 0<br />
."<br />
CurrentAt;sets·<br />
Receivables 0.00 1457.<br />
Mainl&n-arn:e S ar&.t 0.00 597.48<br />
Cash and bank balances 0.00 141-43.1<br />
Total 7893.2 25-751 47251.0 804&0.01 580420.' •••• 31,01<br />
U.bl!lUea<br />
Share ca tal 2367. n25. 13924. 16
NTPC L 0<br />
KJlWlI$ Gu Power ec:t-R&MWor1ts<br />
aJl'Jlnte Sheet<br />
R•• In LAc.<br />
Forth. If ended MJln::h :11 31-M.r-1f 31-M.f·20 31-M.r·21 31-M.r-22 3M~.r-23 31-M.r-24 31-M.r-2S 31-Mar-2E1 31-Mar-21<br />
"<br />
59748<br />
51566.9<br />
8181.51<br />
0<br />
989,9 6«7 432<br />
597-48 597.48 597.4<br />
43116.9 46076.7 47210.91<br />
Tot.' 4U76,1 47251, 456tl.8 51865." U4lJ8.2 5421&.<br />
U.btlttM.<br />
...,.-<br />
Sh8reC 1792.04, 17924. 17924. 17924. 17924. 17924. 17924.5<br />
ReJel'Y8J end J us 21327.1 2 16.1 356A 28920. 33770.7 35032.0 35518.7<br />
Tenn loan<br />
-R ll3e47 4182. 0.00 0.00 0.00 0.00<br />
1353.7 1332. 1335. 1190.5 931. 772.61<br />
T
· ' ..'.<br />
NTPC LTO<br />
Klw •• Gu Power Pro ect· R&MWo•.•.•<br />
C•• hflow Pro ectlon.<br />
R•. In Ilet<br />
For the arended March 31 31""".0' 3,-Mllr.QI 31"'.r-10 3'-Mllr·" 31-MM·12 31.M.1r-13 31oM.r·'" 3'-M.r·15 31-Mar-1. :I'·Mar-11 :l1-Mar·18<br />
Inflow<br />
Orou Cash A.o:rualt 0.00 .00 64. 304
N CL<br />
KawllS GIS POW'llrP • R&M Wor1l;.<br />
C•• hftow Pro<br />
RI. In tics<br />
For the e.r tnded March 31 31-M.,-1' 31-Ma'·20 31·Mar.;l1 31-M.r-ZZ 31-Ma'·23 31-Mar-Z.4 31-M.r·2S 31-M.r·26 31-Mar-2T<br />
Inflow<br />
-<br />
Gros, Cesh Aecruals 5973.7 6023.5 6275. 6722.71 5934.1 5931. 5291.7 2873 1081.1<br />
Inct&aseln<br />
0.00 000 0.00 0.00 0.00 0.00 o. 0.00 0<br />
Term Loan Qr8w1s "<br />
·Ru 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00<br />
1nc::nt8$$ In bank botT'OwI ..t6.e1 -46.81 -21.31 3.46 -125.68 -18.2 -258.91 -159.0<br />
Toto' 5121.' 5971.7 1250403 1726.1 6808. 6273.51 2814. 922.11<br />
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00<br />
4182.3 4182.3 41&2. 4182.3 0.00 0.00 0.00 0.00 o.<br />
-62.41 -62.41 -28.41 4.S1 -167,58 -1.80 -24.33 -345.22 -212.0<br />
41 •. 4119.'<br />
., "-<br />
4187 . -,67.58 -1.10 -24.33 -U5.2 -212.0<br />
n ealance 1 ••. '94'4 .• 21271." 33 1.'<br />
3'''7.<br />
37111.1 48078.7<br />
IUS I Deftclt 1101.' II 7 2100"' 213t.1 -5131." 5297. 1134.1<br />
Closln Ba'ance 'NU•• 21211." 23371. 2&911.1 371".1 43111,9 47210.91
NTPC LTD<br />
K.Wls au Power Pro .ct • RIM Worts<br />
DSCR.nd IRR CAlCULA llONS<br />
RI. in Lies<br />
DSCR C"lcul.tlons 31..Mar-o 31-Ma, 31-M.,-1 31..M.,-11 31-M.,-f 31-AW'·f 31..Mar·1 31·M.,·'<br />
Numerator<br />
- Gross Cash Acc::.ruals 0.00 0.00 4690.7 5676. 5874,2<br />
-Imereslon Term loan! 0.00 0.00 3431.5 3973.2 2300.32<br />
Total 0,00 0.00 '12%.31 •• t.t1 "74.S<br />
Denominator<br />
-lnteres' on Term Loans 0.00 0.00 4.10. 2155. 34J1.5 3555.0 3136. 1882.<br />
