22-09-2019

KOTA SUPER THERMAL POWER STATION,

RRVUNL, KOTA

➢K.C.AGRAWAL, CHIEF ENGINEER

➢M.K.SOMANI, SUPERINTENDING ENGINEER

Brief Introduction- RVUN

Government of Rajasthan constituted the Rajasthan Rajya Vidyut
Utpadan Nigam Ltd. (RVUN) on 19th July, 2000 and was entrusted
with the job of development of power projects under state sector,
along with operation & maintenance of state owned power
stations. The Present installed capacity of RVUNL is 7277.35 MW
Name of Power Station Capacity (MW)
SURATGARH SUPER THERMAL POWER STATION 1500
KOTA SUPER THERMAL POWER STATION 1240
KALISINDH SUPER THERMAL POWER STATION 1200
CHHABRA THERMAL POWER STATION 1000
CHHABRA SUPERCRITICAL THERMAL POWER STATION 1320
DHOLPUR GAS BASED COMBINED CYCLE POWER STATION 330
RAMGARH GAS THERMAL POWER STATION 273.5
MAHI HYDEL POWER STATION 140
GIRAL LIGNITE POWER LIMITED 250
MINI-MICRO HYDEL POWER STATION (10 SCHEMES) 23.85

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Brief Introduction-KSTPS
Kota Super Thermal Power Station is the first coal based power
station of Rajasthan. It is situated on the left bank of River
Chambal. It comprises of total 07 Nos. units with total capacity
of 1240 MW.
Stage Unit Capacity Date Of First Date of Capital Cost
No no (mw) synchronization Commercial Run ( Rs in crore)
I 1 110 17.01.1983 01.04.1983 143
2 110 13.07.1983 01.04.1984
II 3 210 25.09.1988 11.03.1989 480
4 210 01.05.1989 16.01.1990
III 5 210 26.03.1994 18.07.1995 480
IV 6 195 30.07.2003 01.08.2004 537
V 7 195 30.05.2009 01.01.2010 927

Energy Consumption Overview

Thermal Energy Consumption for year 2018-19

Type Quantity Average GCV TOE

Coal 5333096 MT 3877 Kcal/Kg 2067641

Heavy Fuel Oil (HFO) 2166.088 Kl 10062 Kcal/Kl 2.17

Low Sulphur Heavy Stock

668.468 Kl 10330 Kcal/Kl 0.69
(LSHS)

Light Diesel Oil (LDO) 364.118 Kl 10300 Kcal/Kl 0.37

Total 2067003.87

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Energy Consumption Overview

Electrical Energy Consumption for year 2018-19

Type MU % of Total

Construction Power 0.04117 0.005%

Road Light 0.4521 0.052%

Potable water for colony 0.63329 0.073%

Office outside Plant premises 0.36681 0.042%

Fly Ash Silos of Cement Cos. 13.166 1.511%

Auxiliary Power consumption 856.66 98.318%

Total 871.319

Energy Consumption Overview

Overall Energy Consumption for year 2018-19

Type TOE % of Total
Thermal 2067003.87 96.50%
Electrical 74920.034 3.50%
Total 2141923.904

100
80
60
40
20
0
Thermal Electrical

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Specific Energy Consumption Overview

Specific Energy Consumption Data for Last Three Years

Improvement
2016- 2017 2018
Type
17 -18 -19 w.r.t. w.r.t.
2016-17 2017-18

Specific Coal Consumption (Kg/KWh) 0.661 0.684 0.676 -2.27% 1.17%

Auxiliary Power Consumption(%) 11.46 11.04 11.0 4.01% 0.36%

Specific Oil Consumption (ml/KWh) 0.808 0.485 0.404 50.00% 16.70%

Station Heat Rate (Kcal/KWh) 2551 2652 2614 -2.47% 1.43%

Plant Load Factor (%) 68.93 66.40 72.92 5.79% 9.82%

Specific Energy Consumption Overview

Specific Energy Consumption Data for Last Three Years

➢There are 2 major issues which has led to increase in SHR after Year 2016-17.
From FY 2017-18 KSTPS is facing frequent low load operation of units as per
state load (LD) requirement.
➢Earlier Load dispatch center used to give us box up instructions rather than
running all units on 20-30% backdown.
2016-17 2017-18 2018-19
Back down Loss (%) 4.5 6.3 8.65
Box up Loss (%) 17.25 16.71 4.95

➢Due to the low load operation overall efficiency of our units has gone down.
➢ Still we have changed our practices and implemented new methodologies
to improve upon the efficiency during low load operation (these are described
later) which is visible in FY 2018-19 where despite more back down we have
improved the SHR.

