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Annexure B

ID to be filled by BEE Title of the measure Sector .

Installation Of VFD for Condensate Technology : Variable


Year to be filled by BEE
Extraction Pump Frequency Drive
Description of the energy conservation measure:

Two 100% capacity Condensate Extraction Pumps are available to pump the condensate from
condenser Hot well to Deaerator through control valves CD-14/CD-17. For a full load operation of a
unit one pump will be in service and other is kept as a standby. The normal opening position of control
valve is 60 70 % for full load operation (30 40 % of CEP output flow is throttled by the valve).
Instead of Valve Control Variable Speed control using VFD is used to gets maximum energy saving.

Parameter Without VFD With VFD


Valve position 60 % open 95% open
Current 59 A 42A
Power 590KW 440KW

Use of Variable Frequency Drive for Condensate Extraction Pump is done first time in India in the
Power Plant. This can be the trend setter and replicated in other similar power plant. Detailed report is
attached in Annexure C
Picture/ sketch/ drawing before modification Picture/ sketch/ drawing after modification
(if available)

Please refer ANNEXURE - C

Agency that executed the project (with complete address and email):
Yantra Harvest
Rathi Chambers 20 Sadashiv Peth, L.B.S. Marg, Pune
Phone No 020-4331287,4334128 www.yantraharvest.com / gaurangb@yantraharvest.com
Total investment, Rs.: 65,000,00.00 Year of implementation: 2006
First year energy cost savings, Rs.: 44,150,40.00
First year other savings, Rs.: NIL
kWh Coal Gas Oil Other
On annual basis
000 (Tons) Nm3 (kL)
Energy consumption before 4961.664
Energy consumption after 3700.224
Energy tariff, Rs/ kWh/ Ton/ Nm3/ kL Rs 3.5/
kwh
Company complete address: We authorise Bureau to
Dahanu Thermal Power Station, Reliance Energy Ltd. , use this information for
Village : Agwan, Dist : Thane, State : Maharashtra Pin: 401608 dissemination

Contact person who could be contacted for more information:


Mr. Prasad Rao (AVP) Signature
Station Head, Dahanu TPS
Prasad.Rao@relianceada.com Date 15/10/2007
Mobile: 9325118202

Page 2 of 13
Annexure B

Title of the measure


ID to be filled by BEE Sector .
Energy conservation & Efficiency
Improvement of Cooling Water (CW) Technology FLUGLIDE
Year to be filled by BEE Pumps 1 &2 by Corrocoating of Pump Coating
Impellers
Description of the energy conservation measure:

Cooling water (CW) pumps (total 04 nos) are used to supply cooling water (Sea Water) to condenser.

Surface roughness has substantial bearing in the flow characteristics. A rough surface introducing
micro or even macro turbulence and eddies in the boundary layer causing increase in velocity gradient
and effective reduction in cross sectional; area for laminar flow. The boundary layer creates the
blockage in the passage and shifts the flow/head characteristics reducing the pump efficiency.
FUGLIDE Coating increases the efficiency and protects against erosion and corrosion.

The average efficiency of the pumps increased from 69 % to 78%. Due to this the flow in the system
increase and one pump is stopped for 2 hours a day during high tide. This helps to conserve energy
and reduction in auxiliary power. CW pumps 3&4 will be coated in next opportunity.
Picture/ sketch/ drawing before modification Picture/ sketch/ drawing after modification
(if available)

Agency that executed the project (with complete address and email):
Kirloskar Brothers Limited
10 Corporate Park, Sion-Trombay Road, Chembur, Mumbai
Phone No. 022-5289320/5289321
Total investment, Rs.: 6,00,000.00 Year of implementation: 2006
First year energy cost savings, Rs.: 30,940,00.00
First year other savings, Rs.:
kWh Coal Gas Oil Other
000 (Tons Nm3 (kL)
On annual basis
For 04 )
pumps
Energy consumption before 42441.759
Energy consumption after 41557.556
Energy tariff, Rs/ kWh/ Ton/ Nm3/ kL Rs 3.5/
kwh
Company complete address: We authorise Bureau to
Dahanu Thermal Power Station, Reliance Energy Ltd. , use this information for
Village : Agwan, Dist : Thane, State : Maharashtra Pin: 401608 dissemination

Contact person who could be contacted for more information:


Mr. Prasad Rao (AVP) Signature
Station Head, Dahanu TPS
Prasad.Rao@relianceada.com Date 15/10/2007
Mobile: 9325118202

Page 3 of 13
Annexure B

ID to be filled by BEE Title of the measure Sector .