• Re a nt 0.00 O. 0.00 0.00 0.00 4182.3 4182.3 4182.3<br />
0.00 0,00 450.98 21$1. 3-431.5 7137." 7319.1 6064 •.4<br />
0.00 0,00 2," 2.41 2.37 1.20 1.22 1.29<br />
2..u<br />
1.38<br />
1.18<br />
'.00 8.00 7,00<br />
••••<br />
0.00 0.00 0.00<br />
0.00 0.00 0.00<br />
0.00 0.00 0.00<br />
·15.84 ·15. -15,60<br />
5724.9 5774.7 5824.4<br />
3555.0 3136_8 2718<br />
Net Cuh flow -1127. -18118.1 ·17607.11 ·1t3S. 3&30.0 'C'7.151 9295.8 8927.13 8558.8 8190,18 7821.7<br />
IRR<br />
1'."'%
·.,"'<<br />
NTPC LTO<br />
Kawas Gu PO'Wer tct - R&MWor1l.s<br />
OSCR and IRR CALCULAnoNS<br />
Rs. In Lacs<br />
OSCR Cak:ulaUOns 31
Klw" a•• POMt NTPC~ P • M Wortl.s<br />
PAYBACK<br />
R•. lnlaca 0." 0." 1.00 3.00<br />
••••<br />
7.00 9.00<br />
•••• •••• ••••<br />
Forth. ear ended M.n:h 31 31-M.,-OI 31-M.r~ 31-Mar·10 31·".'·11 31-M.(-12 31oM.t-13 31-Mat-104 31-Mar·16 31-M.r-16 31-Mar-17 31-Mar-18<br />
INFLOWS<br />
PBT 0.00 0.00 263.41 1197.1 1749.3 2091.7 2140 2189.S; 2239.5 2289.J.! 2339.11<br />
Add de nocfation incl. AAD 000 0.00 386. 1847.6 2941. 35&C.91 3584.91 3584.91 3584.91 3584.91 3584.91<br />
Add: Interest term loan 0.00 0.00 450.ge 2155.60 3431.5 3973.2 3555.0 3136. 2718. 2300.3 1882.0<br />
LLss : 'nCTtv5I! in Ulortillg C4piUIJ jUndid from inlmud accrual 0.00 0.00 190.49 168.08 241.71 -37."" -15.84 .15.60 -15.60 -15.60 -1560<br />
lJ'Icre.ue in net watkin caitsl 0.00 0.00 761.97 664.3<br />
•••••<br />
-150. -63.35 -62.42 -62.41 -62.41 -62.41<br />
l.e'u: Increase in WorkinR Ca itallban 0.00 0.00 571.4f 498.24 725.'. -112. -47.51 -46.81 -46.81 -46.81 .46.81<br />
tnflows-5ub-total 0." ••••<br />
'10~ ....." 1No." ••.• 1.51 t2'5.M 8127.1 8551.' 81to.1 7821.7<br />
01JTROWS<br />
l..e5s : Capital Expeondilure inc1! I Finand cost) 7893.2 17'" 7 .7<br />
•••• o. o. 0.00 0.00 0.00 0.00<br />
Outflow<br />
Pro Kt Cub Row' (IU MUlIon) (7"320 (17•••. 22 !197~.32 (3352.37 2935.05 9687.51 9295.86 8927.13 8558.65 8190.18 7821.70<br />
Cumulative Investment (~Million (7893.20 25751.43 (4S505.75 {48858.11 (45923.07 {3623S.$5 {26939.10 18012.57 9453.91 1263.74 6557"36<br />
Plybilck (Yeill"5) 1.17 - - - - 8.17
•<br />
=<br />
KawlS Gas ec:t - RAM Works<br />
Add redatlon incl AAO 35&4.91 35&4.91 3786.1 4182.3 3370. 3370. 3001. 1612.2 594.4<br />
P PERIOD<br />
10.00 11.00 11.00 13.00 11.00 18.00 17.00 11.00<br />
I r ended March 31 31.••• ,-1' 31-M.,-2O 31-M.,·21 31oM.,-12 31 31•.•••'-24 31-M.r·ZS 31-M.r-26 31-Mar-27<br />
2368.8 2438 2_. 2s.oo.<br />
2563 2~~ 228~ 1261.2<br />
""".7<br />
Add: Interest term loan 1463.8ol 1045.6C 627.3€ 209.12 0.00 0.00 0.00 0.00 o.<br />
Ln.s: JlfcrtaSt in w
NTPC l TD<br />
Kawu G•• Po~r Pro ect • RIM Worts<br />
T.11ft E.ttmat ••<br />
•. 00 ••00 1.00 2.00 5.0Q 1.00 8.00 9.QO<br />
31-M1r..08 31-M.r-4t 31-M1r·10 31-M.r-11 31-M.r-1( 31-M.r-16 31-Mar-1T 31·M.r-18<br />
