Qpro 2016

Bhusawal Thermal Power
Station, Deepnagar
MAHAGENCO
BTPS WELCOMES
ALL OF YOU
FOR
QPRO-2016
10/11/16

Station, Deepnagar
BHUSAWAL THERMAL POWER

STATION PRESENTS ..
PERFORMANCE IMPROVEMENT OF
UNITS AND REDUCTION IN COST
OF GENERATION
10/11/16

Station, Deepnagar
Unit-2 : 210 MW
10/11/16
Unit-3 : 210 MW

Station, Deepnagar
U4 & U5 - 2 x 500 MW
10/11/16

Station, Deepnagar
BOARD OF DIRECTORS
VISION O MAHAGENCO
Shri Vipinji Shrimali

Managing Director (MSPGCL)
Shri Vijay Singh

Director (Operations, MSPGCL)
10/11/16
Shri J,Shrinivasan
-Director Finance,
MSPGCL)
Shri C.S Thotwe

Executive Director )

Station, Deepnagar
Our young, dynamic and

charismatic leader with a vision
to create a sphere of excellence
at BTPS and who inspires us to
do more.
Shri Abhay A Harne

Chief Engineer, BTPS
10/11/16

Station, Deepnagar
ABOUT MAHAGENCO IN BRIEF
MAHAGENCO has the highest overall generation capacity and the highest
thermal installed capacity amongst all the State Power Generation
Utilities in India. In terms of installed capacity, it is the second highest
generation company after NTPC.
It has a generation capacity of 12077MW comprising 8640 MW

Thermal, 2585MW Hydel, 672 MW Gas Turbine and 180MW Solar
established by GoM under the Central Electricity Act -2003 with the
principal objective of engaging in the business of generation of electricity
to produce the cheapest power to consumers in the State.
It generates power for more than 2,00,00,000 end consumers in
Maharashtra at economical and affordable rates.
It is in process to install its prestigious and one of the largest Sewage

Treatment Plant at Bhandewadi, Nagpur. This plant is expected to deliver
130 Million Litres per day to MAHAGENCOs Koradi Project 3x660MW .
10/11/16
7 Water
This plant will be a milestone in India
regarding Waste

Station, Deepnagar
Bhusawal TPS Credentials

ISO 9001-2008 for Quality
14001-2004 for Environment
Management System
18001- 2007 for OHSAS
Now in process for acquiring
50001-EnMS-2011 Energy
Management Standard
10/11/16

Station, Deepnagar
Bhusawal TPS QEHS Objectives
10/11/16
To achieve Generation Targets decided in

MORM.
To reduce the no. of breakdowns of
auxiliaries.
To reduce the consumption of fuel oil.
To increase green belt in and around plant
premises.
To maintain stack emission below
normative limits.
To reduce energy consumption
To achieve nil accidents in plant.
To increase awareness and enhance skill,
knowledge and competence of staff,
contractors and sub contractors
9

Station, Deepnagar
Quality,
Environment, Health & Safety

Policy
We, at Bhusawal Thermal Power Station of

MAHAGENCO,
engaged
in
Generation
of
Electricity
are
committed
for
continual
improvement
of
our
(IMS)
Integrated
Management System by adhering to applicable
legal requirements, conserving the resources,
protecting
Environment
and
ensuring
Occupational Health & Safety of our employees
as well as contract labours for enhancing
stakeholders satisfaction
10/11/16
10

Station, Deepnagar
One of the oldest power station

of
MAHAGENCO.
BTPS Situated at
the bank of River
Tapi. and 8 Km
away from Bhusawal
town known as
Deepnagar. BTPS is on
Asian Highway no.
46, having @ 705
10/11/16
hectares Area.
11

Station, Deepnagar
The huge coal mines in Vidarbha & Madhya Pradesh are
near to Bhusawal TPS.
The water source is from Suryakanya Tapi River, one of

the main Rivers in Western Region, having capacity to
provide sufficient water bed required for
Power Plant
throughout the year.
Bhusawal is one of the Major Railway Junction on