Energy conservation & Efficiency
Improvement Auxiliary Cooling Water Technology FLUGLIDE
Year to be filled by BEE
Pumps (ACW) by Corrocoating of COATING
Pump Impellers
Description of the energy conservation measure:

Auxiliary cooling water pumps ( 03 nos) are used to supply auxiliary water (Sea Water) in the plate
heat exchangers to cool equipment cooling water (DM Water). Due to corrosion and erosion of the
impeller of ACW pumps the efficiency of the pump decreased to around 57% due to this Two ACW
pump required for the cooling and one is standby.

ACW Pumps impeller and casing is coated by FLUGLIDE Coating and efficiency of pumps improved
from 57% to 77%. Due to this the characteristics of the pump shifted and the flow increased.

One ACW Pump stopped 12 hrs a day during high tide and the requirement is fulfilled by 1 pump at
that time, hence auxiliary power reduced and energy is conserved.

Picture/ sketch/ drawing before Picture/ sketch/ drawing after modification


modification
(if available)

Agency that executed the project (with complete address and email):
Kirloskar Brothers Limited
10 Corporate Park, Sion-Trombay Road, Chembur, Mumbai
Phone No. 022-5289320/5289321
Total investment, Rs.: 3,00,000.00 Year of implementation: 2006
First year energy cost savings, Rs.: 10,77,738.00
First year other savings, Rs.:
kWh Coal Gas Oil Other
On annual basis
000 (Tons) Nm3 (kL)
Energy consumption before 1231.70
Energy consumption after 923.776
Energy tariff, Rs/ kWh/ Ton/ Nm3/ kL Rs 3.5/
kwh
Company complete address: We authorise Bureau to
Dahanu Thermal Power Station, Reliance Energy Ltd. , use this information for
Village : Agwan, Dist : Thane, State : Maharashtra Pin: 401608 dissemination

Contact person who could be contacted for more information:


Mr. Prasad Rao (AVP) Signature
Station Head, Dahanu TPS
Prasad.Rao@relianceada.com Date 15/10/2007
Mobile: 9325118202

Page 4 of 13
Annexure B

Title of the measure


ID to be filled by BEE Sector .
Installation Of VFD for LDO Firing
Pump Technology Variable
Year to be filled by BEE
Frequency Drive
Description of the energy conservation measure:

LDO oil pump is running continuously for the backup as secondary fuel support to boiler in emergency
conditions and during unit startup and shutdown. Flow control of oil is done through recirculation
control valve.

Variable Frequency Drive is installed and Control valve kept open fully. Flow is controlled by varying
the speed of pump by VFD.

Picture/ sketch/ drawing before modification Picture/ sketch/ drawing after modification
(if available)

Agency that executed the project (with complete address and email):
Nelco Ltd, Mahakali Caves Road Chakala, Andheri (East) Mumbai-400093
Phone No 022-8300512 www.nelcoin.com / amdesai@nelcoin.com
Total investment, Rs.: 1,63,223.00 Year of implementation: 2006
First year energy cost savings, Rs.: 1,47,168.00
First year other savings, Rs.: NIL
KWh Coal Gas Oil Other
On annual basis
000 (Tons) Nm3 (kL)
Energy consumption before 126.144
Energy consumption after 84.096
Energy tariff, Rs/ kWh/ Ton/ Nm3/ kL Rs 3.5/
kwh
Company complete address: We authorise Bureau to
Dahanu Thermal Power Station, Reliance Energy Ltd. , use this information for
Village : Agwan, Dist : Thane, State : Maharashtra Pin: 401608 dissemination

Contact person who could be contacted for more information:


Mr. Prasad Rao (AVP) Signature
Station Head, Dahanu TPS
Prasad.Rao@relianceada.com Date 15/10/2007
Mobile: 9325118202

Page 5 of 13
Annexure B

Title of the measure


ID to be filled by BEE Sector .
Installation Of VFD for Seal Air Fans of
Coal Mills Technology Variable
Year to be filled by BEE
Frequency Drive
Description of the energy conservation measure:

Seal Air Fans (110 KW DRIVE) are used to supply seal air to Ball and Tube Coal Mills. Total six coal
mills are there at DTPS and 2 are running in each unit and one is standby.