138.1 000 431. 202•. 3115.14 238217 2015.68 1649.1<br />
0.00 0.00 386. 18A7,6 3584.94 3584.94 3584 3584.9<br />
0.00 0.00 270.5 1293. 2509.4 2509.4 2500 25094<br />
0.00 0.00 48.58 13. 2131.91 265.94 25798 25002<br />
0.00 0.00 0.00 0.00 0.00 000 000 0.00<br />
138.13 •. 00 1131.3 5305.0 9491.4 8742.5 83•.•. 7993.&1<br />
.lseJKwhr •. 00 •. 00 30.60 2•.1' 21.28 19.60 18.16 11.92<br />
scoun n actor<br />
, •••<br />
0.3 9<br />
Discounted Tarm •. 00 0.00 29.&0 2-4.51 18.11 ".11 13.04 11.18 1.51 8.18 6.98<br />
l.evellsed T.rtn Palse/Kwhr 21.• '
N PC L<br />
Kawu Gas Power Pro aet - R&M Worh<br />
T."" &tim.I ••<br />
14.00 11.00 16.00 17.00 18.00<br />
31·M.,-23 31-M.,-:. 31·M.,-2! 31-M.r-Ze 31-M.r-27<br />
0.00 0.00 0.00 0.00 0.00<br />
3370 3370 3001. 1612.26 594.4<br />
2509.4 2509. 2238.87 1216.' 450.5<br />
216,.' 205.62 200.9 180.3 144<br />
000 0.00 000 000 0<br />
6096." $0'5.' 6444.7 3008.1 1189.8t<br />
13.67 13.6-4 13.32 11.5$ 11.6<br />
DIsco actor<br />
DIscounted T.M<br />
levell.eeI T.,.", P"fselKwtl<br />
•<br />
•.3 .2 .248 0.221 •• 1 0.17 0.15 •. 4<br />
5." 5.04 4.40 3.94 3.02 2.69 2.35 1.82 1.63
APPENDIX<br />
II<br />
KEY ASSUMPTIONS
Appendix II<br />
ASSUMPTIONS<br />
The assumptions made by NTPC in the <strong>financial</strong> forecast <strong>of</strong> the Kawas Gas Power Project -<br />
R&M Works are given below:<br />
I. Installed capacity:<br />
• Gas Turbines:<br />
• Steam Turbines:<br />
656.20 MW<br />
(4*106 MW)<br />
(2*116.1 MW)<br />
2. The R&M Works award date has been taken as March 1,2008. The commissioning date<br />
<strong>of</strong> the Units have been taken as:<br />
- First GT<br />
- Second GT<br />
- Third GT<br />
- Fourth GT<br />
- 30.11.2009<br />
- 31.07.2010<br />
- 31.07.2011<br />
- 31.1 0.2011<br />
R&M Works Cost estimation<br />
3. The R&M Works cost estimated by NTPC is based on either the budgetary<br />
<strong>of</strong>fers/purchased order or quotations invited during the year 2004 and 2005.<br />
4. Exchange rate <strong>of</strong> Rs. 45 /- per USD and Rs. 60 /- per Euro has been considered while<br />
computing the cost <strong>of</strong> the R&M Works.<br />
5. A contingency provision <strong>of</strong> 5 % <strong>of</strong> R&M Works costs has been provided in the R&M<br />
Works cost.<br />
6. Interest during construction on all loans is funded through drawls <strong>of</strong>loans/equity.<br />
7. While computing IDC, the interest on debt till the year in which the particular unit is<br />
being commissioned, has been capitalized. Interest thereafter has been charged to revenue.<br />
8. 25% <strong>of</strong> the estimated working capital requirement has been considered as the working<br />
capital margin and it assumed that the working capital margin shall be funded by internal<br />
accruals.