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Specific Energy Consumption Overview

➢From July 2017 the testing of coal samples at loading end & unloading end was
started by Central Institute of Mining and Fuel Research(CIMFR).
➢CIMFR gave a contract to some 3rd Party for sample collection. It started giving
results after around 6 months on rigorous persuasions. These results were quite
unrealistic.
➢In some rakes we found GCV of unloading end to be more than loading end. In
some other rakes it was found to be very high for raw coal.
➢So we raised some referee challenge as per the agreement. Now the results of
referee challenges of July to Nov 17 have come after 1.5 years.

Average Average
Difference
Original Result Referee Result
SECL 3699 3615 -84
NCL 3607 3495 -112

Specific Energy Consumption Overview

➢It clearly shows that the GCV results given by CIMFR were on higher side which
has resulted in Higher SHR.
➢If we take CIMFR results higher by average 100 Kcal/KWh, Then our SHR of
2017-18 would have been around 2584 and the SHR of 2018-19 would have been
around 2547. Which are comparable to 2016-17.
➢Considering more back down SHR of 2017-18 and 2018-19 are better.
➢These results can not be incorporated now as the billing was already
completed.

2016-17 2017-18 2018-19

Specific Coal Consumption (Kg/KWh) 0.661 0.684 0.676

Station Heat Rate (Kcal/KWh) 2551 2584 2547

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Specific Energy Consumption Overview

Specific Energy Consumption Trends for Last Three Years

3000 74

2900 72.92 72
2800
70
2700

2600 68.93 2652 68 SHR

2614
PLF
2500 2551
66
66.4
2400
64
2300

2200 62
2016-17 2017-18 2018-19

Specific Energy Consumption Overview

Specific Energy Consumption Trends for Last Three Years

1.2
70 72.92
68.93
60 66.4
0.808 Auxiliary Power
50 Consumption (%)
0.684 0.676
Plant Load Factor (%)
40 0.661
0.6
30 Specific Coal
0.485
Consumption (Kg/KWh)
20 0.404 Specific Oil
11.46 11.04 11 Consumption (ml/KWh)
10

0 0.3
2016-17 2017-18 2018-19

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Information on Benchmarks
The data regarding performance of Power Plants are not made public by
most of the utilities. Most of the Power Plants only publish data regarding
Plant Load Factor(PLF). In today’s environment PLF is not proper indicator
of performance as the PLF depends on demand, various PPA’s, Inter state
agreements, Renewable Power availability etc.
The Rajasthan Electricity Regulatory Commission (RERC) give us benchmarks
which are :
Normative
Capacity Normative Specific Oil Availability
Unit No. SHR
(MW) APC (%) (ml/KWh) (%)
(Kcal/KWh)
Unit # 1 110 3000 10.5 0.5 82
Unit # 2 110 3000 10.5 0.5 82
Unit # 3 210 2500 9 0.5 82
Unit # 4 210 2500 9 0.5 82
Unit # 5 210 2500 9 0.5 82
Unit # 6 195 2500 9 0.5 82
Unit # 7 195 2328 9 0.5 82
TOTAL 1240 2561.7 9.27 0.5 82

Information on Benchmarks
Type RERC Norms 2016-17 2017-18 2018-19
Availability (%) 82 88.42 90.52 87.52
Auxiliary Power Consumption (%) 9.27 11.46 11.04 11.0
Specific Oil Consumption
0.5 0.808 0.485 0.404
(ml/KWh)
Station Heat Rate (Kcal/KWh) 2562 2551 2652 2614
CERC allows compensation to Generating Power Station for losses on account of
frequent back down / boxed up as per the instructions of SLDC(State Load
Dispatch Center) in the following parameters:
Station Heat Rate (SHR)- 50 to 150 Kcal/KWh as per the % of Backdown
Auxiliary Power Consumption-0.35 to 1 % as per the % of Backdown
Oil consump. on account of Start-ups-20 to 50 Kl/startup as per type of start up
We in our state do not get any compensation from RERC with regards to frequent
back down / boxed up, while we are facing back down / boxed up for about 50 %
time. This is the main reason that we are not been able to achieve the RERC
Benchmark.

