485

THERMAL PO THERMAL PO
THERMAL PO THERMAL PO THERMAL POWER WER
WER WER WER
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ST ST STA A
A AATIONS TIONS
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THERMAL PO THERMAL PO
THERMAL PO THERMAL PO THERMAL POWER WER
WER WER WER
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487
First Prize Thermal Power Stations
GURU HARGOBIND THERMAL PLANT
Lehra Mohabbat, Distt. Bathinda (Punjab)
Unit Profile
Guru Hargobind Thermal Plant is the third and the latest of the thermal plants of
Punjab State Power Corporation Limited and is located 23 km short of Bathinda on
National High Way No. 64 and is situated opposite Village Lehra Mohabbat. Total
plant area is 1025 Acres. Basic fuel is coal and furnace oil. Stage-I consists of two
units of 210MW each. Stage-II consists of two units of 250 MW each. GHTP Lehra
Mohabbat comprises of two stages. Unit-1 & 2 of stage-I were synchronized on 29-
12-97 & 16-10-98 and the units started commercial operation w.e.f. 26-6-99 and
4-1-99 respectively. Unit-3 & 4 of stage-II are generating electricity w.e.f 05.02.2008
& 11.10.2008 and these units started commercial operation w.e.f. 16.10.2008 &
25.01.2010 respectively.
GHTP has surpassed its own records of highest generation during previous four
successive years and is being operated at the lowest cost of generation amongst
all PSPCL power plants despite having higher interest and depreciation. This plant
has shown excellent performance and huge savings have been made in terms of
earning incentives by performing better than PSERC targets through meticulous
planning.
488
During 2009-10, GHTP Lehra Mohabbat known for its performance has surpassed
another milestone by generating 75152 Lac units (Including 14729 Lac Units
generated by Unit-4 during stabilization period before its commercial operation)
against the target of 65790 Lac units set by Central Electricity Authority, New
Delhi. The plant load factor of 96.44% for commercial operation is the highest ever
plant load factor in PSPCL. The plant has surpassed its own previous highest record
of 95.10% plant load factor achieved during the year 2007-08. This plant load
factor of 96.44% achieved during 2009-10 is even higher than the plant load
factor of 95.99% which was achieved by GHTP Stage-I units and was the highest
amongst all state sector power plants during 2008-09.
The plant utilization factor of GHTP remained more than 100% at an ever highest
value of 100.38% during 2009-10. The auxiliary consumption during this year
remained at its lowest ever value of 8.23% against a PSERC target of 9.00%, thus
saving Crores of rupees, which speaks of high plant performance at which the
plant is being operated. The oil consumption remained at 0.373 ml/ kWh against
the set target of 1.0ml/kWh.
GHTP has achieved the highest ever monthly generation of 7065 Lakh units at a
plant load factor of 103.21% during March 2010 which is highest ever monthly
plant load factor at any plant of PSPCL.
GHTP Unit 1 has run continuously from 28.02.2009 to 12.09.2009 (195.4 days)
without any interruption. This is a new record of longest continuous run by any unit
of PSPCL.
The relentless pursuit of excellence has helped to make GHTP a trend-setter, leader
and a light house in Punjab State Power Corporation Limited by achieving high
plant performance and economy. GHTP has taken a lead in cutting down its capital
overhauling period from traditional practice of 45 days to as low as 28.5 days and
annual overhauling period from 20 days to less than 14 days resulting into savings
of Crores of rupees by PSPCL in terms of purchase of power. This had been possible
due to lust of excelling continuously prevailing amongst GHTP engineers and staff.
In the year 2009-10, annual maintenances of unit no. 1 & 2 were carried out in less
than 29 days against approved shut down period of 40 days. The units were brought
on bar 11.12 days ahead of schedule; thereby an extra generation of 560 Lac units
saving Rs. 30 Crores approx. was done in terms of power purchase.
The new records set by GHTP Lehra Mohabbat during 2009-10 are as under:
Annual plant load factor: 96.44% Better than the All India
State Sector
National highest 95.99%
achieved by GHTP Stage-I
units during 2008-09.
489
2009-10 previous record
(Actual)
Highest ever annual generation: 7515.2 MU 5610.09MU in 2008-09
Highest ever annual plant 96.44% 95.10% in 2007-08
load factor:
Highest ever annual plant utilization factor: 100.38% 100.31% in
2007-08
Highest ever annual deemed plant load factor 97.53% 97.07% in
2003-04
Lowest ever annual Auxiliary Cons. (%): 8.23% 8.71% in
2008-09
Plant performance and energy consumption
Sr. Operating Unit Year
No. parameters 2006-07 2007-08 2008-09 2009-10
1 Actual Gen. MU 3443.172 3508.587 4441.92 6042.262
2 Plant Avail. Factor % 94.33 94.81 95.98 96.07
3 Plant Utilization % 99.21 100.31 98.86 100.38
factor
4 Plant load factor % 93.58 95.10 94.89 96.44
5 Deemed PLF % 95.31 95.65 96.05 97.53
6 Auxiliary % 8.80 8.87 8.71 8.23
Consumption
7 Sp. Coal Kg/kWh 0.551 0.589 0.601 0.601
Consumption
8 Sp. Oil ml/kWh 0.327 0.228 0.802 0.367
Consumption
9 Heat Rate Kcal/kWh 2440 2446 2459 2421
10 Thermal Efficiency % 35.25 35.15 34.97 35.52
Energy Conservation
The following benefits have been accrued to GHTP as a result of implementation of
innovations / best practices to improve the energy efficiency of GHTP:
GHTP has achieved thermal efficiency of 35.52% during 2009-10 against a
target of 34.40% set up by Punjab State Electricity Regulatory Commission.
