Thursday, January 16, 2014

PART II

CONCEPT PAPER

ON

    ACCELERATION OF ENERGY EFFICIENT RENOVATION AND MODERNIZATION AND LIFE EXTENSION (R&M & LE) OF OLDER COAL BASED THERMAL POWER UNITS, INTRODUCTION OF CONCURRENT ENERGY EFFICIENT R&M AND LE (CEE R&M AND LE) OF COAL BASED THERMAL POWER UNITS IN OPERATION, UNDER CONSTRUCTION AND NEW UNITS OF STATE POWER UTILITIES AND THEIR FUNDING.



DECEMBER, 2013

PART-2

BY

Prahalad Rao, Consultant (MOB:9212151469)
 

 

 

 

1.0        

 INTRODUCTION OF CONCURRENT ENERGY EFFICIENT RENOVATION AND MODERNIZATION AND LE (CEE R&M AND LE) PROGRAM AND PROVISIONING FUNDS FOR COAL BASED THERMAL POWER UNITS IN OPERATION, UNDER CONSTRUCTION AND NEW UNITS.


1.1         CONCURRENT ENERGY EFFICIENT R&M AND LE (CEE – R&M AND LE) - THE LOGIC AND THE NEED


1.1.1      The concept of R&M and LE is presently confined to only older coal based thermal power units in the country. This suggests that coal based thermal power units in operation are to be taken up for EE R&M and LE on completion of their life cycle. Till then the utilities will be undertaking only routine operation and maintenance works to the extent allocation of funds are available to them as revenue expenditure to keep the plant running. Experience has shown that routine O&M fails to focus on major deficiencies started developing in the unit. These become noticeable only through Energy Audit and Condition Assessment studies of the unit Such studies are able to identify as precisely as possible unseen major technical and operational defects affecting the operational efficiency resulting in sub optimum utilization of the unit capacity.

1.1.2      EE R&M and LE studies and implementation of measures recommended therein is considered normally not feasible during the operation life time of the unit since it involves sizeable capital expenditure compared to revenue expenditure for routine O&M. Therefore, the utilities have been shying away from initiating action for such studies during operational life of the unit. Longer shut down period normally needed for EE R&M and LE when the State is undergoing shortage of power and lack of adequate financial resources to capital expenditure are the factors that stop the utilities from moving towards that end.

1.1.3      The need for taking up CEE R&M and LE of units in operation is suggested for following reasons::

(a)  CEE R&M and LE can be carried out within 25%-30% of EPC cost of a new generating unit of indigenous origin if undertaken during operational life time of the plant compared to 40%-50% or more of the above cost when undertaken on completion of life cycle of the unit if the unit continues to be in operational condition.

(b)  This is so because periodical CEE R&M enables early detection of defects impacting operational efficiency of the unit due to technical and operational deficiencies and correction of defects by up-gradation through available technology.

(c)  CEE R&M prevents growth and occurrence of defects that would have developed otherwise in the unit and enhances its operational efficiency on a continual and assured basis with increasing energy generation and revenue earning capacity as well as automatically lengthens life of the unit beyond its life cycle as a result of its periodical attention and up-gradation compared to EE R&M and LE on completion of its life cycle involving higher capital cost with no certainty and assurance of the anticipated improvements and efficiency due to surprises and uncertainty of adaptability and integration of the available technology at that time with older technology of the unit.

(d)  CEE R&M and LE will eliminate EE R&M and LE of the unit on completion of its life cycle since the unit continues to maintain sound technical health even at the end of its life cycle for reasons of Concurrent EE R&M and LE studies and implementation of the recommended measures done periodically during its operational life time with much lower capital cost.

(e)  CEE R&M and LE will lessen the shut down period of the unit with continual implementation of CEE R&M and LE periodically minimizing extent and scope of major defects developing in the unit compared to a longer shut down period sought by the implementing EPC Contractors, including in some cases, extension of time, for various reasons specially the surprises and unforeseen development, for completion.

(f)   Incidences of breakdown of the unit that take place due to serious defects and deficiencies developing in the unit which are not noticeable during routine O&M of the plant and lack of in- depth technical studies and implementation measures.

(g)  Technology as available at the time of Concurrent CEE R&M and LE can be availed and applied as CEE R&M and LE is undertaken periodically and enables true and fair assessment of the unit performance through Energy Audit and Condition Assessment studies and practical implementation of the program for improvements and up-gradation of the unit. This is not so in the case when the unit is taken up for EE R&M and LE after it outlived its life cycle. Experience shows that operational, technical and performance data in such cases is not readily available and, if available, not fully reliable which affect authenticity and quality of studies and their recommendations.

(h)  CEE R&M and LE periodically undertaken will result in minimization of expenditure on routine O&M of the unit year after year as the unit will continue to be maintained and run with greater operational efficiency through periodical technological up-gradation and improvements of unit and all its systems.

(i)    CEE R&M and LE opens up new window for development of newer technologies based on the experience gained through periodical CEE R&M and LE with scope for newer employment opportunities.

(j)    CEE R&M and LE also opens up scope for gradual growth of indigenous consultancy, competency, capacity and capabilities with increasing opportunities under CEE R&M and LE compared to EE R&M and LE undertaken once on completion of life cycle of the unit. It is pertinent to note that lack of experienced and technical competent consultants within the country is one of the reasons in slowing down the implementation process of EE R&M and LE of older power units.

(k)  CEE R&M and LE will ensure maintaining higher level operational efficiency of the unit throughout its normative Life Cycle period and will continue with same level of efficiency thereafter at least up to 35-40 years beyond 25 years life cycle.. With further CEE R&M and LE measures when the Unit completes 35-40 years, it is possible that the operational life of the Unit may continue with assured efficiency up to 45-50 years.

(l)    CEE R&M and LE will assure consistent and continuous additional energy and revenue to the Utility resulting from its higher level of operational efficiency with the periodical up-gradation and improvements of its operational capacity.

(m) Several barriers that were identified from time to time and considered responsible for delaying the implementation of EE R&M and LE of Older Coal Based Thermal Power Plants will have no impact nor will affect the suggested CEE R&M and LE Program.