Central Railway and well connected to all major cities of
India.
10/11/16
12

Station, Deepnagar
Bhusawal TPS first unit of capacity 62.5 MW was

commissioned on 17th July 1968.
The current Installed capacity of Bhusawal TPS is

1,420 MW.
10/11/16
Unit
No
Capacit
y
(MW)
62.5
17th July 1968
Unit Retired -15th Dec 2010
210
30
Was under Economic Shutdown

from 13th Sept 2014 and resumed
on bar 31.10.2015
Date of
Commissioning
th
Aug 1979
210
4th May 1982
500
16th Nov 2012
500
3rd Jan 2014
Remark
Unit -3 was under shutdown from

20-04-2015 to 12-06-2015 due to
non scheduling by SLDC.
13

Station, Deepnagar
To Generate the Electricity, Bhusawal TPS use coal

form WCL, MCL, SECL and blending with Imported
coal.
Imported Coal used for 2 X 500 MW units only.
Daily coal requirement of 2 X210 MW coal is @

7,000 MT and 2X500 MW is 16,000 MT, i.e. Total
requirement is 23,000 MT.
Bhusawal Thermal
Power Station yearly coal
Coal
Sr. No
Linkage Quantity (LMT)
Linkage is asCompany
below:
10/11/16
WCL
28.00
SECL
19.32
MCL
19.32
Total
66.64
14

Station, Deepnagar
BTPS Unit-2 Performance for last

three years
Unit-2
YEAR
FY 201213
FY 201314
FY 201415
FY 201516
10/11/16
Gener PLF %
ation as per
(Mus) MERC
norms
921.7
36
959.8
89
275.0
9
342.9
7
80
PLF
(%)
APC
(Mus)
52.65
APC % APC (%)

GCV
Heat
SOC
SOC
as per
(Kcal/kg Rate (ml/Kwh (ml/kw
MERC
)
(Kcal/kw ) as per
h)
norms
h)
MERC
norms
103.88
11.27
3009
2834
4.31
51.07
121.96
28.78
78.51
10.75
2.00
12.71
2756
2789
49.86
18.13
2470
2733
3.62
41.03
11.96
3217
2727
2.16
15
6.21

Station, Deepnagar
Bar Chart showing Generation, PLF and APC of
unit 2
1200.00
90.00
Unit-2
80.00
1000.00
78.51
800.00
60.00
52.65
50.00
51.07
40.00
400.00
30.00
28.78
18.13
200.00
11.27
12.71
11.96
20.00
10.00
0.00
0.00
FY 2012-13
Generation (Mus)
FY 2013-14
PLF MERC
(%)
FY 2014-15
FY 2015-16
PLF & APC
Generation
600.00
70.00
APC (%)
Unit-2 was under Economic Shutdown from date 13-09-2014 to 31-10-2015.
10/11/16
16

Station, Deepnagar
BTPS Unit 3 Performance for last

three years
Unit-3
YEAR
FY
2012-13
FY
2013-14
FY
2014-15
FY
2015-16
10/11/16
PLF %
as per
Genera MERC
tion norms
(Mus)
1118.5
05
1124.4
4
824.46
5
957.06
80
PLF
MERC
(%)
APC
(Mus)
63.03
125.62
60.41
135.46
44.39
85.51
APC %
SOC
as per
Heat (ml/Kw
GCV
SOC
MERC
h) as
Rate
(ml/kw
norms APC (%) (Kcal/kg (Kcal/kw per
)
h)
MERC
h)
norms
11.23
3117
2751.
12.05
2763
2761
109.98
13.34
2584
2718.
2.54
102.94
10.76
3152
2724
0.64
10.75
3.07
2.00
4.67
17