490
Auxiliary consumption of GHTP remained at its lowest ever value of 8.23%.
At GHTP, differential pressure across feed control valves of Boiler feed pump
has been reduced from its normal value of 6.0Kg/cm
2
to 0.4Kg/cm
2
. This has
resulted in reduction of nearly 13 Amperes of current on 6.6 KV on each running
BFP.
One no. CW pump of 975 KW for Unit 1 & 2 is being stopped in winter by
running 3 no. CW pumps in parallel for two units against normal running of 2
no. CW pumps for each unit separately.
Two no. TACW pumps of 110 KW each are being stopped in winter by running
one no. TACW pump against normal running of 2 no. TACW pumps for each
unit.
As DM water make up is very low, so one no. hot well make up pump has been
put into operation for two units against running of one no. separate pump for
each unit.
125 Watt Mercury vapour lamps have been replaced with 70 watt Sodium
vapour lamp, wherever possible.
The deviation in all the parameters affecting efficiency of the plant have been
made available online to the operators. Alarm signals are generated in all such
cases to take corrective actions by the operator.
Start up of auxiliaries has been optimized.
Providing energy efficient PA fans during erection of GHTP Stage-II units.
Providing VFDs on ID fans during erection of GHTP Stage-II units.
GHTP has declared its Energy Management Policy as under:
Energy Management Policy
Team of engineers and staff of GHTP Lehra Mohabbat are committed to evolve,
improve and sustain in energy conservation through:
Improved plant utilization.
Benchmarking specific energy consumption with the best norms in country.
491
Monitoring of energy consumptions to identify the areas for improvements.
Optimum Utilisation of auxiliaries for optimization of energy consumption.
Promoting energy awareness and encouraging employee participation for energy
conservation.
The team of engineers and officials of GHTP are fully committed and motivated to
bring more laurels to PSPCL and the state of Punjab. Suggestions for improvement
keep pouring in, are encouraged, discussed and implemented. In house interactions
and training sessions help in not only sharing experiences but also to appreciate
the efforts & contribution of each individual in achievements of the GHTP team.
492
First Prize Thermal Power Stations
220 MW SAMALKOT COMBINED
CYCLE POWER STATION
RELIANCE INFRASTRUCTURE LIMITED
Samalkot, Distt. East Godavari (Andhra Pradesh)
Unit Profile
Samalkot Combined Cycle Power Plant has been developed by RINFRA at Samalkot,
Andhra Pradesh. The main fuel for the plant is natural gas being supplied by Gas
Authority of India Ltd. (GAIL). The plant is also designed to use Naphtha as main
fuel and HSD as backup fuel. Raw water is drawn from Samalkot irrigation canal
and pumped to the in-plant open water reservoir by RINFRA. An Intake Pump
House has been set up by RINFRA near the intake point for this purpose. The
power generated by the Gas Turbine and the Steam Turbine generators are stepped
up to 220KV and fed to a 220KV outdoor substation. The power is evacuated by
APTransco through overhead transmission lines. RINFRA has necessary agreement
with APTransco for this purpose. The project has been executed by the consortium
of Ansaldo Energia, Italy and RINFRA, on a turnkey basis. The Gas Turbine Generator,
Heat Recovery Steam Generator and Steam Turbine Generator along with their
respective auxiliaries has been designed and supplied by Ansaldo.
493
Energy Consumption
220 MW Samalkot Combined Cycle power station is commissioned in year 2002.
As a responsible and foreseeing the energy demand, station has taken initiative for
implementation of several energy conservation activities in the plant. For the year
2009-10 initiatives are listed below,
S. Energy Conservation Power Annual Annual Implemen- Annual
No Activities Saving Energy Saving tation Energy
(kW) Saving INR - Cost Saving
kWh Lakh Lakhs Lakh
kWh
1 Replacement Of GRP 128.95 1129602 25.42 20.005 11.2960
solid cell fan blade with
Epoxy Coated Hollow
Energy Efficient Fan
Blade
2 Modifying Cooling Tower 22.80 199728 4.49 2.844 1.9973
makeup system from
Motor driven pumping to
Gravity system.
3 HPBFP VFD Pressure 30 262800 5.91 0.000 2.6280
Optimization
4 LPBFP VFD Pressure 3 25404 0.57 0.000 0.2540
Optimization
5 Illumination System: 1.33 11651 0.26 0.189 0.1165
Building Replacement
of FL lamps (40W) with
CFL (20W) lamps at
non essential area.