Two seal air fans are provided for each coal mill .One is in service and other kept auto stand by.
Hence at a time 4 Seal Air fans are in service at DTPS. Pressure of air required for sealing of the mill
is control by controlling position of Suction Damper of Seal Air Fan. This cause the energy loss.

Variable Frequency Drive are provided in Six Seal air fans one for each mill and the seal air pressure
is controlled by varying the speed of the drive and suction damper is kept open fully.

Picture/ sketch/ drawing before modification Picture/ sketch/ drawing after modification
(if available)

Agency that executed the project (with complete address and email):
Hi- REL Pvt Ltd., B117, GIDC Electronic zone sector 25, Ghandhinagar
www.hirel.net , parag_nanavati@hirel.net
Total investment, Rs.: 45,132,90.00 Year of implementation: 2006
First year energy cost savings, Rs.: 88,200,00.00
First year other savings, Rs.:
kWh Coal Gas Oil Other
On annual basis
000 (Tons) Nm3 (kL)
Energy consumption before 5544
Energy consumption after 3024
Energy tariff, Rs/ kWh/ Ton/ Nm3/ kL Rs 3.5/
kwh
Company complete address: We authorise Bureau to
Dahanu Thermal Power Station, Reliance Energy Ltd. , use this information for
Village : Agwan, Dist : Thane, State : Maharashtra Pin: 401608 dissemination

Contact person who could be contacted for more information:


Mr. Prasad Rao (AVP) Signature
Station Head, Dahanu TPS
Prasad.Rao@relianceada.com Date 15/10/2007
Mobile: 9325118202

Page 6 of 13
Annexure B

Title of the measure


ID to be filled by BEE Sector .
Replacement of Ignitor Oil Guns with
High Energy Arc (HEA)
Year to be filled by BEE Technology

Description of the energy conservation measure:


Oil guns are used to provide ignition support during startup and shutdown of units and backup fuel
during emergency conditions. Ignitor guns are used to provide ignition energy for the oil guns. To
ensure reliability of oil guns, gun trial has to be taken once a week of three oil elevations (4guns in
each elevation) in both units.

Healthiness of Ignitor guns is ensured by scavenging of the oil guns (4 elevations two in each units)
Ignitor guns are replaced by HEA in all four elevations. Due to installation of HEA, scavenging
scheduled stopped and oil consumption reduced. The reliability of the system improved and start-
up time and shutdown time is reduced by half hour each.

Picture/ sketch/ drawing before modification Picture/ sketch/ drawing after modification
(if available)

Agency that executed the project (with complete address and email):
Boiler Controls Private Limited
1/5, Alexandria Road, Trichy , Tamilnadu
Phone No 0431-2412419
Total investment, Rs.: 12,00,000.00 ( 16 nos.) Year of implementation: 2006
First year energy cost savings, Rs.: 2,81,680.00
First year other savings, Rs.:
kWh Coal Gas Oil Other
On annual basis
000 (Tons) Nm3 (kL)
Energy consumption before 10 kl
Energy consumption after NIL
Energy tariff, Rs/ kWh/ Ton/ Nm3/ kL Rs 3.5/ Rs
kwh 28,168.00
/ KL
Company complete address: We authorise Bureau to
Dahanu Thermal Power Station, Reliance Energy Ltd. , use this information for
Village : Agwan, Dist : Thane, State : Maharashtra Pin: 401608 dissemination

Contact person who could be contacted for more information:


Mr. Prasad Rao (AVP) Signature
Station Head, Dahanu TPS
Prasad.Rao@relianceada.com Date 15/10/2007
Mobile: 9325118202

Page 7 of 13
Annexure B

Title of the measure


ID to be filled by BEE Sector .
Replacement of V-belt with Flat belt of
Air Washer Unit
Year to be filled by BEE Technology Flat Belt Drive

Description of the energy conservation measure:

Air washer unit used for fresh air circulation in the main plant area. V- belt drive of one of the unit is
replaced with efficient flat belt.