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Information on Benchmarks

Benchmark provided under implementation of PAT Cycle-II

NIN Energy India Private Limited Audit Team conducted PAT Verification
Audit at KOTA SUPER THERMAL POWER STATION from 21.06.2019 to
22.06.2019 to verify the PLANT PERFORMANCE w.r.t Benchmarks as per
Rule 9 of 269 of (E) PAT Rules (2012) for assessment period 2018-19

Achieved heat rate during Assessment period, kCal/kWh 2756.69

Baseline Heat rate, kCal/kWh 2840.16
Notified target heat rate, kCal/kWh 2797.47
Baseline production, MU 8010.21
E certificates + 32665.6

KSTPS Achieved better Heat Rate then the Targeted

Heat Rate and earned E-Certs

Energy Saving Projects Implemented in Last Three Years

Adopted better operational and maintenance practices to achieve

performance improvement.

➢2016-17

•Reduced running hours of compressors by arresting air leakages and reducing

pressure set point from 6.4 kg/cm2 to 5.8 kg/cm2.

•Running of CT Fan in U# 6 & 7 has been regulated so as to maintain required

vacuum and at the same time reducing no. of CT fans running to save APC.

•Adopted better maintenance practices during annual shutdown & effective

preventive maintenance of equipments periodically resulted in reduced
Unburnt Carbon in Bottom & Fly Ash, Reduced draft power of Unit.

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Energy Saving Projects Implemented in Last Three Years

➢2017-18
• 3 Mill operation in U# 3 & 4 during partial load conditions resulted in saving
of 30-35 Amp current in each unit. Taking into account the PLF of 63 % for
Stage-II and sent out cost of KSTPS as Rs 3.04 the total saving of Approx.
Rs.53 Lacs achieved in the year.
• During winter season and low load conditions, due to low river water
temperature the vacuum in stage II improved. Sensing this as an opportunity,
Unit # 3 & 4 were run with 3 CWPs (1460 KW) instead of 4 Nos. with minimal
drop in vacuum able to save 139 Amps of 6.6 KV supply.
• Reduction in running of Raw Water pumps (365 KW HT Motor) from 3 to 2
resulted in saving of 32 Amp .
• Above efforts for optimum running of CW & Raw Water Pumps resulted in
total saving of Approx. Rs. 70 Lacs in the year.

Energy Saving Projects Implemented in Last Three Years

➢2017-18
• Drum level control by BFP (4000 KW HT Motor) scoop scheme implemented
resulting in saving of approx. 10 Amp. in each unit# 5, 6 & 7 Saving App.
Rs.46 Lacs.
• Saving in running hours of 1 No. BCW pump in Stage-I (i.e. 4 Nos. to 3 Nos.)
when both units were in operation.
• Adopted modern LED Lightings as energy conservation project which resulted
in better illumination with less energy consumption.
▪ Existing 110 Nos. 70W HPSV well glass fittings replaced with 36 W LED
Lights.
▪ Existing 170 Nos. 36W Conventional FTL having copper ballast replaced
with 18W LED Lights.
▪ Existing 93 Nos. 250W HPSV well glass fittings replaced with 120 W LED
Lights.
▪ Adopting LED lightings resulted in total saving of Approx. Rs. 4 Lacs in the
year.

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Energy Saving Projects Implemented in Last Three Years

➢2018-19
• New Vacuum Pumps installed in U # 3 & 4 one in each unit resulting in
saving of approx. Rs.45.8 Lacs per unit.
• More Lightings replaced with Energy Efficient LED Lightings.
• Drum level control by BFP (4000 KW HT Motor) scoop scheme implemented
resulting in saving of approx. 10 Amp. In unit # 3 & 4 each. Saving App.
Rs.30 Lacs.
• Feed control station DP reduced from 8 kg/cm2 to 5.5 kg/cm2 in Unit 1 & 2
resulting in reduction of BFPs current loading.
• FD fans of Unit 3 & 4 are of 800 kw capacity. It was analysed that Single FD
fan in these units can cater to full load air requirement. Based on this
analysis, it was decided to run unit with single FD fan in service and
achieved saving of 15 Amp in each unit. Saving App. Rs. 46 Lacs.
• Adopted checking of ducts, APH Seals etc at regular intervals and
accordingly arrested all leakages during any available opportunities in place
of attending during annual shutdown.