6 Standby Closed cooling 4.6 40296 0.91 0.000 0.4030
water PHE isolated
from ACW as well as
CCW side
7 Wind Ventilators 4.3 224431 5.05 3.206 2.2443
Station Energy Consumption Performance Report
Power Plant for its own operation has many equipment, station in day to day
activities calculate own energy consumption as follows,
Aux Power Consumption in MUs=
(Gas Turbine Generator + Steam Turbine Generator) Export Energy Meter Reading
Energy Meter Reading
Aux Power Consumption in % =
(Aux Power Consumption in MUs x 100)/ (Station Generation in MUs)
494
Station Auxiliary % Reduction
Capacity Power in MU's
Million Units In Percent
MW MU's kWhr/kWhr %
Year 2008-09 220 33.1659 3.2780 Base Year
Year 2009-10 220 30.7755 1.9749 7.21
Auxiliary Power Consumption in Million Units
29
30
31
32
33
34
Auxiliary Power Consumption in MU's
2008-09
2009-10
Auxiliary Power Consumption in %
0
0.5
1
1.5
2
2.5
3
3.5
Auxiliary Power Consumption in %
2008-09
2009-10
Above data revels that, due to several energy conservation measures & efficient
operation of the station, station could achieve ~ 7.21 % reduction in auxiliary
power consumption in the period of 2009-10.
Energy Conservation Commitment, Policy and Set-Up
SPS considers energy conservation as its major objective to achieve cost effective
power generation. Monthly review meeting on Energy conservation projects is being
conducted in the presence of Unit Head. Reward & Recognition scheme are at place
at corporate level to motivate Employees in view of Energy Conservation.
During the period several best practice initiatives were undertaken for overall
improvement in all round performance.
495
1. Improve the Heat Rate.
2. Reduce the Auxiliary power consumption
3. Reduction in consumption of Resources (i.e. Water, prcess chemicals)
Energy Management Cell
PLANT HEAD
(RINFRA-SPS)
ENERGY MANAGER
Senior. Manager
(Mech. Maint.)
Asst. Manager
(Operation)
Asst. Manager
(C&I Maint.)
Asst. Manager
(Elect. Maint.)
Energy Conservation & Efficiency Improvement
At SPS there are state-of-art maintenance techniques and strategies to conserve
energy.
The Energy Management cell of SPS consists of qualified energy managers and
auditors who ensure adherence to constantly evolving energy efficiency standards.
The various energy conservation measures that have been put into practice are:
Installation of VFD in HPBFP, LPBFP, Raw Water Pumps
De-staging of CEP
Modification In DD Hydraulic Oil System
Wind Turbo Ventilators
Normal FL lamps & ballast are replaced by High Lumen Lamps & HF Ballast.
Corrocoating of CW / ACW Pumps
Installation of Energy Efficient Epoxy Coated Cooling Tower Cell Fan Blades.
Modification of motor driven Cooling Tower Makeup system to Gravity System.
496
Draining of Abnormal sump Water by gravity to common monitoring basin.
Plant Compressor Air System pressure set point reduced from 8.5 Bar to 7.5
Bar
Steam & Water Analysis System (SWAS) drain water recovery to reserve feed
water tank.
During Summer Bypassing of Pretreatment plant.
Energy saver installed in MLDB.
Dosing Of Alum in Pretreatment plant by gravity
Dosing Of H2 SO4 in Circulating water System by gravity
Dosing Of H2 SO4 in Effluent Treatment Plant by gravity
Illumination System : Building
Replacement of FL lamps (40W) with CFL (20W) lamps at non essential area
Illumination System : Street Lights
Replacement of HPSV lamps (270W) with CFL (75W) lamps
Steam Turbine Condenser Bullet Cleaning is practiced during opportunity.
For improving steam turbine & HRSG performance, Evaporator section chemical
cleaning is practiced.
As a proactive, after implementation of many energy saving program Station has
conducted third party plant energy audit in Sep09.
Station has implemented SAP package in 2004 for preventive maintenance activity
and corrective maintenance activity. After implementation of SAP package historical
data of the plant is maintained in the server and is readily available for any analysis.
For efficient operation of the station, predictive maintenance is done on plant assets,
as transformer dissolve gas analysis, plant equipment thermography, vibration
analysis of all critical equipments, current signature analysis on electrical
equipments, Tan delta test on electrical system.
497
Year Station PLF Station Avail.
% %
2003-04 66.19 94.33
2004-05 61.00 98.30
2005-06 45.28 89.39**
2006-07 50.46 97.40
2007-08 60.67 97.41
2008-09 52.50 97.08
2009-10 80.86 90.25**
Plant Performance (PLF/AVL) up to last financial year
Note: ** Station was under Major Overhaul.
Energy Conservation Activities
1. Replacement of Cooling Tower
GRP solid cell fan blade with
Epoxy Coated Hollow Energy
Efficient Fan Blade:
The CW system is open re-circulating type
with an induced draft cooling tower.
Circulating water pumps discharge is led
to the condenser. Outlet is returned to the
cooling tower for cooling. There are total
ten numbers cooling tower cells which are
fitted with individual fans. During design,
fans were made up of GRP solid fan blades.
During ENCON activity and vendor discussion it was revealed that, energy
conservation opportunity is available and all cell fan blades are replaced with Epoxy
Coated Hollow Energy Efficient Fan Blade.