Picture/ sketch/ drawing before modification Picture/ sketch/ drawing after modification
(if available)

Agency that executed the project (with complete address and email):
Techno Enterprises , 19 Sharda Apartment, Chakala, Andheri East Mumbai 400 099
Phone 022-28242872
Total investment, Rs.: 80,000.00 Year of implementation: 2006
First year energy cost savings, Rs.: 93,000.00
First year other savings,
kWh Coal Gas Oil Other
On annual basis
000 (Tons) Nm3 (kL)
Energy consumption before 390.131
Energy consumption after 363.559
Energy tariff, Rs/ kWh/ Ton/ Nm3/ kL Rs 3.5/
kwh
Company complete address: We authorise Bureau to
Dahanu Thermal Power Station, Reliance Energy Ltd. , use this information for
Village : Agwan, Dist : Thane, State : Maharashtra Pin: 401608 dissemination

Contact person who could be contacted for more information:


Mr. Prasad Rao (AVP) Signature
Station Head, Dahanu TPS
Prasad.Rao@relianceada.com Date 15/10/2007
Mobile: 9325118202

Page 8 of 13
Annexure B

Title of the measure


ID to be filled by BEE Sector .
Replacement of FD fans blade pitch
control actuators with BECK make
Year to be filled by BEE actuators Technology .
Description of the energy conservation measure:
2 Nos. FD fans are used to provide combustion air required in the furnace for combustion of fuel.
Blade pitch control is used for controlling air flow. Electrical actuators are used for the operation of
servo mechanism. Comparison between AUMA (old) And BECK actuators shown in the table

AUMA BECK
Power Supply 415 VAC 230 VAC
Current consumption (A) 3.5 Amps 0.38 Amps
Response with Change in More than 2.5% Less than 0.2%
Demand.
Manual / Local Operation Difficult Very Easy
Remote Operation from HMI Not smooth compare to Very Smooth.
as well as Back Up Desk. Digital Control Actuator.

Due to installation of BECK actuators the secondary air flow required for combustion of fuel can be
controlled in with accuracy of 2 T/ hr compared to 15 T/hr by old actuators. Maintenance cost is also
reduced due to less numbers of components and Excess air supplied to the Furnace is fine tuned.
This reduced the power consumption by FD fans by 2 Amps each
Picture/ sketch/ drawing before modification Picture/ sketch/ drawing after modification
(if available) AUMA Actuators BECK Actuators

Agency that executed the project (with complete address and email):
Total investment, Rs.: 6,60,000.00 (2 nos) Year of implementation: 2006
First year energy cost savings, Rs.: 11,42,662.00
First year other savings, Rs.:
kWh Coal Gas Oil Other
On annual basis
000 (Tons) Nm3 (kL)
Energy consumption before 7019.214
Energy consumption after 6692.738
Energy tariff, Rs/ kWh/ Ton/ Nm3/ kL Rs 3.5/
kwh
Company complete address: We authorise Bureau to
Dahanu Thermal Power Station, Reliance Energy Ltd. , use this information for
Village : Agwan, Dist : Thane, State : Maharashtra Pin: 401608 dissemination

Contact person who could be contacted for more information:


Mr. Prasad Rao (AVP) Signature
Station Head, Dahanu TPS
Prasad.Rao@relianceada.com Date 15/10/2007
Mobile: 9325118202

Page 9 of 13
Annexure B

Title of the measure


ID to be filled by BEE Sector .
Fuel Conservation by reduction in DM
Year to be filled by BEE make up by substituting HFO by LDO Technology Fuel Substitution
Description of the energy conservation measure:

At DTPS three oil guns elevation provided for backup ignition support and abnormal conditions in each
unit. AB elevation is provided by LDO oil and CD, EF Elevation by Heavy Furnace Oil (HFO). Steam is
used for atomizing of HFO and compressed air is used for atomization of LDO. Steam is supplied
around the HFO pipes to keep temperature of HFO above 90 degC, so that HFO is ready to fire.