1.1.4      The above stated logic and the need for CEE R&M and LE also applies to Coal Based Thermal Power Units under various stages of construction and new Units at various stages of processing. However, the method of funding and implementation are different for each category...

1.2         CLASSIFICATION OF COAL BASEDTHERMAL POWER UNITS FOR THE PURPOSE OF CEE R&M AND LE.


Coal Based Thermal Power Units in Operation.

S. No.
Unit Capacity (MW)
Life Cycle completed up to 12th Plan (31.03.2017)
Units in operation remaining to be completed beyond 12th Plan (31.03.2017)
No.
Capacity (MW)

Years
No.
Capacity (MW)
1.     
Below 100 MW
4
290
25
-

2.     
100 -250 MW
17
3120
25
39
9122
3.     
250 -500 MW
2
1000
25
6
3000
4.     
500 MW and above
-
-
-
3
1800

Total
23
4410
25
48
13922

1.2.1.1          Details are given in Annexure 1 and 1A of this paper. Figures in Annexure 1 and 1A are indicative compiled figures based on website data and are subject to change.

1.2.1.2          As will be seen from the above analysis, of the 71Units in operation of total capacity of 18332MW, 23 Units with capacity of 4410MW will be completing their life cycle at the end of the 12th Plan (2016-17) which are to be considered as addition to 58 Units covered presently in the 12th Plan as stated in 1.4 above. Funding of additional 23 Units is proposed in 1.11 above. The remaining 48 Units of capacity of 13922MW are in various years of operation and will be completing their life cycle subsequent to the 12th Plan period.

1.2.1.3          CEE R&M and LE of remaining 48 Units in operation presently is proposed as below.
..
1.2.2      Eligibility Conditions
a.    Coal Based Thermal Power Unit must be owned and operated by the State Power Utilities.
b.    Unit should be in operation and should have completed operational period of not less 5 years from its COD
c.    Unit should have been approved by CEA for inclusion under CEE R&M and LE Program.
d.    Utility of the Unit should have fully repaid loan availed by it from the FIs against the Unit
e.    Utility must be agreeable to mortgage the assets of the Unit to FIs against the loan to be availed for CEE R&M and LE.
f.     Utility must also be agreeable to complete and comply with all the loan covenants and loan documentation as may be specified by the FIs in the Letter of Sanction of Loan.

1.2.3      Method of Implementation
1.2.3.1          Break up of Life Cycle of remaining 48 Units referred to in 2.2.1 above is as follows:

5 years and below
9
Above 5 years but below 10 years
19
Above 10 years but below15 years
Nil
Above 15 years but below20 years
9
Above 20 years and up to 25 years
11
Total
48

1.2.3.2          These are classified Group-wise as under:
Group A 9 Units
Group B 19 Units
Group C 9 Units
Group D 11 Units

1.2.3.3          Debt repayment status of loans availed by the utilities from the FIs is presumed to be as below

Group A Loans fully repaid
Group B Loans fully repaid
Group C Loans fully repaid
Group D Loans yet to be fully repaid

1.2.3.4          37 Units which come in Group A, B and C may be considered under Concurrent EE R&M and LE Program. 11 Units in D are to be considered under the above program as and when the loan availed against each Unit is fully repaid to the FIs..

1.2.3.5          Total estimated capital cost of CEE R&M and LE of each Unit should not exceed 40% of prevailing EPC cost of new generating unit of indigenous origin for each of 37 Units under Group A, B and C considering the fact that the Utilities owning these Units would have fully repaid loans to FIs availed against the Units and have short to medium period for life cycle completion.

1.2.3.6          Total estimated capital cost of CEE R&M and LE of each Unit should not exceed 30% for each of 11 Units under Group D considering these Units are yet to repay loans in full to FIs availed against the Units and would have become eligible for inclusion under CEE R&M and LE Program soon after the Utility has repaid fully loans availed from FIs against the Unit and have a longer life cycle to be completed.

1.2.3.7          Total estimated capital cost referred to in (e) and (f) will be derived from the DPR of each Unit approved by the Board of Directors of the Utilities.

1.2.3.8          CEE R&M and LE of 37 Units in Group A, B and C will be implemented in the following manner :

(a)   CEE R&M and LE of 37 Units in operation, the life cycle completion period of which is between 5 years and below and 20 years which have fully repaid their loans availed from FIs against the Units may be taken up for implementation in four Blocks with first Block of below 5 years, second Block of 5 years but below 10 years, third Block of 10 but below 15 years and fourth Block of 15 but below 20 years..

(b)    CEE R&M and LE of 11 Units in operation, the life cycle completion period of which is between 20 years and 25 years which have not fully repaid their loans availed from FIs against the Units may be taken up for implementation after the loan is fully repaid in four Blocks from the date of repayment of final installment with first Block of 5 -10 years, second Block of 11-15 years, third Block of 15-20 years and fourth Block of 20-25 years.

1.2.3.9          Utilities of 37 Units in Group A, B and C may initiate action for inviting Bids for selection of CEE R&M and LE Consultant for Energy Audit, Condition Assessment, Review and Examination of all the relevant Engineering and Technical aspects of the Unit and preparation of Detailed Project Report.(DPR)..

Six months before the beginning of each FYB a Consultant may be engaged for -
(a)  Energy Audit and Condition Assessment as well as overall operation efficiency and performance assessment.
(b)  Submission of Detailed Project Report which will be numbered for each FYB as First Bock DPR, Second Block DPR, Third Block DPR and Fourth Block DPR.
(c)  Recommending measures to be taken up for up- gradation of the Unit and enhancement of its operational efficiency and on such other action oriented matters as are considered relevant.

1.2.3.10       Utilities of 11 Units in Group C and D may initiate action for inviting Bids for selection of CEE R&M and LE Consultant for Energy Audit, Condition Assessment, Review and Examination of all the relevant Engineering and Technical aspects of the Unit and preparation of Detailed Project Report (DPR) at least one year in advance calculated backward from the due date of repayment of last and final installment of loan to FIs availed against the Unit.

Before the expiry of six months of the completion period of each Block a Consultant may be engaged for –
(a)  Energy Audit and Condition Assessment as well as overall operation efficiency and performance improvement
(b)  Submission of Performance Report (PR) which will be numbered for each completion period Block as First PR, Second PR, Third PR, Fourth PR and Fifth PR
(c)  Recommending measures to be taken up for up- gradation of the Unit and enhancement of its operational efficiency and on such other action oriented matters as are considered relevant.