These cell fan blades are with reduced weight and designed for same air flow with
higher efficiency.
Total investment : INR. 20, 00,533 /-
First year energy cost savings : INR. 25, 41,605/-
Power saving of 128.95 kW is achieved.
498
2. Modifying Cooling Tower makeup
system from Motor driven pumping
to Gravity system.
For maintaining cooling tower basin level,
Clarified water from the clarified water reservoir
is pumped by Cooling Tower make-up pumps
and fed to the cooling tower basin to maintain
normal level in Cooling Tower basin
For maintaining cooling tower basin level, two Cooling Tower makeup motors of 30
kW are installed, at a time only one pump is in service.
As an energy conservation measure, system study is done for modifying existing
system to gravity system & system is taken in service from Feb 15, 2010.
Total investment : Rs. 2,44,444 /-
First year energy cost savings : Rs. 4, 49,388/-
Power saved is 22.8 kW.
3. HPBFP VFD Pressure Optimization
DP across FRS was maintained at 7.0 Bar.
After reducing DP to 5.0 Bar, i.e. by reducing
pressure by 2-Bar, temperature margin of @
9.0 Deg Cent is observed, which is above
saturation temperature for avoiding economizer
steaming.
So by reducing 2 Bar pressure, power
consumption of HPBFP reduced by @ 30.00 kW
Total investment : NIL
First year energy cost savings : Rs.5, 91,300/-
Power Saving is 30 kW.
4. LPBFP VFD Pressure Optimization
For maintaining LP drum level, boiler feed water
is pumped by two LPBFP Pumps (one working
& one stand-by).
System study revealed that by reducing
pressure by 0.7 Bar, we are having saturation
temperature margin of @ 6.0 Deg Cent which
is sufficient for maintaining temperature above
economizer steaming.
499
So by reducing pressure by 0.7 Bar, power consumption of LPBFP reduced by @ 3
kWh,
Annual energy saving of 26280 kWh
First year energy cost savings, Rs. 57,159/-
Investment is: NIL.
5. Illumination System: Building.
Replacement of FL lamps (40W)
with CFL (20W) lamps at non
essential area
As energy conservation activity Rinfra-SPS has
replaced existing FL tubes at non essential area
with CFL.
Total 133 nos FL tubes were replaced with CFL
lamps.
Existing FL tube power consumption was 40 W & CFL lamp power consumption is
20 W.
Energy saving of 35,460 kWh per annum achieved.
Total investment : Rs. 18,900 /-
First year energy cost savings : Rs. 26,214.3 /-
6. Standby Closed cooling water
PHE isolated from ACW as well as
CCW side
The closed cooling System supplies CCW Water
to the various coolers of auxiliary equipment
like lube oil coolers of GT, ST; HP/LP feed pumps
etc. CCW water pumps are used to supply the
CCW water after cooling in the PHE (plate type
heat exchanger) where CCW water is cooled
by rejecting Heat to the ACW (Auxiliary cooling water).
Standby PHE isolated from CCW as well as ACW side. It has been observed that
both the ACW motor current reduced.
Total investment : NIL
First year energy cost savings : Rs. 90,666 /-
Power Saving is 4.6 KW.
500
7. Wind Ventilators
At Rinfra-SPS at different locations depending
on the heat load, motor operated ventilation
systems are installed.
For adopting renewable energy technologies,
Rinfra - SPS has evaluated several
methodologies.
After evaluating site requirement, it was decided to change motor driven ventilation
system with wind driven ventilators.
Wind ventilators operating working principle is on thermo-siphon.
Total investment : Rs. 3,20,645 /-
First year energy cost savings : Rs. 5, 04,970/-
Power saving of 4.27 KW per fan.
Energy Management Policy
Reliance Energy Limited is committed to be the most efficient integrated energy
utility in the world.
Our mission is to use all energy resources most efficiently and thereby minimizing
the impact of our operations on environment and conserving the scarce natural
resources.
This we plan to achieve by,
Adopting appropriate energy efficient and clean technologies in process design,
procurement, implementation and also continually upgrade our performance
Managing efficient use of all forms of energy by adopting industry wide best
practices
Continually benchmarking our energy performance against the best in the
world and improving our competitiveness by training and knowledge sharing.
Creating awareness about efficient use of energy and conservation methods
amongst all our stakeholders
Carrying out regular energy audits to identify areas for improvement
Complying with all relevant state regulatory and statutory requirements on
energy management.
501
Environment & Safety
Reliance Energy believes in sustainable development and aims at preservation and
promotion of environment in all its activities. SPS has qualified ISO14001 & OHSAS
18001 since Dec2005 & committed to follow all the guidelines as per ISO standards.
Following major improvements have been made during last three years:
Zero discharge is continuing since May 2006.
Water Consumption & Chemical Consumption reduced by Maintaining COC up
to 12.
Continuous monitoring of Stack Emission through CEMS & modern in-house
Environment Analysis Laboratory and confirm Air, water, emission, hazardous
waste, noise parameter within target limit.
Annual Third party Safety audit against naphtha leakage, fire, lightening arrester
completed in Aug09.
SPS has got distinction for zero accident free hours till end of this financial
year 2008-09.