Steam used for this purpose is supplied from Auxiliary steam header ( 12 ksc & 240 degC) which gets
steam from CRH / Main steam ( 39ksc , 340 degC / 148 ksc , 540 degC) . There is wastage of steam
through Steam Traps and HFO Heaters drain due to condensation. Due to this more DM water makeup
is required. HFO supplied to the CD and EF elevation is substituted by LDO and the steam and water
requirement is reduced saving the coal fired in the furnace and DM makeup required

DM water requirement is reduced by 0.1% due to the fuel substitution. Due to this heat rate is
reduced by 1.1 kcal/ kwh which reduced Coal Consumption by 1154.89 MT/ annum

Picture/ sketch/ drawing before modification Picture/ sketch/ drawing after modification
(if available)

Agency that executed the project (with complete address and email):
Total investment, Rs.: Year of implementation: 2006
First year energy cost savings, Rs.: 26,24,155.92
First year other savings, Rs.:
kWh Coal Gas Oil Other
On annual basis
000 (Tons) Nm3 (kL)
Energy consumption before
Energy consumption after
Energy tariff, Rs/ kWh/ Ton/ Nm3/ kL Rs 3.5/ 2272.21
kwh
Company complete address: We authorise Bureau to
Dahanu Thermal Power Station, Reliance Energy Ltd. , use this information for
Village : Agwan, Dist : Thane, State : Maharashtra Pin: 401608 dissemination

Contact person who could be contacted for more information:


Mr. Prasad Rao (AVP) Signature
Station Head, Dahanu TPS
Prasad.Rao@relianceada.com Date 15/10/2007
Mobile: 9325118202

Page 10 of 13
Annexure B

Title of the measure


ID to be filled by BEE Sector .
Oil conservation with reduction in
frequency of Oil Gun trials
Year to be filled by BEE Technology

Description of the energy conservation measure:

Oil guns are used to provide ignition support during startup and shutdown of units and backup fuel
during emergency conditions. Ignitor guns are used to provide ignition energy for the oil guns. To
ensure reliability of oil guns, gun trial has to be taken once a week of three oil elevations (4guns in
each elevation) in both units.

Ignitor guns are replaced with High Energy Arc Ignitors. In subsequent oil guns trial it is observed that
HEA are more reliable than ignitor guns, hence frequency of oil gun trial reduced and scheduled once
a month. Due to this oil consumption by oil guns and ignitor guns during gun trial reduced.

The reliability of the guns observed to be same as before and reduce oil consumption substantially.

Picture/ sketch/ drawing before modification Picture/ sketch/ drawing after modification
(if available)

With old With revised


schedule scheduled

Average OIL 7.5 KL 0.5 KL


Consumption /
month

Agency that executed the project (with complete address and email):
Total investment, Rs.: NIL Year of implementation: 2006
First year energy cost savings, Rs.: 23,66,112.00
First year other savings, Rs.:
kWh Coal Gas Oil Othe
On annual basis 000 (Tons) Nm3 (kL) r

Energy consumption before 90 KL


Energy consumption after 6 KL
Energy tariff, Rs/ kWh/ Ton/ Nm3/ kL Rs 28,168.00 / KL
Company complete address: We authorise Bureau to use
Dahanu Thermal Power Station, Reliance Energy Ltd. , this information for
Village : Agwan, Dist : Thane, State : Maharashtra Pin: 401608 dissemination

Contact person who could be contacted for more information:


Mr. Prasad Rao (AVP) Signature
Station Head, Dahanu TPS
Prasad.Rao@relianceada.com Date 15/10/2007
Mobile: 9325118202

Page 11 of 13
Annexure B

Title of the measure


ID to be filled by BEE Sector .
Installation Of VFD for Vent Air Fans of Technology Variable
Year to be filled by BEE Dry Ash Silo System Frequency Drive
Description of the energy conservation measure:

Classifiers are provided for the classification of coarse and fine ash collected from ESP hoppers. Vent
fans (2 x 90 KW Drives) are used fro conveying fine ash classified in classifiers to fine ash silo through
bag filters.