Station, Deepnagar
Bar Chart showing Generation, PLF and

APC of unit3
1200.00
Unit-3
85.51
80.00
1000.00
70.00
63.03
60.41
60.00
50.00
600.00
44.39
40.00
400.00
200.00
PLF & APC
Generation
800.00
90.00
30.00
20.00
12.05
11.23
13.34
10.76
0.00
10.00
0.00
FY 2012-13
FY 2013-14
Generation (Mus)
PLF MERC
FY 2014-15
(%)
FY 2015-16
APC (%)
B.T.P.S. Unit-3 was under shutdown from 20-04-2015 to 12-06-2015 due to non scheduling by SLDC.
10/11/16
18

Station, Deepnagar
BTPS Stage-II Performance for

last three years
Stage-II
YEAR
FY
13
FY
14
FY
15
FY
16
PLF %
as per
MERC
Genera
norms
tion
PLF (%)
(Mus)
2012- 2040.2
41
2013- 2084.3
29
2014- 1099.5
55
2015- 1300.0
3
10/11/16
80
APC
(Mus)
55.45
229.50
56.65
257.43
29.89
159.84
83.86
143.97
APC %
as per
MERC
norms
10.75
Heat
SOC
Rate
(ml/K
(kcal/K
Heat
wh)
GCV
SOC
wh) as
as
Rate
APC (%) (Kcal/k
(ml/kwh
per
(Kcal/kw per
g)
)
MERC
MERC
h)
norms
norm
s
11.25
3066
2788
3.634
2791
12.35
2759
2764
2775
14.54
2554
2743
2721
11.07
3168
2739
2724
5.392
2.00
2.807
1.022
19

Station, Deepnagar
Bar Chart showing Generation, PLF and APC of
Stage II units
Stage-II
90.00
83.86
Generation
2000.00
1500.00
80.00
70.00
57.84
60.00
55.69
50.00
40.00
1000.00
PLF & APC
2500.00
40.00
30.00
20.00
500.00
12.35
11.25
14.54
11.07
0.00
10.00
0.00
FY 2012-13
FY 2013-14
Generation (Mus)
PLF MERC
FY 2014-15
(%)
FY 2015-16
APC (%)
After ESD & AOH Unit-2 synchronized on dated 31-10-2015

B.T.P.S. Unit-3 was under shutdown from 20-04-2015 to 12-06-2015 due to
non
scheduling by SLDC.
10/11/16
20

Station, Deepnagar
Bar Chart showing CV & PLF of Stage II units
BTPS 210 MW CV Vs PLF
GCV (Kcal/kg)
3500
90.00
80.00
70.00
60.00
50.00
40.00
30.00
20.00
10.00
0.00
3000
2500
2000
1500
1000
500
0
FY 2012-13
10/11/16
PLF (%)
FY 2013-14
FY 2014-15
FY 2015-16
21

Station, Deepnagar
Heat Rate
SOC
APC
Stage II Performance FY 2015-16

2800
12.27
14.00
12.75
12.48
11.67
11.92
12.00
11.07
2758
10.50
2748
9.98
10.00
2731
2719
2711
8.00
2700
2686
APC (%)
SOC(ml/Kwh
Heat Rate
2700 Kcal/Kwh
2694
6.00
4.32
4.00
1.74
0.49
2600
42095
10/11/16
0.75
0.56
42156
42186
0.98
0.27
42217
42248
42278
42309
2.00
0.90
0.00
42339
22

Station, Deepnagar

three years
Unit-4
YEAR
FY
13
FY
14
FY
15
FY
16
10/11/16
2012201320142015-
PLF
as
Genera
per
APC
tion
PLF (%)
MERC
(Mus)
(Mus)
Norm
s%
908.63
57.84
81.81
7
2134.4
55.69
194.81
46
85
2600.1
40.00
181.015
89
2970.5
83.86
189.37
05
APC %
as per
MERC
Norms
APC
(%)
Heat
GCV
SOC
Rate
(Kcal/k
(ml/kw
(Kcal/
g)
h)
kwh)
9.00
3720
2649 3.80
9.13
3108
2699 5.66
6.96
3030
2456 0.84
6.38
3276
2430 0.36
23