1.2.4      Mode of Funding, Interest Payment and Repayment of Loan
1.2.4.1          Funding may be on the basis of the Total Estimated Capital Ratio stated in 2.2.3.5 and 2.2.3.6.and the Total Estimated Capital Cost referred to therein will be as provided in approved DPR.

(a)  The terms and conditions of financing by PFC/REC may be as follows:

1.2.4.2         Mode
Loan
1.  Loan Limit
(a)   Utilities of 37 Units which have fully repaid loans may be considered eligible immediately to apply for loans for Concurrent EE R&M and LE to PFC/REC equivalent to 80% of the estimated capital cost in 2.2.3.5  of each Unit.

(b)   Utilities of 11 Units which are yet to repay loan in full availed against the Unit may be considered eligible to apply for loan for Concurrent EE R&M and LE to PFC/REC as and when Utilities have repaid the loan in full to FIs availed against the Unit, equivalent to 80% of the estimated capital cost in 2.2.3.6 of each Unit.

(c)   Balance 20% of the estimated capital cost stated in (i) and (ii) will be met by the Utilities from their own resources.

2.  Disbursement of sanctioned Loan
(a)   Loans sanctioned by PFC/ REC for each Unit referred to in 1 (a) above will be disbursed by PFC/ REC to the Utilities on compliance of the loan covenants and completion of loan documentation in installments of 15% in the First Block Year, 20% in the Second Block Year, 30% in the Third Block Year and 35% in the Fourth Block Year.

(b)   Loans sanctioned by PFC/ REC for each Unit referred to in 1 (b) above will be disbursed by PFC/ REC to the Utilities on compliance of the loan covenants and completion of loan documentation in installments of 15% in the First Block Year, 20% in the Second Block Year, 30% in the Third Block Year and 35% in the Fourth Block Year.

1.2.4.3   Opening of Multi Option Deposit (MOD) Account by the State Power Utilities with their Bankers.
1.2.4.3.1       Funds received as per 3 (a) or (b) above will be invested in Multi Option Deposit (MOD) Account by the State Power Utilities to be opened with their Bankers after completing the procedure as required by the Bankers.
(a)   MOD will be maintained for each Unit Loan separately with the amount to be deposited being equal to the amount of installment disbursed. ,
(b)   The interest on the amount deposited will be not less than Term Deposit interest rate to enable the Utility to lessen, if not, offset its interest liability to PFC/REC.
(c)   The amount will be invested within three days of the date receipt from PFC/REC.
(d)   The period of deposit will be corresponding to the period envisaged for completion of the Unit as per the DPR.
(e)   The State Power Utility may draw the funds from the MOD according to its Financial Phasing Requirements prepared by the Utilities and approved by their Board/Director (Finance).
(f)    Each drawl from the MOD will be authorized only after obtaining the approval of GM (F) or Director (F) as per the internal systems and control of the utility.
(g)   MOD system permits the Utility to make payment through Crossed A/c Payee Not Negotiable Cheques to the Contractor implementing the Unit direct according to the Schedule of Activities completed and subject to compliance of other terms and conditions under the Terms of Payment specified in the Bidding Documents. To that extent, the MOD will get reduced and the interest will be applicable on that basis, however, the average interest earned need to be maintained at least equal to Term Deposit Interest Rate.

5. Repayment Period of Loan
10 years in equal half yearly installments from COD of the Unit after completion of CEE R&M and LE Works and commissioning of the Unit.
6. Grace Period for Repayment of Line of Credit
PFC/REC may consider approving Grace Period for repayment of Loan in years equal to the period envisaged for completion of the Unit considering the intent of the Loan..
  i.    Rate of Interest (ROI)
(a)Concessional Interest Rate as applicable to EE R&M and LE Loans.
(b)   Interest may be payable to PFC/REC Quarterly commencing from the date of disbursement for the First Block Year referred to iii (a) or iii (b) above, as the case may be..
(c)   Interest liability payable to PFC/REC will be met by the Utility from out of the interest earned on MOD to the extent earned thereon.
8 Subsidization of differential rate of interest between the interest charged by PFC/REC and interest earned on the MOD maintained by the Utility with its Bankers, if becomes necessary..
MOP may subsidize the Utility differential rate out of the funds under Restructured Accelerated Power Development and Reform Program  (R-APDRP)

9 Loan Processing Fee
PFC/REC may consider waiving the Processing Fee considering the intent of Line of Credit.
10 Commitment Charges
PFC/REC may consider waiving the Processing Fee considering the intent of Line of Credit.

1.2.5      Coal Based Thermal Power Units under various Stages of Construction

 S. No.
Units Capacity
No. of Units
Total Capacity (MW)
1
Below 100 MW
2
100
2
100-250 MW
 -
 -
3
250-500 MW
4
1000
4
500 MW and above
13
7760

Total
19
8860

1.2.5.1    Details are given in Annexure. Figures in Annexure 2 are indicative compiled figures based on website data and are subject to change.

1.2.5.2    Above analysis ,show that 19 Units are under various stages of Construction of total capacity of 8860MW. These are likely to be commissioned in the 12th Plan.

1.2.6      Eligibility Conditions
Eligibility Conditions for Coal Based Thermal Power Units under Construction will be the same as applicable to Coal Based Thermal Power Units in Operation as given in paragraph 2.2.2 above.

1.2.7      Method of Implementation
Method of Implementation of Coal Based Thermal Power Units under various stages of construction will be the same as applicable to Coal Based Thermal Power Units in Operation as given in paragraph 2.2.3 above with the variation that their eligibility for consideration under CEE R&M and LE will commence from the date of completion a period of 5 years from the date of their COD in the order of their commissioning and COD.

1.2.8      Mode of Funding, Interest Payment and Repayment of Loan
Mode of funding, interest payment and repayment of loan of Coal Based Thermal Power Units under construction will be the same as applicable to Coal Based Thermal Power Units in operation as given in paragraph 2.2.4 above with the variation that they will become eligible for applying for CEE R&M and LE Loan after the completion of a period of 5 years from the date their COD in the order of their commissioning and COD.