Capitalisation <strong>of</strong>R&M Works is as follows:<br />
9. The Capitalisation Schedule <strong>of</strong>R&M Works is as follows:<br />
SNo. Description <strong>of</strong> the Scheme Capitalisation<br />
I<br />
GT Components Life Extension:<br />
• First GT • November 2009<br />
• Second GT • July 2010<br />
• Third GT • July 2011<br />
• Fourth GT • October 2011<br />
II Renovation and Modernization <strong>of</strong> Along with each GT's<br />
Gas Turbine Control system<br />
III Renovation and Modernization <strong>of</strong> Along with Second and Fourth<br />
Steam Turbine, WHRB and other GT's<br />
combined cycle equipments<br />
control system up-gradation<br />
including Man Machine Interface<br />
(MMI), Vibration Monitoring<br />
system, UPS system<br />
IV Up-gradation <strong>of</strong> Simulator Year 2009-10<br />
V Replacement <strong>of</strong> Halon System Year 2009-10<br />
Means <strong>of</strong> Financing<br />
10. The debt to equity ratio during construction (for the R&M cost) has been assumed to be<br />
70:30. For this R&M Works, only domestic currency loans have been considered.<br />
11. The terms assumed for the domestic currency loans are as follows:<br />
Loan<br />
Interest Rate<br />
Financial fee<br />
Repayment period<br />
Ru ee<br />
10.00 % .a<br />
0.50%<br />
10 annual equal installments from the<br />
next year <strong>of</strong> completion <strong>of</strong> the R&M<br />
work (i.e. ear 2012-13 onwards)<br />
12. The post tax return on equity has been assumed at 14% p.a. for tariff computation, as per<br />
the CERC norms.<br />
13. Interest on bank borrowing for working capital has been assumed at @ 12.75 % p.a (i.e.<br />
SBI PLR rate)
Assumptions <strong>of</strong> operational and <strong>financial</strong> norms<br />
14. The life extension <strong>of</strong> GTs has been considered for 15 years.<br />
J 5. Tariff during the extended life <strong>of</strong> 15 years shall be as applicable as per the existing CERC<br />
Tariff norms.<br />
J 6. The levelised tariff for the 15 years has been worked out taking full capacity <strong>of</strong> the KGP?<br />
i.e. GTs (4*106 MW) and STs (2*116.1 MW) throughout the life extension period. This would<br />
imply that the Steam Turbines and other components <strong>of</strong> the plant shall also be available for the<br />
extended period <strong>of</strong> the <strong>project</strong>. In this regard, it is assumed that if and whenever additional<br />
expenditure is required to be incurred on the Stream Turbines and other components, KGPP will<br />
get compensated by way <strong>of</strong> appropriate increase in tariff accordingly at that point <strong>of</strong> time in<br />
future.<br />
17. The stable PLF is assumed to be 80% as per CERC norm. Auxiliary <strong>power</strong> consumption<br />
has been taken at 3%.<br />
J 8. Tariff depreciation has been assumed at an average rate <strong>of</strong> 6 % p.a. at SLM <strong>of</strong> the R&M<br />
cost with suitable adjustment for advance against depreciation as per CERC norm and is limited<br />
to 90% <strong>of</strong> the asset value. Advance against depreciation has been adjusted against depreciation<br />
after the loan repayment is over.<br />
19. In the pr<strong>of</strong>it & loss account, actual interest on term loan has been taken whereas for tariff<br />
computation purposes, interest on term loan has been taken on normative repayment <strong>of</strong> loan<br />
basis (i.e. as per the CERC norms - in case any moratorium period is availed, depreciation<br />
provided for in the tariff during the years <strong>of</strong> moratoriwll shall be treated as repayment during<br />
those years and interest on loan capital shall be calculated accordingly).<br />
20. Income tax has not been considered in the tariff calculation.<br />
21. For computing levelised tariff, yearly tariff has been discounted @ 12 % over the period<br />
<strong>of</strong> extended life <strong>of</strong> GTs.