Station, Deepnagar

APC of unit4
3500
100.00
Unit-4
3000
92.07
2500
2000
60.00
64.34
62.94
50.00
48.73
40.00
30.00
1000
9.00
9.13
6.96
6.38
20.00
10.00
0.00
FY 2012-13
Generation (Mus)
10/11/16
80.00
70.00
1500
500
90.00
FY 2013-14
FY 2014-15
PLF (%)
FY 2015-16
APC (%)
24

Station, Deepnagar

three years
Unit-5
YEAR
PLF %
Genera
as per
tion
PLF (%)
MERC
(Mus)
Norms
FY
0
2012-13
FY
643.9
2013-14
3
FY
2695.
2014-15 92
FY
2563
2015-16
10/11/16
APC
(Mus)
SOC as
APC%
Heat
per
GCV
SOC
as per
Rate
MERC
APC (%) (Kcal/k
(ml/kw
MERC
(Kcal/kwh Nor
g)
h)
Norms
)
(ml/kw
h)
77.93 49.47
85%
7.68
3118
2656
0.84
69.88 199.74
7.41
2925
2502
0.90
79.21 164.30
6.41
3277.
99
2420
0.55
25

Station, Deepnagar

APC of unit4
3000
2500
90.00
Unit-5
79.21
77.93
70.00
69.88
2000
60.00
50.00
1500
40.00
1000
30.00
20.00
500
7.68
7.41
6.41
FY 2013-14
FY 2014-15
FY 2015-16
10.00
0.00
Generation (Mus)
10/11/16
80.00
PLF (%)
APC (%)
26

Station, Deepnagar
BTPS Stage-III Performance for last

three years
Stage-III
YEAR
FY
13
FY
14
FY
15
FY
16
10/11/16
Generati
PLF (%)
on (Mus)
Normati
Heat
GCV ve Heat
SOC
Rate
(Kcal/k Rate
(ml/kw
(Kcal/k
g)
(kcal/K
h)
wh)
wh)
APC
(Mus)
APC
(%)
62.94
81.81
9.00
3720
2425
2649
3.80
53.07
244.28
8.79
3110
2425
2691
4.54
66.99
380.75
7.19
2554
2425
2721
2.81
85.64
353.67
6.39
3127
2434
2717
1.25
2012908.637
2013- 2778.37
6
2014- 5296.10
9
2015- 5533.50
5
27

Station, Deepnagar

APC of Stage III units
6000
Stage-III
85.64
80.00
5000
4000
70.00
66.99
62.94
60.00
53.07
50.00
3000
40.00
2000
30.00
20.00
1000
9.00
8.79
7.19
6.39
10.00
0.00
FY 2012-13
FY 2013-14
Generation (Mus)
10/11/16
90.00
FY 2014-15
PLF (%)
FY 2015-16
APC (%)
28

Station, Deepnagar
BTPS 500 MW CV Vs PLF
4000
GCV (Kcal/kg)
85.64
3500
3000
2500
80.00
60.00
53.07
50.00
2000
40.00
1500
30.00
1000
20.00
500
10.00
0.00
FY 2012-13
10/11/16
90.00
70.00
66.99
62.94
PLF (%)
FY 2013-14
FY 2014-15
FY 2015-16
29

Station, Deepnagar
Heat Rate
SOC
APC
Stage III Performance FY 2015-16

2600
9.00
7.78
6.29
6.42
6.98
6.77
6.28
2510
2500
2479
Heat Rate Kcal/Kwh
2470
2432
2423
4.00
3.00
2385
2.00
1.39
1.13
0.37
10/11/16
5.00
2389
2300
42095
5.81
6.00
2450
2428
2400
7.00
6.19
APC (%)
SOC(ml/Kwh
6.61
8.00
42125
0.52
42156
0.60
42186
0.43
42217
0.05
42248
42278
0.10
1.00
0.15
42309
0.00
42339
30