502
Second Prize Thermal Power Stations
GMR VEMAGIRI POWER GENERATION
LIMITED
Vemagiri Village, Distt. East Godavari (Andhra Pradesh)
Unit Profile
GMR Vemagiri Power Generation Ltd., promoted by GMR Group of companies,
established a natural gas based power generation unit with an installed capacity of
388.5 MW at Vemagiri village, Kadiyam Mandal of East Godavari District Andhra
Pradesh between latitudes 160 55' & 170 and longitude 810 45' & 810 50'. The
site which is about 7-8 km south east of Rajahmundry town The Vemagiri project
consists of one advanced class industrial heavy-duty type Gas Turbine with generator
(GE's PG 9351 FA), one steam turbine with generator, one triple pressure heat
recovery steam generator (HRSG) all capable of operating in combined cycle mode.
The combined cycle system is an optimized and matched system of high technology
power generation equipment, software and services configured for convenient
integration with the balance of the plant to form an economical power plant.
Economical performance of function, either power generation or power and thermal
energy production with an efficiency of around 55 - 58%, is the outstanding
characteristic of combined-cycle systems
503
Energy Consumption
With the implementation of various energy conservation projects and the conversion
of HSS pot lines to Pre-Baked pots, there is a substantial reduction of energy
consumption. There is steady decline of specific energy consumption in the last
two years, which is evident from the table and graphs, which are mentioned below:
Unit 2009-10 2008-09
Annual Generation MU 3011.2 678.2
Total Electrical Energy
Consumption MU 94.0 29.6
Fuel Consumption MMSCM 568.8 128
Specific energy Consumption (Billion kCal/ year) 5.12 1.24
Heat Rate kCal/kWh 1700.82 1825.31
504
Energy and resource conservation during the project stage
Case study
GVPGL has taken many proactive measures to ensure that its activities do not
have adverse impacts on the environment. Towards this end, it has taken up many
projects involving process improvement or modification and installation of latest
energy saving equipment to save natural resources like water, mitigate pollution,
and conserve energy.
1. Rainwater Harvesting
The objective of the rain water
harvesting is recharging groundwater.
The rain water collected from the roof of
buildings is channelized through the rain
water down comers and routed to the
garland drain around the buildings. These
garland drains are connected to the plant
storm water drainage network system all
around the plant. Several recharge wells
will be located at strategic.
505
locations within the plant and will be interconnected to the storm water drainage
system.
The storm water drain will be finally connected to the Guard Pond. The
surplus water received in the Guard Pond will be diverted to Kadiyam ava
drain
2. DLN -Dry Low Nox combustion
Natural gas is used as a fuel in the GVPGL facility, which emits NOx.
Conventionally, NOx emissions are controlled by using pure DM water or
injecting steam along with the fuel. This method involves consumption of
natural resources like water, power, additional fuel, and chemicals, and, in
turn, needs pollution control measures.
The alternative latest technology for controlling NOx emissions is using
DLN burners, which do not use DM water or steam and maintain the NOx
levels at less than 20 PPM (parts per million). NOx (oxides of nitrogen) are
the main air pollutants emitted from the facility. DLN (dry low- NOx) burners
have been installed in the facility to control NOx emissions
The dry low NOx II (DLN-2) control system regulates the distribution of
fuel delivered to a multi-nozzle combustor arrangement. The fuel flow
distribution to each combustion chamber fuel nozzle assembly is a function
of combustion reference temperature (TTRF1) and IGV temperature control
mode. Diffusion, piloted premix, and premix flame are established by
changing the fuel flow distribution in the combustor. By a combination of
fuel staging and shifting of burning modes from diffusion at ignition through
full pre-mix at high load, dramatically lower NOx emissions can be achieved
above 40% load than with conventionally controlled and fired combustion
systems
506
Mode/Operating Range
_ Primary - Fuel to the
primary nozzles only. Flame
is in the primary stage only.
This mode of operation is
used to ignite, accelerate
and operate the machine
over low- to mid-loads, up
to a pre-selected
combustion reference
temperature.
_ Lean-Lean - Fuel to
both the primary and
secondary nozzles. Flame is
in both the primary and
secondary stages. This mode of operation is used for intermediate loads between
two pre-selected combustion reference temperatures.
Secondary - Fuel to the secondary nozzle only. Flame is in the secondary zone
only. This mode is a transition state between lean-lean and premix modes.
This mode is necessary to extinguish the flame in the primary zone, before
fuel is reintroduced into what becomes the primary premixing zone.
Premix - Fuel to both primary and secondary nozzles. Flame is in the secondary
stage only. This mode of operation is achieved at and near the combustion
reference temperature design point. Optimum emissions are generated in premix
mode
GVPGL is the only plant in INDIA with DLN 2+ (advance technology of DLN)
technology with a NOx level less than 25 ppm.
Now the upcoming gas based power plants are adopting this technology for
their new plants.
Now during the operational stage the NOx values maintained are as below
507
And continues Emission Monitoring system is installed online which monitors the
flue gas parameters.
400 KV Switch Yard
A 400 KV switchyard with one and
half beaker switching scheme is
provided for evacuation of power
generated in the plant through two
nos 400 KV transmission lines to
APTRANSCO sub stations due to which
the line current is minimum and hence
transmission losses are minimize
hence forth distribution losses are
minimized.