1.2.9      New Coal Based Thermal Power Units.
1.2.9.1    The number and names of New Coal Based Thermal Units based on their current status clearances including Environmental Clearance could not be ascertained and not included in this paper. However, it is assumed that a number of Coal Based Thermal Power Units are in various stages of completion of clearances, approvals, financing arrangements etc. and are in the pipeline for initiation of construction. The Logic and the Need for inclusion of New Coal Based Thermal Power Units under CEE R&M and LE is different compared to the Logic and the Need for (a) Coal Based Thermal Power Units in Operation and (b) Coal Based Thermal Power Units under construction discussed in detail above. The Logic and the Need for coverage of New Coal Based Thermal Power Units under CEE R&M and LE are briefly stated below:

1.2.9.2    The State Electricity Boards (SEBs) that existed prior to their restructuring and the Generating Companies (GENCOs) created by the States as result of restructuring had been carrying out routine Operation and Maintenance (O&M) of the Units according to the funds allocated as revenue expenditure under their Budget. This practice continues to be followed presently. Major overhauling of few Units due to accident or for reasons of a serious nature had been done by some of the SEBs but no SEB/GENCO had undertaken periodical Renovation and Modernization and Life Extension( up-gradation) of the Units to enhance their operational efficiency, up-rate capacity, generate additional energy and revenue and to maintain reasonably good health of the Units as they started aging.. This could be attributed to adequate funds not being available to the Utilities from time to time for incurring capital expenditure for the Units for the above purpose. .For want of periodical up-gradation, most of the Units continued to under- perform with declining trend in the operational parameters and efficiency..

1.2.9.3    To wait for initiation of EE R&M and LE for New Coal Based Thermal Units after they outlived their operational life cycle but are capable of continuing their operation would have resulted in their operational degradation and declining capacity utilization by the time of their life cycle completion due to extensive and intensive damage to their major components necessitating substantially higher level of capital expenditure investment. Such expenditure could be substantially saved through CEE R&M and LE during their operational life time .itself. After an Unit has completed five years of its operation from COD, if CEE R&M and LE is inducted from the sixth year extending over its remaining life cycle, on a Five Year Block (FYB) basis, status of functional capacity of major components can be ascertained through appropriate studies and, based on such studies, measures to restore /upgrade the Unit could be implemented.. This would enhance Unit’s operational efficiency on a continual basis with its automatic life extension beyond its normative life cycle

1.2.9.4    Ensuring availability of adequate funds to the Utilities for meeting capital expenditure for CEE R&M and LE of New Coal Based Thermal Power Unit in future during each FYB beginning from completion of 5 years from COD up to 10th Year (First Block,), 11th to 15th Year (Second Block), 16th to 20th Year (Third Block) and 21st to 25th Year (Fourth Block) would facilitate Unit to operate economically and efficiently and eliminate the need for any comprehensive renovation and modernization process at the end of 25 years. The Utilities, as earlier stated, had not been able to adopt such an approach so far solely for want of required financial resources and have compulsively taking up EE R&M after the Unit has outlived its life. It needs to be appreciated that CEE R&M and LE would assure the Utilities to maintain and operate the Unit with periodical up-gradation with newest available technology in each FYB and availability of the Unit with increasing generating capacity and regular revenue flow all the time and would save longer time span of 3-5 years for completion of EE R&M and LE presently being undertaken for older Units with several uncertainties and unforeseen developments unfolding on completion of EE R&M and LE..

1.2.9.5    Estimated Capital Cost of the future New Coal Based Thermal Power Projects may include estimated cost of identifiable components of capital nature for meeting capital expenditure of CEE R&M and LE in percentage terms of the total estimated cost of the Project. Total cost for the capital expenditure of CEE R&M could represent 30% of the total estimated cost of the Project. The cost so included for CEE R&M and LE in the total estimated Project cost may be allocated in equal proportion to each new Unit Capacity according to the number of Units envisaged under the Project. This is explained by way of an example below:

1.2.9.6    Assuming that
(a)  Project comprises 3x500 MW Capacity = 1500 MW
(b)  Current cost per/MW = INR 50m
(c)  Total estimated Project Cost = 1500x50= INR 75000m
(d)  Earmarking 30% of (c) for CEE R&M = INR 75000x30/100= INR 22500m
(e)  Allocation for each Unit = 22500/3 = INR 7500m = 33.33% for each New Unit.
(f)   Total estimated Project cost including provision for CEE R&M and LE = 75000+22500=INR 97500m

1.2.9.7    The provision of INR 7500m or 33.33% of 30% of the total estimated Project cost may be earmarked for FYB @ 5% or INR 1125m for the First Block, 7.5% or INR 1688m for the Second Block, 9.5% or INR 2138m for the Third Block and 11.33% or INR 2549m for the Fourth Block of each new Unit. This is a provision for each year and the actual utilization and application of the fund so available will, however, be based on detailed study and assessment of the capital components required for CEE R&M and LE in each year of each 5 year block .and the capital expenditure will be incurred accordingly from out of the amounts earmarked for each Unit as stated above..

1.2.9.8    Comprehensive Energy Efficient R&M has been taken up for Bandel TPS (WBPDCL) at the total estimated cost of INR 4725m, Koradi TPS (MAHAGENCO) at the total estimated cost of INR 4860m and Nashik TPS (MAHAGENCO) at the total estimated cost of INR 4815m, the average cost of which works out to INR 4800m. For setting up a greenfieid 210 MW TPP, the estimated cost at present per MW cost of INR 45m, will be INR 9450m. The average cost of INR 4800m of the above three projects compared to the green field cost of 210 MW TPP of INR 9450m, works out to 50.75% of the estimated cost of the green field project.

1.2.9.9    The proposed provisioning of INR 7500m towards CEE R&M and LE for each new Unit represents an increase of 56.25% or an average of 14.06% for each FYB or 2.81% per annum, over the average cost of EE R&M and LE of INR 4800m as worked out above for EE R&M and LE of three Older Units undertaken which have outlived their life cycle. It may be argued that it is more economical to undertake EE R&M and LE of an Older Unit on completion of its life cycle rather than taking up CEE R&M and LE concurrently for each FYB from the 6th year of COD considering increase in the cost in the latter case compared to the former case. This argument does not hold good for the following reasons:

(a)  The average cost of EE R&M and LE of Older Units now undertaken is an one time investment cost but unsure of the additional cost on account of escalation in the cost of equipment and material considered due to delay in its implementation because of uncertainty of assumptions as well as further additional cost that may become necessary on account of surprises and unforeseen developments during implementation. This is so because as of now no EE R&M and LE Older Unit Project has been completed and the final outcome of the capital cost is unknown.