Innovative Projects implemented

Running of Unit on single FD Fan:

▪ Unit No. 3 & 4 of KSTPS, Kota were designed with 2 FD Fans (each 50 %
duty) with 800 Kw motors .

▪ Oxygen at APH I/L was optimized from 3.5% to 2.5% . It was observed that
at full load the blade pitch control opening remains between 10-15%.

▪ During low load conditions the blade pitch opening reduced to minimum
and Oxygen at APH I/L remained above 3.5%.

▪ It was decided to analyse the effects of single FD fan operation. The analysis
of unit tripping on FD fan failure during last 5 years showed that there was
no such tripping.

▪ Considering all aspects it was decided to run the Unit on single FD Fan first
during low load operation. Then it was implemented for full load operation
as well.

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Innovative Projects implemented

Running of Unit on single FD Fan:

▪ Modified earlier logics according to the new requirements like running of 4
Mills with Single FD fan.

▪ This resulted in saving of power consumption of 1 FD fan (800 KW) in each

unit. Considering the increase in current of 1 running FD, 15 Amp current
was reduced in each unit. Taking into account the PLF of 63 % for Stage-II
and sent out cost of KSTPS as Rs 3.04 the total saving of Rs. 46 Lacs achieved
in the year.

▪ In addition to current saving , it has provided better total air flow control as
blade pitch opening increased to 50 – 60% at full load. Fan efficiency
improved. We are able to maintain Oxygen during low load conditions.

▪ This is a unique practice adopted by KSTPS, Kota in the Power generation

sector.

Innovative Projects implemented

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Innovative Projects implemented

Running of Unit 3&4 with 3 CW pumps in place of 4 CWPs:

▪ Unit No. 3 & 4 of KSTPS, Kota were designed with 2 CWP(each 50 % duty)
with 1460 Kw motors . The units are having once through cooling system
with water intake directly from river.
▪ As per original BHEL design CW interconnection line was provided
between both units.
▪ Improvement in vacuum has been observed during winter seasons due to
fall in water temperature.
▪ Detailed analysis of vacuum v/s CW I/L temperature carried out.
▪ Finally it was decided to run Unit # 3&4 with 3 CW pumps and
interconnection valve open during winter season. This has resulted in
current saving of one CWP (approx. 139 Amps) with minimal drop in
vacuum. It resulted in total saving of Approx. Rs. 70 Lacs in the year.

Innovative Projects implemented

Drum Level Control Through BFP scoop (Zero DP across feed water valve) in
Unit# 3 to 7:

▪ Originally drum level auto control for 210 MW units was designed to
control drum level by throttling FW control valve through three element
control scheme.
▪ As per scheme DP across FW control station was maintained around 8
kg/cm2 by BFP scoops.
▪ Throttling of FW control valve lead to loss of energy.
▪ After detailed analysis , it was decided to modify the scheme to increase
the opening of FW control valve
▪ Accordingly the drum level control scheme modified to control drum level
by modulating BFP scoop through three element control scheme. FW
control valve has been kept full open.

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Innovative Projects implemented

▪ This has eliminated the throttling energy loss across FW control valve.
▪ This has resulted in reduction of BFP discharge pressure by 8 Kg/cm2. Due
to this saving in BFPs (4000 KW) current to the tune of 10 Amps has been
achieved in each unit which is around 90 KW per unit.
▪ This reflects to approximate saving of 75 Lacs per year taking into account
the PLF of 63 % for Unit 3 to 7 and sent out cost of KSTPS as Rs 3.04.
▪ Unit 1 & 2 are 36 yrs. old 110 MW LMZ units & still in operation and able
to achieve full load during suitable conditions.
▪ This scheme could not be implemented in Unit #1&2, but we have
replaced the old pneumatic actuators with Electro-Mechanical Actuators
for better control and reduced DP across FW water line set point to 5.5
kg/cm2 from 8 kg/cm2.