Energy and resource conservation during the operational stage
In compliance with requirements (process improvement/modification)
Tuning of IGV Angle
The gas turbine compressor air flow is regulated by IGV (Inlet guide vane)
The DLN-2.0+ combustor emission performance is sensitive to changes in
fuel to air ratio. The DLNx combustor was designed according to the airflow
regulation scheme used with IGV Temperature Control The IGVs open from
their minimum value as the turbine increases load while on the exhaust
temperature control curve until they reach a maximum at Base L Operation
of the gas turbine. During the performance review GVPGL decided to change
the operating range of the Inlet Guide vane from 26C - 82C to an operating
range of 26C- 86 C.
1. "Increasing the maximum operating angle of IGV to 86 degrees has reduced
the pressure drop across the compressor and a lower in resultant
temperature depression of air flow. The compressor ratio was increased
from 14.2 kg/cm2 to 14.6 kg/cm2 which have significantly improved
compressor efficiency and GT / Plant output.
2. This change in IGV angle has significantly reduced the attemperation water
consumption in the superheated of HRSG. Attemperation reduced to 23
MT as against 40 MT earlier thereby improving the Heat Rate of the Plant.
Provision of Re heaters in HRSG
GVPGL is provided with condenser preheaters which will heat the feed water
and release the burnt flue gases at a minimum temperature of around 89 deg C
which improves the HRSG efficiency and also reduces the environmental effects.
Reheater is provided on exhaust of High pressure system which gets heated in
508
HRSG and come as Hot reheat steam which enters as IP-steam to steam turbine
and expands due which the overall efficiency of Plant increases
Beyond compliance to statutory requirements (proactive practices)
Process modification in the auxiliary cooling water system of the
steam turbine
The cycle of concentration was increased from 6 to 8 in the auxiliary cooling
water system of the steam turbine. This reduced effluent generation, chemical
consumption, and load of effluent treatment.
GVPGL designed to operated in Combined cycle mode always in view of this no By-
pass stack is envisaged, hence forth GVPGL cannot operate in simple cycle which
minimizes the environmental impact effects and saves the fuel energy.
ELECRTICAL SYSTEM
a. Lighting voltage optimization: The voltage supply level for the plant
lighting is more. It was proposed to change the tap positions in
transformer. After changing the tap positions voltage and current are
reduced.
b. Dedicated lighting transformer installed
c. For discharge lighting, optimum voltage is around 210V
d. For every 1% increase in voltage above optimum level, energy
consumption increases by 1%
e. About 10% of total saves found by optimization of voltage. Nil investment
f. Annual savings - Rs 4.00 Lakhs
509
Sl. No. Energy Saving Description Savings Investment payback
Actions period
1 HP-BFP ARV passing Install multistage 100 kW 25 Lakhs 7 months
pressure reduction
drag valves Pressure
is reduced in many
stages (13 - 40)
avoiding the high
pressure difference
across the valve and
thereby reducing the
further erosion of its
seat
2 Maintain a Optimum Reduced pressure 40 KW NIL 0
DP across the feed drop across CV
station gradually Target to 6
bar and operate the
CVs at maximum
opening
3 Using of the IA 1.) Estimates the 7.6 Lakhs 0.5 1 month
instead of CPD for header pressure drop
the inlet air pulsation during the IA pulsation
& according action plan
to be determined
4 Use of Both PHE in Operation of both NIL 0
parallel operation PHE's in parallel
operation has
decreased the DP
across Heat exchanger
5 Optimizing the air Established optimum NIL 0
pressure pressure required for
the control valves and
maintained optimum
header pressure which
decreased the
compressor loading
rate
6 Lighting Transformer Optimum voltage 10% NIL Nil
Optimum voltage maintained in line with
the safe equipment
peration by changing
ap position to adjust
the voltage to 210V in
lighting transformer
510
Environmental Profile
The company has an Environmental Policy at both corporate and facility levels. It
also has an environment Environmental Management Plan
Environmental Management Plan
Environmental risk Management is in Place and the Objective of the Environmental
risk management is "To determine the risk of major hazards having damage potential
to environment, life & property and provide a scientific basis to assess safety level
of the facility and preventive measures against failure occurrence".
Detailed characterization of various environmental components Viz Air, water, Noise,
Land and Socio-economic were studied and measures were determined. An dedicated
ambient Air Quality Monitoring station is in place for continuous monitoring of
ambient air quality consists ting of suspended particulate Matter (SPM) and gaseous
pollutants like oxide of Nitrogen (NOX) and sulphur Dioxide (SO2)
Environment Policy
511
Second Prize Thermal Power Stations
DR. SHYAMA PRASAD MUKHARJEE THERMAL
POWER STATION, CSPGCL
Korba-East (Chhattisgarh)
Unit Profile
Chhattisgarh State Power Generation Co. Ltd. is a fully integrated utility engaged
in generation of electricity. 2X250MW DSPM TPS KORBA (EAST) is one of the
company's best generating facilities at Korba. Power generated from DSPM is
transmitted through State Load Dispatch Center.