(b)  The provisioning considered for CEE R&M and LE in the total estimated cost of a new Project assumes an annual escalation of 2.81% over the remaining life cycle of 20 years from 6th year of COD which is reasonable, detailed CEE R&M and LE studies are undertaken before the start of a FYB of each Unit which enables identification and pinpointing the precise deficiencies in the operation process of the Unit, recommends specific measures including replacement of components with available new technology for sustaining, if not increasing, the operational efficiency of the Unit for each FYB. This does not involve any surprises or unforeseen developments and the need for undertaking EE R&M and LE on completion of the life cycle of Unit. By reason of continual up-gradation of the Unit based on techno-commercial-financial studies and implementation of measures recommended therein using the funds from the provisioning made in the total estimated project cost at the beginning itself, the Unit is assured of performing at higher operational efficiency level all through it remaining life cycle and further increase of its life cycle for the next 10-15 years.

(c)  It may be mentioned that the in case of EE R&M and LE of Unit after it outlived its life completion necessitates approval of the regulatory authority for each Unit with need for greater and sound justification for the additional capital cost proposed excluding the surprises and unforeseen development that may occur during actual implementation whereas in the case of CEE R&M and LE, the approval of regulatory authority is needed one time for provisioning of cost of CEE R&M and LE as Deferred Capital Expenditure (DCE) covering all the Units capacity included in the Project and such expenditure does not affect the financial results and tariff at the start of COD but only as and when the expenditure is incurred from out of the provision of DCE is actually incurred in each FYB of the Unit based on the detailed studies. It may also be possible that the actual expenditure incurred in the FYB may be less than the provision resulting in savings to the Utility.

(d)  It may also be mentioned that CEE R&M and LE proposed for the Units (a) in operation, (b) under various stages of construction and (c) new projects in the pipeline, if introduced and implemented in each FYB will ensure availability of the Unit on regular and uninterrupted basis which will, in turn, help availability of sustained and additional energy generation as a result of regular studies and up-gradation with newer technology undertaken on performance and operational efficiency parameters of the Unit in each FYB and is expected to make up peak and energy deficit to a substantial extent which is the need of the hour.

1.2.9.10 The 30% capital expenditure proposed for inclusion in the total estimated cost of a new Project as addition to the estimated cost of the Project assumes the character of “Deferred Capital Expenditure (DCE)” to be incurred for CEE R&M and LE of the new Unit in each FYB after completion of 5 year period from the date of its COD. Its utilization in the accounting method of the Utility is reflected  when that expenditure is occurred in each FYB, capitalized in the FY in which CEE R&M and LE is completed and thereafter charged to Depreciation in the Profit & Loss Account of the Utility in each FY over the life cycle of the Unit according to its normal accounting policy.. Being a provision in the total estimated cost of the Project with its deferred use from the 6th year of COD for each FYB thereafter, DCE is not treated as part of the total estimated cost of the new Project for working the financials of the Project including the Tariff and IRR and, accordingly, will not have any impact on the financial viability and economic justification of the new Project.

1.2.9.11 Thus the provisioning of 30% of the estimated cost of Project cost for the purpose of meeting the cost of CEE R&M and LE on FYB basis beginning from 6th year of COD for the entire life cycle of the new thermal power project suggested above is to be regarded as in order and justifiable.

1.2.9.12  CEA Guidelines on R&M and LE (October, 2009) provide for the cost of LE and U works of Older Units limited to 50% of the EPC cost of new generating unit of indigenous origin  whereas the suggested percentage is 30% of the total estimated cost of the Project. Limit of 50% of the EPC cost of new generating unit of indigenous origin  for LE and U works of Older Units appears to be based on the assumption that EE R&M and LE is intended to be undertaken for Unit that has outlived its life cycle and would need a higher level of investment. A limit of 30% is proposed for CEE R&M and LE as mentioned above keeping in mind that the capital expenditure is assigned in ascending percentages for CEE R&M and LE for every FYB, the Unit continues to be maintained in good and technical healthy condition with sustained if not increasing operational efficiency and would not involve any EE R&M and LE on completion of its useful life cycle and no additional capital expenditure is needed for the Unit at that point of time. Ascending percentage order is considered to correspond to the need for a higher capital expenditure with the aging of the Unit

1.2.9.13 The underlying essence of CEE R&M and LE through Deferred Capital Expenditure (DCE) is summarized below:

(a)  The capital expenditure (CAPEX) includes expenses like renovations or equipment up gradation of equipment which adds value to the assets of a company. Moreover, the capital expenditures generally depreciate with time and feature a long life. In accounting terms, expenditure is considered as a capital expenditure if the asset is a recently purchased capital asset or an investment that is helpful in improving the useful life of an existing capital asset. Moreover, if expenditure is a capital expense, it should be essentially capitalized, which requires the company to increase the cost of expenditure over the assets’ useful life.

(b)   Only expenditure that increases the future benefits from the existing asset beyond its previously assessed standard of performance is included in the gross book value, e.g., an increase in capacity. The cost of an addition or extension to an existing asset which is of a capital nature and which becomes an integral part of the existing asset is usually added to its gross book value (ICAI Accounting Standard (AS) 10).