The fineness of ash depends on classifier speed and air flow through the system. As of present airflow
is controlled by manual damper in the suction of the vent fan. The damper position is to be adjusted
from time to time to get the desired quality of ash.

Damper control being manual does not provide scope for fine control, also it gets disturbed frequently.
Damper controls flow by restricting the path of air resulting in considerable loss of power and
increased noise level.

Damper control is replaced by Variable Frequency drive and air pressure and flow is controlled.

Picture/ sketch/ drawing before modification Picture/ sketch/ drawing after modification
(if available)

Agency that executed the project (with complete address and email):
Hi- REL Pvt Ltd., B117, GIDC Electronic zone sector 25, Ghandhinagar
www.hirel.net , parag_nanavati@hirel.net
Total investment, Rs.: 7,00,000.00 Year of implementation: 2006
First year energy cost savings, Rs.: 7, 05,200.00
First year other savings, Rs.:
kWh Coal Gas Oil Other
On annual basis
000 (Tons) Nm3 (kL)
Energy consumption before 11388
Energy consumption after 937.32
Energy tariff, Rs/ kWh/ Ton/ Nm3/ kL Rs 3.5/
kwh
Company complete address: We authorise Bureau to
Dahanu Thermal Power Station, Reliance Energy Ltd. , use this information for
Village : Agwan, Dist : Thane, State : Maharashtra Pin: 401608 dissemination

Contact person who could be contacted for more information:


Mr. Prasad Rao (AVP) Signature
Station Head, Dahanu TPS
Prasad.Rao@relianceada.com Date 15/10/2007
Mobile: 9325118202

Page 12 of 13
Annexure B

ID to be filled by BEE Title of the measure Sector .


Energy conservation by reduction in
Year to be filled by BEE Running hours of Air Compressors Technology
Description of the energy conservation measure:

Innovative project with NIL investment


Applied six-sigma methodology
Identification of problem, preparation of process map
Collection of relevant data and Calculation of process capability
Defined cost of poor quality
Identified potential causes and applied six-sigma tools like Brainstorming, fish-bone diagram,
cause &effect matrix, Brainstorming matrix, etc.
Performed Design of Experiments (DOE) and validated the same through Regression
analysis.
Preparation, implementation of control plan and sustaining in the form of QIPs,SOPs and
SOGs.
Not only reduced variation in aux power consumption of air compressors but also succeeded
in stopping the running of extra compressor.

Picture/ sketch/ drawing before modification Picture/ sketch/ drawing after modification
(if available)

MONTHWISE AUX. POWER CONSUMPTION (1000 Units)


600
522.3 522.3
524.4 516.7 518.1
504.7 507.8
500
503.3 522.3 504.5 506.4 471.0 462.6
400 336.9 348.2 348.2 348.2
339 348.9 348.2
348.2
300 336.9 338.8 337 337
338.36 331.8
300.2

200

100
ACTUAL BASE LINE TARGET
0

MAR JUN SEP DEC MAR JUN SEP DEC MAR JUN

Agency that executed the project (with complete address and email):
Total investment, Rs.: NIL Year of implementation: 2006
First year energy cost savings, Rs.: 61,32,000.00
First year other savings, Rs.:
kWh Coal Gas Oil Other
On annual basis
000 (Tons) Nm3 (kL)
Energy consumption before 5820
Energy consumption after 4068
Energy tariff, Rs/ kWh/ Ton/ Nm3/ kL Rs 3.5/
kwh
Company complete address: We authorise Bureau to
Dahanu Thermal Power Station, Reliance Energy Ltd. , use this information for
Village : Agwan, Dist : Thane, State : Maharashtra Pin: 401608 dissemination

Contact person who could be contacted for more information:


Mr. Prasad Rao (AVP) Signature
Station Head, Dahanu TPS
Prasad.Rao@relianceada.com Date 15/10/2007
Mobile: 9325118202

Page 13 of 13