DSPM units are the 2X250MW sets supplied by BHEL INDIA and are in operation
since March-2008. Since commissioning DSPM is performing well and presenting
example of best operation and maintenance practices.
DSPM units are maintaining very high level of Plant Load factor (PLF) when compared
to national average.
Unit I came into operation on dated 21/10/2007 where as Unit II put into operation
dated 20/03/2008. Taking minimum period of stabilization both units have started
performing well and during 2008-2009 the PLF of DSPM reached up to 84.8% and
during the year 2009-2010 the PLF of DSPM increased up to 87.65% At Present
the DSPM TPS is performing best with a PLF of 94.93% up to Oct. 2010.
512
Energy Consumption
Overall station generation during 2008-09 and 2009-10 is as follows
Secondary station fuel oil consumption and station auxiliary power consumption of
the plant during 2008-09 and 2009-10 is as follows.
513
Average station heat rate of the plant is as follows
Overall station PLF of the plant is as follows
Energy conservation & savings details
After commissioning during 2008-09, DSPM units with a minimum period of
stabilization achieved annual PLF of 84.8% with overall generation of 3714.07 MU.
The gross heat rate was 2577 kCal/kWh.
By the time 2009-10 by best operation and maintenance practices, as mentioned
above our PLF improved from 84.8% to 87.65%with a generation of 3838.93MU.
514
By reducing unnecessary tripping by best operation and maintenance activities
station reduced its specific oil consumption from 1.358 to .756 ml/kWh .
By operating the unit at optimum parameter and minimum deviation from designed
data, station improved its heat rate from 2577 kCal/kWh to 2481.43 kCal/kWh.
Activities implemented by the station to achieve Energy Saving
1. By operating unit at designed parameter overall efficiency of plant is improved.
2. Reduction in partial loading results in higher PLF hence improvement and
electrical energy saving.
3. Reducing partial losses.
4. Avoiding idle running hours of CHP.
5. Utilizing max capacity of conveyor Belts of CHP.
6. Proper switching control of lighting load.
7. Reduction in specific oil/coal cons results in saving in aux power cons.
8. Utilizing max capacity of existing aux by operating at full load.
9. Proper up keeping of running aux reduces outage of aux and consequently
unwanted outages of units.
10. Reducing various steam, water, coal and air leakages.
Future Energy Reduction Targets
1. Secondary fuel consumption below 0.70 Ml/Kwh.
2. Specific coal consumption below 0.70 Kg/Kwh.
3. Auxiliary power consumption below 7.7%.
4. DM water make up below 1.0 %.
515
Certificate of Merit Thermal Power Station
ULTRATECH CEMENTS LIMITED
UNIT BIRLA WHITE
7.5 MW THERMAL POWER PLANT
Jodhpur (Rajasthan)
Unit Profile
Birla White is the 7th largest White Cement plant in the world and largest in India
in Plant capacity. Birla White has moved from a single commodity premium product
to a multi specialty product company with market leadership position and exporting
to 26 countries in 6 continents.
TPP has Atmospheric fluidized bed Combustion (AFBC) steam Boiler - capacity 38
TPH and is designed to fire multi fuels as below.
1. F-grade coal - 100%
2. Lignite - 100%
3. Combination of Pet coke & F grade coal in ratio of 60:40
Birla White commissioned its 7.5 MW capacity Thermal Power Plant in the month of
March 2007. This plant is a multi-fuel plant done on an EPC basis. The supply of 38
TPH boiler is from CVPL Trichy and Turbine is from HTC China. Enhanced capacity
of Thermal Power Plant 7.5MW to 8.0MW by modification in Boiler and Turbine in
the month of August, 2010.
516
Thermal Power Station Design Details
Thermal Power Station Operating Details
S N Particulars Current completed Previous completed
Design details financial year financial year
2009-10 2008-09
(a) Capacity of the station (MW) 8.00 7.5
(b) Average Station Gross Heat Rate 3650 3650
on GCV basis of the fuel used,
(kcal/kWh)
(c) Station Net Heat Rate on 2800 2800
GCV basis of the fuel used,
(kcal/ kWh)
(d) Station Auxiliary Power 10 10
Consumption (%)
(e) Station Secondary Fuel Oil NA NA
Consumption (ml/kWh)
S N Annual Operating Parameters Current completed Previous completed
financial year financial year
2009-10 2008-09
1 Overall Station Generation (Million
kWh/year) 62.34 54.8
2 Overall Station PLF (%) 95 84
3 Coal/ Lignite/ Pet coke Consumption (Million Metric Tonne)
(Please specify the name of Fuel used)
Overall Station fuel consumption
(Coal/ Lignite/Biomass
Consumption) (Million Metric
Tonne/ year) 0.33
Average Gross Calorific Value
(GCV)of fuel (kcal/kg) 7215 4142
Overall Thermal energy used in
the station due to the use of
above fuel
(Billion kcal/ year) 23764.34 20013.68
Gross Heat Rate on GCV basis
(kcal/ kWh)
517
1 Overall Station Gross Heat Rate
on GCV basis (kcal/ kWh) 3300 3637
2 Net Heat Rate on GCV basis
(kcal/ kWh)
Overall Station Net Heat Rate on
GCV basis (kcal/ kWh) 2766.09 2750
3 Auxiliary Power Consumption of
Gross Energy Generated (%)
Overall Station Auxiliary Power
Consumption (%) 8.2 9.5
Raw material Consumption during last 2 years. (MT per year)
S. N. Name 2008-09 2009-10
1 Pet coke 6844.97 2931
2 Coal 11121.31 213
3 Lignite 32480.46 0
Energy Conservation Commitment, Policy and Organizational Set-Up
The management of Birla White is committed to reduce energy
consumption.