(c)  Machinery spares of the nature of capital spares/insurance spares should be capitalized separately at the time of their purchase whether procured at the time of purchase of the fixed asset concerned or subsequently. The total cost of such capital spares/insurance spares should be allocated on a systematic basis over a period not exceeding the useful life of the principal item, i.e. the fixed asset to which they relate. (ICAI Accounting Standards Interpretation (ASI) 2)

(d)  Annual funding for facilities operations and maintenance is expected to accommodate major maintenance and thereby compensate for the aging process of facilities and equipment. Separate funding for functional improvements in operating budgets is necessary to protect funding of capital renewal. Major maintenance is typically treated as a residual category after budgeting for plant administration, building and equipment maintenance, custodial services, utilities, and grounds maintenance. The residual treatment often leaving major maintenance and functional improvements unfunded has proven to be inadequate to meet plant needs and is how most equipments reached their current levels of deferred maintenance. The preferred approach is to establish an appropriate level of funding for major maintenance and capital renewal in the operating budget to prevent continued obsolescence of facilities and equipment. (Capital Renewal and Deferred Maintenance Programs by Harvey Kaiser)

(e)  An appropriate level of funding established at the beginning of a comprehensive facilities funding program may have to include catch-up costs (Capital Renewal and Deferred Maintenance Programs by Harvey Kaiser)

(f)   Deferred maintenance projects for mechanical and electrical systems, utilities infrastructure, or central energy plants can be treated as unique capital renewal projects for energy conservation. Facilities audits have shown that 40 to 50 percent of deferred maintenance exists in these categories. The rationale that energy conservation will result from these projects is based on cost-benefit analyses identifying payback periods. Thus an investment in energy conservation can be considered self-financing.( Capital Renewal and Deferred Maintenance Programs by Harvey Kaiser)

(g)  A five-year capital budget plan provides a level of confidence for the utility in the facilities management by regularly reviewing overall capital requirements. A level of capital requirements is established in long-range budget base planning, offering flexibility for emergencies or special situations that cannot be anticipated. (Capital Renewal and Deferred Maintenance Programs by Harvey Kaiser)

(h)  View a facility as a collection of components and systems .The deterioration of a component can cause breakdowns in other parts of a system. Evaluation of a repeated maintenance problem should consider the system nature of facilities. Facilities deterioration can be offset by maintenance management staff pooling knowledge of unsatisfactory conditions that are developing into major problems (Capital Renewal and Deferred Maintenance Programs by Harvey Kaiser)

1.2.10   Eligibility Conditions
(a)  Future New Coal Based Thermal Power Unit must be owned by the State Power Utilities.
(b)  Utility should have obtained all the Statutory and Non- Statutory Clearances, Consents, Approvals, Permits etc. for the setting up of the Project as per the requirements of the Policies of the Central/ State Governments for developing the New Power Project including Clearances from MOEF
(c)  Utility should have completed the Detailed Project Report (DPR) covering all aspects of Techno-Commercial-Financial and the status of fulfillment of the requirements of obtaining Statutory and Non- Statutory Clearances, Consents, Approvals, Permits etc. of the Project through reputed Consultants with full justification on the Technical Feasibility and Financial Viability of the Project.
(d)  In DPR, a separate Section titled “CEE R&M and LE” will be provided incorporating therein the main policy features, approach and methodology of its implementation and the manner of drawl of funds and their utilization for the purpose with respect to each Unit of the Project for which DEP is prepared, according to the Policy Guidelines issued by CEA based on this Draft Concept Paper as approved by CEA.
(e)  Utility should have obtained approval of its Board of Directors to the DPR including approval to the Equity to be provided through internal Sources and Debt to be secured from the FIs.
(f)   Unit should have achieved its Financial Closure and has become eligible for consideration by the FIs for financing.
(g)  Utility of the Unit should have submitted its Loan Application to the FI for sanction of loan for the Unit.
(h)  Utility must be agreeable to mortgage the assets of the Unit to FIs against the loan to be availed for CEE R&M and LE.
(i)    Utility must also be agreeable to complete and comply with all the loan covenants and loan documentation as may be specified by the FIs in the Letter of Sanction of Loan.

1.2.11   Mode of Funding, Interest Payment and Repayment of Loan for CEE R&M and LE of New Coal Based Thermal Power Projects (Units)

(a)      The terms and conditions of financing by PFC/REC may be as follows:

1.  Source
Indian FIs/ Multi-lateral /Bi- Lateral FIs
2.  Mode
 Loan for the New Project + Provision for CEE R&M and LE
3.  Loan Limit
Estimated Project Cost all inclusive + a provision limited to 30% of the estimated Project Cost as “Deferred Capital Expenditure” for “Concurrent Energy Efficiency R&M and LE (CEE R&M and LE) subject to Debt : Equity Ratio as specified in the DPR or as applicable according Lending Policies of FI.
4.  Sanction of Loan
Estimated Project Cost all inclusive + a provision limited to 30% of the estimated Project Cost as “Deferred Capital Expenditure” for “Concurrent Energy Efficiency R&M and LE (CEE R&M and LE) subject to Debt : Equity Ratio as specified in the DPR or as applicable according Lending Policies of FI.
5.  Disbursement of Loan
a.     Project Loan (excluding CEE R&M and LE provision) may be released in installments according to phasing of expenditure and procurement plan by the Borrower subject to fulfillment by the Borrower all the loan conditions, covenants and loan documentation governing the disbursement of Project Loan.
b.     
b.    Loan provision limited to 30% of the total loan sanctioned and earmarked for CEE R&M and LE of Units covered under the Project may be released in lump sum at the time of release of First Installment of the loan to the Borrower subject to fulfillment by the Borrower such additional loan conditions, covenants and documents/undertakings as may be deemed appropriate and prescribed by the FI in the Letter of Sanction of Loan, in addition to the fulfillment of the normal governing conditions, covenants and loan documentation for the Project Loan.
.
c.     FI may specify as a Pre-condition in the Letter of Sanction of Loan that the disbursed amount of CEE R&M and LE loan component in lump sum to the Borrower shall be subject to the Borrower opening Multi Option Deposit (MOD) Account with its Banker (s) for each Unit of Project in the following manner:

