STUDY OF BASE LOAD OF TATA

STEEL & EXPLORE WAY TO

REDUCE IT

LDC, ELECTRICAL T & D

1
What is Base Load
• At MPDS#1 island where PH#3, PH#4, PH#5 and DG are the source, many of the
critical process do not have local DG back to prevent capital damage in case of total
power failure. Hence continuous power supply is required to be maintained to
these plants to prevent capital damage.

• These plants have critical having no DG back up:

• A to F Blast Fce, G Blast Fce, Coke Plant, LD#1, part load of 500 TPD, Power Houses
aux, Blower Houses, Pump House#2, West Plant area part load, Centac Compressor,
SP#2 part

• To ensure continuous supply when above situation would arise, generation in in-
house Power Houses is to be maintained at least to Base Load level at all time to
prevent capital damage in case situation arises.
A typical process flow of Base load management

Incidence
In house To manage base
Occurred(Inhouse High in house
generation goes load Start DG / fire High works power
TG/Boiler tripping power cost to
below base load LDO in in house cost
or BFG/CO gas manage base load
80MW Boiler
shortage)
Business case: The Base Load is the minimum generation that needs to be
maintained in PH#3 + PH#4 + PH#5 at any time. Present value is 80 MW. If
generation in the three power house is lower than 80 MW during gas shortage, 80
MW is maintained by either coal firing at PH#4 or by running DG. This inccurs cost
which is essential to ensure power supply to avoid capital damage

Problem/Opportunity Statement: With stoppage of coal firing planned in PH#4,

the impact is expected to significantly increase since coal firing will be replaced
with LDO firing. Reduction is Base Load will result in saving in cost of LDO firing /
DG running.
 BFG restriction priority List at EMC
Consumption
Normal BF Gas cut
BFG restriction during
Plant Consumption /restriction in
priority at EMC Restriction
Lakh N M3 Lakh N M3
Lakh N M3

PH3 & PH4 Gen reduced to 80 MW 4.7 3.3 1.4

PH6 Gen reduced to 60 MW 3.2 1.5 1.7

Pellet plant One Ball mill 0.75 0.35 0.4

BF pr reduce then CO 0.1 0.08 0.02

Lime plant 7 ,8 & 9 increase in mix
Bl Fce stove 7.5
 Minimum Technical Limit at In- House Generation
S.No Generating Capacity(MW) Minimum Remarks
Station Technical
Limit(MW)
1. PH#3 30+30 40 Considering that in case of
both TGs and all 4 boilers in
operation, for <40MW,
problem in maintaining
steam quality(temperature)

2. PH#4 12.5+20+25 18 Considering the minimum

(12.5 is usually boiler working limit and
OFF) thereafter meeting the
average process steam
requirement

3. PH#5 30 12 The minimum process LP

steam requirement is
considered
*For stability of islanded system, max. 5% fixed load fluctuation(3.5MW) can be
allowed. The max. rating of single motor that can be started is 500kW.
 Plant Total Shedable Base load Loads under shedding
Load load as of as of now
now
At emergency DG 2.16 0 2.16 -
Bus
IGD 500 TPD 2.5 6.25 2.5 9.8MW MAC at 47.75Hz

MPDS1 Stn Tranf 2.6 2.5 0.1 Timken at 48Hz

LD1 21.25 4.65 16.67 i)Sec emission ID fan 1, 2 & 3 of 1100 kW
each at 48.0Hz
Id fan 1 &2 of 2650 kW each U/F at 47.5
BFRS(G Bl fce) 12.06 2 10.06 i)IOH four no. Trf at 47.5 Hz
ii) Stock Hse & Coal Handling both DE
dusting Fan at 48.0Hz
PH3 48.24 28 20.24 i)NDPH F1 at 48.3Hz
ii)MM C16 & C27 feeder at 47.6Hz
iii)T-30 C5 & C14 feeder at 47.3Hz
iv)WRM C7 &C8 feeder at 47.3Hz
WSS excluding 4th 58.71 30.29 28.42 i)All town except T3 at 49.2Hz
boiler ii)225 TPD BOCI & Sp1 F1 & F2 at 47.5 Hz
iii)Filter plant & GO feeder#1 at 47.19 Hz
iv)GO feeder#2 at 47.0Hz
v)SP#2 WGF at 47Hz
Total 148.27 73.69 80.15
 LD-2 Vessel ID Fan, LD-1 Changes in Base Load in last 20 years
& LD-2 secondary
emission, LLoad reduction
machine/repair Load reduction in in LD#2 Comp Load reduction
shop:7MW A&B Fce & PH#4 :2.5MW in LD#1: 1MW
Aux:3MW and IGD:2MW
Load reduction
in
CRM,IGD&LD2:1
2.5MW

Load reduction
in LD#1: 6MW
MW

*Reasons for Technical Limit (70MW):-

1)Due to Generating station Stability of PH#3,PH#4 and PH#5 (Total=70MW:PH#3:40 MW; PH#4:18 MW: PH#5:12 MW), considering
all generator and boilers in service)
2)System will be unstable for any outage /change in source/load.
 Base Load Base Load
Yearly change Load details
reduced (in MW) increased
(in MW)
Base load reduced-
i) A & B Fce closed -1.2 MW
FY-09 3 0 ii)PH4 Aux load reduced (change-over from coal firing to gas firing)- 1.8
MW
Base load reduced-
Fy-10 2. 5 0 i) LD2 Compressor Hse load (Source change-over of HSM from MPDS#1 TO
MRSS#1)– 2.5 MW
Base load reduced-
i) Feeder tripping at CRM -3 MW
ii) 500 TPD IGD MAC load as it is down- 4.5 MW
iii) LD2 base load reduced after Source change over from MPDS#1 to
FY- 11 15.5 3 MRSS#1 - 8.0 MW
Base load increased-
i) F Fce load increased(BF upgradation) – 1.5 MW
ii) G Fce load increased(BF upgradation) – 1.5 MW
Base load to be reduced- at LD1-7 MW and IGD – 2 MW
i) LD1 Vessel ID fan – 2.0 MW implemented
ii) New RCPH load - 1.8 MW+1.6MW* FY 18 – H1
iii) HT Compressor - 0.3 MW implemented
iv) CC2 ECR Mould cooling Pump -0.6 MW
FY- 18 v) LF ID fan - 0.9 MW implemented in one LF
H1: 6.1 vi) IGD – 2MW FY 18 – H2
Target 0
H2: 2.9
Base load has been reduced to 77.4 MW wef 16-08-17
and further reduced to 74 MW by 04-09-17 and further
reduced to 72 MW as on 10.10.2017 and 71 MW by
14.12.2017
*With sttopage of cooling casting will be aborted and 1.6MW load electromagnetic stirrer will reduce automatically
 Savings
BF Gas availability will increase in network by reducing Base load and cost avoidance
BFG avl Increase Cost saving
Action Base load MW Reduce in NM3 (LDO cost ) in
(4000NM3/MW) Cr

6 MW in FY'17 H1 24000
LDO saving
Base Load reduction 0.69 PH3/4- 36
KL,DG-90 KL
3 MW in FY'17 H2 12000

Actual saving as on 17.12.2017 by reducing base load to 71 MW:

Oil Saving- 203 KL
Amount saving- 91.40 Lakh
Thanks