Innovative Projects implemented

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Utilization of renewable energy sources

The Government of Rajasthan has constituted a separate company for

development of Renewable energy resources as:

RAJASTHAN RENEWABLE ENERGY CORPORATION

LIMITED
The installed capacity of Wind and Solar Power Projects in Rajasthan State is as
follows:

1. Total Wind Power Installed 4139 MW

2. Total Solar Power Installed 2361 MW

Emission data

SPM (Mg/NM3) SO2 (Mg/NM3) NOX (Mg/NM3)

Actual Valve Actual Valve Actual Valve
Unit Applicable (during the Applicable (during the Applicable (during the
Norms month of Norms month of Norms month of
July'19) July'19) July'19)
I 150 83.02 600 589.00 600 389.50
II 150 90.78 600 594.20 600 445.90
III 150 127.98 600 565.40 600 472.20
IV 150 144.75 600 575.80 600 496.70
V 150 139.60 600 574.50 600 416.80
VI 150 147.50 600 - 600 -
VII 50 48.86 600 541.80 600 284.10

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Emission data

We have three ambient Air Quality monitoring stations in plant area to monitor
the air quality. We are already sending all the environment related data like
Stack PM, ETP data, River Water data etc to RPCB/CPCB servers online. We are
also displaying all stack & ETP Data for public at the Plant entrance.

Emission data

➢ KSTPS, Kota is presently complying with all the Environment norms.

However as per new environment notification dated 7th December 2015
KSTPS U # 1 to 6 has to reduce the SPM Level within 100 mg/NM3 . It
has also been made mandatory to install FGD, Cooling Tower, De-NOx
system in all the units.

➢ RVUN had awarded a consultancy to M/s FICHTNER Consulting

Engineers (India) Pvt Ltd for feasibility study and preparation of Detailed
project Report to meet out these new environment norms in all units of
KSTPS, Kota along with other power stations of RVUN. The Consultant
has submitted the DPR and the implementation is under process. We
are in process to implement all the measures within the scheduled time.

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Fly Ash Utilization

2016-17 2017-18 2018-19

Ash Generated (MT) 1538878.91 1568289.76 1818277.81

Cement Companies 1021310.4 1036798.7 1217787.02
Brick, Block & Tile Co. 229006.61 191021.11 221007.01
Utilization
Wet Ash Brick Kiln 301793 415079 412848
(MT)
Total 1552110 1642899 1851642
In Percentage 100.86 104.76 101.83

KSTPS, Kota is a very old plant, so a lot of ash was accumulated in Ash
Pond. With sustained efforts we have been able to utilize the ash from ash
pond as well. The Utilization of more than 100 % is due to this.

Team work, Employee Involvement and Monitoring

Daily Monitoring System at KSTPS

➢ Daily Plant meeting is being conducted of all senior officers of KSTPS Kota
which is chaired by Chief Engineer (KSTPS).
➢ Last day’s plant performance reports are presented before them.
➢ Fuel availability, Key parameters and various problems are reviewed
during the meeting.
➢ Discussions are held regarding the problems faced by different
departments.
➢ Necessary directions are issued for rectification of problems and measures
to be taken for performance improvement.
➢ A note of discussion is prepared indicating implementing agency for
different measures and it is widely circulated.
➢ The discussion notes are reviewed on weekly basis.
➢ We have a system where any employee can give his suggestion for
improvement, these are also discussed & if suited we implement it.

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Training Programs

➢ Conducting Training Programs by external industry experts are regular

feature at KSTPS, Kota.
➢ Training programs are conducted for all level of employees. This includes
Chief Engineer and goes upto Technical Staff and Contract Labour
engaged.
➢ KSTPS, Kota has a dedicated training center “K.C.Kasliwal Training
Institute” for conducting various training programs regularly.
➢ During Last FY 2018-19 total 65 No of Training programs were organized
at KSTPS, Kota and various outside places.
➢ Recently a Training was Conducted By IIM, Calcutta at Management
Development Center IIM Calcutta for Senior officers of RVUN on
“Emotional Intelligence at Work”

Training Programs

Major Training programs conducted at KSTPS, Kota during 2018-19 are:

➢ Introduction of Advancement in Rotary Air Preheater Technology
Conducted at Jaipur
➢ Steam Turbine & Generator Training Conducted By Siemens Ltd., Gurgaon.
at Vadodara
➢ Symphony Harmony DCS Training Conducted By ABB India Ltd., Bangalore.
at Bangalore
➢ Profitability through Energy Conservation & Efficiency Seminar Conducted
By CII (Confederation of Indian Industry), Jaipur at Jaipur
➢ Emission Control Technologies - Implementation, Monitoring &
Compliance Training Conducted By Centre for Science & Environment
(CSE), New Delhi