“XYZ Borrower – CEE R&M and LE for Unit No._____of _____________Coal Based Thermal Power Station at _____________”

and deposit the amount so received into the said MOD A/c in equal proportion for each Unit within three days of receipt of the lump sum amount aforesaid and will send a confirmation in writing to the FI of having complied with the above requirement along with an Undertaking on a Non-judicial paper of appropriate value duly signed by an authorized officer of the Borrower to the effect that the amount deposited in each of the said MOD A/c shall be utilized by the Borrower solely and exclusively for the Concurrent Energy Efficiency R&M and LE of the Unit during the period of the Life Cycle of the Unit within seven days from the date of deposit of the amount in the MOD A/c of each Unit.
6.  Operation of Multi Option Deposit (MOD) Account.
(a)   The interest on the amount deposited will be not less than Term Deposit interest rate to enable the Utility to lessen, if not, offset its interest liability to FI.
(b)   The period of MOD A/c will be initially for ten (10) years from the date .of its opening and  deposit of the amount to be extended for next ten (10) years and thereafter for five (5) years covering the Life Cycle of 25 years of the Unit.
(c)   The Borrower will draw the funds from the MOD A/c in the following manner for utilizing for CEE R&M and LE of the Unit named in the above A/c:

(d)   5% of the deposit in the First Five Year Block beginning from the 6th Year and ending at the 10th Year .from the date of COD; or the actual expenditure incurred on account of CEE R&M and LE during that period.
(e)    7.5% of the deposit in the Second Five Year Block beginning from the 11th Year and ending at the 15th Year from the date of COD;.
(f)    9.5% of the deposit in the Third Five Year Block beginning from the 16th Year and ending at the 20th Year from the date of COD; and
(g)   11.33% of the deposit in the Fourth Five Year Block beginning from the 21st Year and ending at the 25th Year from the date of COD.

(h)   For the purpose of drawl of the funds from the MOD A/c in the manner as aforesaid shall be subject to fulfillment of the following conditions:

(i)     Each drawl from each Unit MOD A/c will be authorized only after obtaining the approval of GM (F) or Director (F) as per the internal systems and control of the Borrower.
(ii)    In case the actual expenditure on CEE R&M and LE in a particular Five Year Block (FYB) is less than the specified percentage for that FYB, the drawl from the Unit MOD A/c will be limited to the actual expenditure.
(iii)   The CEE R&M and LE expenditure in a particular a particular FYB is greater than the specified percentage, the difference may be met from the deposit in such a manner that the total expenditure on CEE R&M and LE up to the Fourth Five Year Block is within the total amount of the deposit.
(iv)  If the total expenditure on CEE R&M and LE exceeds the deposit at the end of the Fourth Five Year Block or at the end of any earlier Five Year Block, the excess expenditure over the deposit will be met by the Borrower from its own resources.
(v)   The average interest earned on the deposit in the Unit Mod A/c will not be less than the Term Deposit interest rate in order to lessen interest liability burden of the Borrower to the FI on CEE R&M and LE loan component.
(vi)  The interest earned on the Unit MOD A/c will used by the Borrower solely for meeting its periodical interest liability to the FI.
(vii) In case interest earned on the Unit MOD A/c falls short of meeting the periodical interest liability of the Borrower to the FI, such shortfall amount will be met by the Borrower from its own resources or through subsidization of differential interest amount if made available by MOP under the funds earmarked for R&M and LE under Restructured Accelerated Power Development and Reform Program (R-APDRP).
7.    Rate of Interest (ROI)
a)     Concessional Interest Rate as applicable to EE R&M and LE Loans.
b)    Interest may be payable to FI Quarterly or Semi-annually as may be specified by the FI...
8.  Subsidization of differential rate of interest between the interest charged by FI and interest earned on the Unit MOD A/c to the Borrower if its interest liability to the FI is higher than the periodical interest earned by it ..on Unit MOD A/c.
MOP may consider subsidizing the Borrower differential rate out of the funds earmarked for R&M and LE under (R-APDRP)

9.  Repayment Period of Loan
12 years in equal half yearly installments considering the intent of the loan..
10.  Grace Period for Repayment of Loan
 One year commencing from date of COD considering the intent of the Loan..
11.  Loan Processing Fee
FI may consider waiver of Processing Fee considering the intent of the loan.
12.  Commitment Charges
FI may consider waiver of Commitment Charges on undrawn portion of the loan sanctioned considering the intent of loan.

 

ANNEXURE - I


UNIT CAPACITY-WISE COAL BASED THERMAL POWER UNITS IN OPERATION WITH TOTAL PERIOD OF OPERATION AND THEIR REMAINING LIFE CYCLE

S. No.
Unit Capacity (MW)
State
Total Period of Operation till the end of 12th Plan (31.3.2017) from the date of Commissioning
Remaining Life Cycle Period of Units (Life Cycle assumed as 25 years
1.              
Below 100 MW




2x70, 2x75
Gujarat
25
-
2.              
100-250 MW




1x110
Rajasthan
4
21

2x120
Unit 1
Unit 2
Gujarat
19

25
6

-

1x250
Madhya Pradesh
4
21

1x250
Uttar Pradesh
5
20

1x250
Uttar Pradesh
5
20

2x250
Rajasthan
7
18

2x250
Chhattisgarh
10
15

2x250
Delhi
5
20

3x210
Tamil Nadu
23
2

4x210
Unit -1
Unit -2
Unit -3
Unit- 4
Chhattisgarh

34
33
32
31

-
-
-
-

4x210
Unit- 1
Unit- 2
Unit- 3
Unit- 4
Andhra Pradesh

23
22
10
10

2
3
15
15

2x210
2x250
Punjab
19

6

2x250
Stage- V
Stage- V
Andhra Pradesh

20
19


5
6


5x210
West Bengal
18
7

4x210
Madhya Pradesh
25
-

4x120
Maharashtra
25
-

6x250
Rajasthan
19
6

2x351
Gujarat
4
21

4x210
2x250
West Bengal
21
4
3.              
250-500 MW




1x500
Stage VI
Andhra Pradesh

6

19

1x500
Madhya Pradesh
25
-

1x500
Maharashtra
25
-

1x500
Andhra Pradesh
8
17

1x500
Chhattisgarh
4
21

1x500
Gujarat
4
21

2x500
West Bengal
21
4
4.              
500 MW and above




1x600
Haryana
7
18

1x600
Tamil Nadu
5
20

1x600
Tamil Nadu
4
21

Figures in Annexure 2 are indicative compiled figures based on website data and are subject to change.