Monthly review on energy consumption by top management.
Launching of Power Champion Scheme to encourage employees for energy
consumption and recognition of best performance teams.
Monthly Review of Energy consumption on section wise on 2nd working
day of every month in Mass communication meeting.
Up gradation of technology with low energy consumption, like installation
of RABH in place of ESPs, Installation of Vertical Roller Mill for Cement
Grinding etc.
Explore the possibility of cheaper alternative fuel and waste products
(Like agro waste, Bio fuel etc.)
At the project planning level, finalize only low energy consumption with
eco friendly technology.
Continuous monitoring of energy consumption through ENERCON energy
system.
518
Energy Conservation Achievements
Year of
Commissio
ning of the
projects
Project
description
Achievement of energy savings per year basis
Invest
ment
incurred
on the
project
Rs.
(Lakhs)
Electri
city
(Kwh)
Fuels*
Coal
(tonn
es)
F.Oil
(kL)
Gas
(lakh
Nm3)
Total
(fuel) in
(MTOE)
Total
savings
in (Rs.
Lakhs)
2009-10 Modification in NA 5030 NA NA 1710
boiler flue gas
path &
refractory
inside the
boiler to
increase the
alternate fuel
firing other
than Indian
coal Rs 2
Lakhs
Modification in 8.94 NA NA NA
discharge duct 0
of Boiler &
replaced the
flap type
dampers by Rs. 2
plate type shut Lahs
off dampers to
reduce the
pressure drop
in duct
Optimization of 2.44 NA NA NA
auxiliary cooling 0
water pump 249.85 Rs. 05
operation to Lahs
speed mode by
providing VFD
drive
Modification in 1.22 NA NA NA
discharge duct 0
of ID fan &
replacement of
Flap type
dampers to Rs. 0.4
plate type shut Lahs
off dampers to
reduce the
pressure drop
in duct
519
Optimization of 0.48 NA NA NA
condensate 0
extraction
pump to speed Rs. 0.2
mode by Lahs
providing VFD
drive
TPP plant 0.98 NA NA NA
lighting circuit 0 Rs. 0.2
modification Lahs
Optimization of 0.756 NA NA NA
Ash handling
operation
based upon the
Hooper levels
instead of
continuous
running NIL
Reduction in 0.24 NA NA NA
boiler PA 0
header
pressure by
installing IGV
damper in PA
fan duct NIL
Optimization of 0.33 NA NA NA
cooling tower 0
fan operation
with
temperature
difference NIL
1. Automation of Ash Handling System. Prepared and Implement a group logic
sequence of all the fourteen drives of ASH Handling System in DCS to run in
automatic mode for selected period of time set by the operator with start /
stop alarm indication and the indication of run time and stop time. Prepare
the tantalizer for calculating the total running hours and observe that system
is running for twelve hours a day. The power consumption of Ash Handling
System is reduced by 0.756 Lakhs kWh per annum
2. Auxiliary cooling water is operating on direct on line starter. During plant
team observation it was found that it is operating through throttling resulting
in consuming of more power. Given supply to cooling tower motor through
variable voltage variable frequency drive (VVVFD) and by maintaining, required
flow and pressure by varying the speed of the motor, the power consumption
of Auxiliary cooling water pump is reduced by 2.44 Lakhs kWh i.e. saving of
Rs 11.71 Lac per annum.
3. Plant was using 70 watt HPSV (High Pressure Sodium Vapor) fitting , which
was replaced with 18 watt CFL fitting. The CFL fitting is giving the required
illumination for path
520
4. Firing of 100% Petcoke (Petroleum Industry waste) in AFBC boiler , a use of
alternative fuel over fossil fuel like Indian coal .Resulted in
Conservation of coal energy.
Reduction in direct electrical energy by reduction in auxiliary power
consumption of power plant due to petcoke being a high heat value &
low ash fuel.
5. Installed KVAR controller and HT capacitor and main RSEB Line
Environment and Safety
Major Environmental Projects taken during the year 2008- 10
The significant achievements and efforts of BW during 2009 are given below:
Tree plantation around 5000 during 2009 & 2010 at various location in Thermal
Power Plant, Cement plant, colony, school and near by villages.
There is zero effluents discharge from industry. Only domestic waste water
(sewage) is being treated at sewage treatment plant (STP) and consumed in
Plant and Horticulture.
Installed higher capacity bag house at crusher
Installed bag house at coal dump hopper
Safety
Birla White is an OHSAS 18001:2007, certified Unit, It continuously focus on
Birla White has a structured Safety, Health & Environment (SHE) Subcommittee
which comprising of the representation from the various functions.