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Training Programs

➢ Industrial & Fire Safety for Thermal Power Plant Training Conducted By
National Safety Council, Mumbai at KSTPS, Kota
➢ Operational safety aspects of utility boilers Training Conducted By NPTI,
Badarpur at KSTPS, Kota
➢ GST, IFRS (IND AS), Income Tax, Limited Review and audit training
Conducted By Centre of Excellence of ICAI, Jaipur
➢ Induction Training Program for Newly Recruited Junior Engineers Training
Conducted By CBIP, New Delhi at Gurgaon
➢ Induction Training Program for Newly Recruited Assistant Engineers and
Junior Engineers Conducted By NPTI, Badarpur at Faridabad.
➢ Energy Efficiency Management in Power Station Training Conducted By
Efficient Powertech Solutions (P) Ltd., Delhi at KSTPS, Kota

Training Programs

➢ Maintenance Management System – Predictive and Reliability Centered

Maintenance Training Conducted By Efficient Powertech Solutions (P)
Ltd., Delhi at KSTPS, Kota.
➢ CW System including CW Pumps and Cooling Tower Training Conducted at
KSTPS, Kota.
➢ Aux power optimization and improvement Training Conducted at KSTPS,
Kota
➢ Partial loading Operation and Performance Optimization Training
Conducted at KSTPS, Kota.
➢ Strategies for Cost Effective Maintenance Management System in a Power
Station Training Conducted at KSTPS. Kota.
➢ 195 MW training simulator is also installed at KSTPS for dedicated
operation training to RVUN Engineers .

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Long Term vision on Energy Efficiency

Under Implementation:
➢ We have Planned to install VFD’s for ID Fan Motors in our Unit No. 6 & 7.
We have already received Regulatory Commission approval for
implementing this through additional capitalization.
➢ We have Planned to install Energy Accounting and Management System at
KSTPS. This will help in online monitoring of energy consumption all HT
Motors. We have already received Regulatory Commission approval for
implementing this through additional capitalization.
➢ Replacement of Air Pre Heater Seals with Soft Touch Seals to reduce Air
Ingress & Leakages.
➢ Installation of Acoustic Leak Detection System for early Boiler Tube
Leakage Detection and avoiding secondary damages.
➢ All Lighting Loads are being shifted to LED technology in phased manner.
➢ All Ceiling fans are being replaced with energy efficient 28 W Ceiling fans.

Long Term vision on Energy Efficiency

Future Planning:
➢ We are planning to install VFD’s on BFP’s and CEP’s of Unit 5,6 & 7.
➢ Principally decided to procure only Energy Efficient motors in future.
➢ The Environment Norms has changed. Our Units will not be meeting these
norms. A Consultancy was awarded for feasibility study and preparation of
Detailed project Report to meet these new environment norms to M/s
FICHTNER Consulting Engineers (India) Pvt Ltd for Our Unit # 5, 6 & 7. The
Consultant has submitted the DPR and the implementation is under
process.
➢ The Unit # 1 to 4 at KSTPS are very old. These do not meet many of the
upcoming environment norms. So A Consultancy was awarded for
feasibility study and preparation of Detailed project Report to meet these
new environment norms to M/s FICHTNER Consulting Engineers (India) Pvt
Ltd. The Consultant has submitted the DPR.
➢ We are planning to give consultancy for improvement in Unit # 3 & 4 so that
These Units can meet the Regulatory commission’s norms of SHR & APC.

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Awards

KSTPS has Received many meritorious awards various agencies. Recent

Achievements are listed below:
• KSTPS, Kota was awarded “Golden Shield” with certificate of merit by
Government of Rajasthan for best performance in the field of Energy
Conservation.

Awards

• The Centre for Science and Environment Green Ratings has awarded
us “Green Leaf” for Environment Protection.

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K.C.AGRAWAL, M.K.SOMANI,
CHIEF ENGINEER, SUPERINTENDING ENGINEER,
9413385679 9413349728
ce.ktps@rrvun.com se.comml. ktps@rrvun.com

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