ANNEXURE - IA



NAME-WISE COAL BASED THERMAL POWER UNITS IN OPERATION
S.No.
Name
Unit Size
Capacity (MW)
State
Commission Date
Total Period of Operation of Plant till end of 12th Plan (2016-17)
Remaining Life Cycle period of Plant (life cycle period assumed 25 years of operation)
Total Period of Operation of Plant till end of 13th Plan (2021-22)
Remaining Life Cycle period of Plant (life cycle period assumed 25 years of operation)
1
2
3
4
5
6
7
8
9
10










1
Ramgarh CCPP Extn
1x110
110
Rajasthan
GT - 2013
4
21
9
16
2
Dhuvaran TPS
2x110
220
Gujarat
NA
NA
NA
NA
NA
3
Sikka TPS
2x120
240
Gujarat
Unit 1 - 1998
19
6
24
1





Unit 2 - 1993
24
1
25 years completing in 2018
NA
4
Akrimota TPS
2x125
250
Gujarat
NA
NA
NA
NA
NA
5
Satpura TPS Extn
1x250
250
Madhya Pradesh
Unit 10 - 2013
4
21
9
16
6
Harduaganj
1x250
250
Uttar Pradesh
Unit -9 - 2012
5
20
10
15
7
Parichha Extn
1x250
250
Uttar Pradesh
Unit - 5 - 2012
5
20
10
15
8
Kutch TPS
2x70, 2x75
290
Gujarat
1990
25 years completing in 2015
NA
25 years completing in 2015
NA
9
Bhawendra Singh Deo TPS
4x50, 2x120
440
Chhattisgarh
NA
NA
NA
NA
NA
10
Chhabra TPS
2x250
500
Rajasthan
2010
7
18
12
13
11
Surat TPS
4x125
500
Gujarat
NA
NA
NA
NA
NA
12
Dr. Shyama Prasad Mukherjee TPS
2x250
500
Chhattisgarh
2007
10
15
15
10
13
Kakatiya TPS
1x500
500
Andhra Pradesh
2009
8
17
13
12
14
Korba West ST-III
1x500
500
Chhattisgarh
Unit 5- 2013
4
21
9
16
15
Ukai TPP Extn
1x500
500
Gujarat
Unit -6 - 2013
4
21
9
16
16
Pragati CCGT- III
GT 3 - 250, GT4 - 250
500
Delhi
GT-3 -2012
5
20
10
15





GT-4 - 2013
4
21
9
16
17
Rajiv Gandhi TPS
1x600
600
Haryana
2010
7
18
12
13
18
Mettur TPP Extn
1x600
600
Tamil Nadu
Unit 1- 2012
5
20
10
15
19
North Chennai Extn
600
600
Tamil Nadu
Unit 2 - 2013
4
21
9
16
20
North Chennai TPS
3x210
630
Tamil Nadu
1994
23
2
25 years completing in 2019
NA
21
Pipavav CCPP
Block 1- 351, Block 2- 351
702
Gujarat
Block 1- 2013
4
21
9
16





Block -2 - 2013
4
21
9
16
22
Budge Budge TPS
3x250
750
West Bengal
NA
NA
NA
NA
NA
23
Korba West Hasdeo TPS
4x210
840
Chhattisgarh
Unit I - 1983
25 years completing in 2008
NA
25 years completing in 2008
NA





Unit 2 -1984
25 years completing in 2009
NA
25 years completing in 2009
NA





Unit 3 -1985
25 years completing in 2010
NA
25 years completing in 2010
NA





Unit 4 -1986
25 years completing in 2011
NA
25 years completing in 2011
NA
24
Rayalseema TPS
4x210
840
Andhra Pradesh
Unit 1- 1994
23
2
25 years completing in 2019
NA





Unit 2- 1995
22
3
25 years completing in 2020
NA





Unit 3 - 2007
10
15
15
10





Unit 4- 2007
10
15
15
10
25
Guru Hargobind TPS
2x210, 2x250
920
Punjab
1998
19
6
24
1
26
IB TPP
8x 120
960
Odisha
NA
NA
NA
NA
NA
27
Kothagudem TPS
2x250,1x500
1000
Andhra Pradesh
Stage V- 1997
20
5
25
Nil





Stage V - 1998
19
6
24
1





Stage VI - 2011
6
19
11
14
28
Bakreshwar TPS
5x210
1050
West Bengal
1999
18
7
23
2
29
Chandrapura TPS
3x130, 3x120, 2x250
1250
Jharkhand
NA
NA
NA
NA
NA
30
Sanjay Gandhi TPS
4x210, 1x500
1340
Madhya Pradesh
1993
24
1
25 years competing in 2018
NA
31
Khaperkheda TPS
4x120,1x500
1340
Maharashtra
Unit 1- 1989
25 years completing in 2014
NA
25 years completing in 2014
NA





Unit 2- 1990
25 years completing in 2015
NA
25 years completing in 2015
NA





Unit 3- 2000
17
8
22
3
32
Suratgarh STPS
6x250
1500
Rajasthan
1998
19
6
24
1
33
Mejia TPS
4x210, 2x250, 2x500
2340
West Bengal
1996
21
4
25 years completing in 2021
NA
34
Amravati
10x270
2700
Maharashtra
NA
NA
NA
NA
NA
Total Capacity
25762

Figures in Annexure 2 are indicative compiled figures based on website data and are subject to change.




Annexure - II


UNIT CAPACITY-WISE COAL BASED THERMAL POWER UNITS UNDER CONSTRUCTION
S.No.
No. of Units
Unit Capacity
Total Capacity
State
Implementing Agency


(MW)
(MW)


1
Below 100 MW

1
30
30
Assam
APGCL

1
70
70
Assam
APGCL
2
100-250 MW

Nil




3
250-500 MW

1
250
250
Gujarat
GSECL

1
250
250
Maharashtra
MSPGCL

2
250
500
Rajasthan
RRVUNL
4
500 MW and above

2
500
1000
Chhattisgarh
CSPGCL

1
500
500
Maharashtra
MSPGCL

2
500
1000
Uttar Pradesh
URVUNL

2
600
1200
Maharashtra
MPGENCO

1
600
600
Rajasthan
RRVUNL

1
600
600
Tamil Nadu
TNEB

1
600
600
Andhra Pradesh
APGENCO

1
660
660
Maharashtra
MSPGCL

2
800
1600
Andhra Pradesh
APPDL
Total
19

8860








 Figures given in the statement are indicative compiled figures based on Website Data and are subject to change