Station, Deepnagar
PERFORMANCE OF STAGE II UNITS

Bar Graph of Energy Charges for Stage II units
4
3.5
3
2.5
2
1.5
1
0.5
0
3.14
3.72
3.47
2.94
Normative EC (Rs/KWh)
Actual EC(Rs/Kwh)
Unit 2 & 3 Normative Actual

EC (Rs/KWh) EC(Rs/Kwh
)
10/11/16
FY 2012-13
FY 2013-14
FY 2014-15
FY2015-16
3.05
3.28
3.5
2.92
3.14
3.47
3.72
2.94
31

Station, Deepnagar
PERFORMANCE OF STAGE III UNITS

Bar Graph of Energy Charges for unit4
4
3.5
3.21
3.42
3.08
2.78
Unit 4 Normative EC (Rs/KWh)
Unit 4 Actual EC(Rs/Kwh)
2.5
2
1.5
1
0.5
0
FY 2012-13
FY 2013-14
FY 2014-15
Unit 4
10/11/16
FY 201213
FY 201314
FY 201415
FY 2015-16
Normative Actual
EC
EC(Rs/Kw
(Rs/KWh) h)
3.04
3.21
2.95
3.42
3.02
3.08
32

Station, Deepnagar
PERFORMANCE OF STAGE III UNITS

Bar Graph of Energy Charges for unit 5
4
3.5
3.42
3.08
2.78
Normative EC (Rs/KWh)
Actual EC(Rs/Kwh)
2.5
2
1.5
1
0.5
0
FY 2013-14
FY 2014-15
Unit 5
10/11/16
FY 201314
FY 201415
FY201516
FY 2015-16
Normativ Actual
e EC
EC(Rs/Kw
(Rs/KWh) h)
2.95
3.42
2.95
3.08
2.37
2.78
33

Station, Deepnagar
BEST POWER STATIONS MAHAGENCO
DURING Dec 2015 ( Nov 2015 )
STATION
CAPACI
TY
(MW)
BHUSAWAL 1420
RANK
PLF (%)
1st / 3rd
PARAS
500
2nd / 1st
NASHIK
630
3rd / 2nd
1340
4th / 4th
83.15 /
82.98
82.18 /
86.09
81.21 /
83.21
72.90 /
74.43
KHAPERKH
EDA
10/11/16
34

Station, Deepnagar
BEST UNITS IN MSPGCL BASED ON

PLF (%) Dec - 2015 / (Nov -2015)
STATION
UNIT
CAPAC
ITY
RANK
PLF (%)
PCQ
L D LOSS
%
NASHIK
UNIT
5
210
1/1
91.67 /
91.93
0.58
7.69
BHUSAWAL
UNIT
5
500
2/3
86.46 /
88.01
0.07
12.34
CHANDRAP
UR
UNIT
4
210
3/5
86.31 /
85.98
1.02
12.67
BHUSAWAL
UNIT
4
500
4/2
86.10 /
89.05
0.28
12.00
CHANDRAP
UR
UNIT
3
210
5 / 11
84.80 /
76.69
0.83
14.00
PARAS
UNIT
4
250
6/4
83.95 /
86.97
1.15
12.14
CHANDRAP
UR
UNIT
7
500
7/7
81.95 /
81.94
4.64
12.14
NASHIK
UNIT
4
210
8/8
81.89 /
81.46
1.43
8.84
10/11/16
35

Station, Deepnagar
Challenges faced by BTPS over

last three years
BTPS had faced many challenges in achieving sustainable

generation over the past three years, the major one being poor quality
coal supply and also reduced coal linkage. The units are designed for a
coal GCV of 5000kcal/kg and there has been a steady decline of
received coal GCV from 3066 to 2554 kcal/kg from 2012-13 to 201415. This directly affects the plant performance in terms of its PLF
deterioration , higher Auxiliary Consumption, more forced outages, High
R & M , poor Unit Heat Rate, parameters not meeting MERC norms and
as a result increased cost of generation.
In the Rainy Season period the coal received is wet, sticky & muddy.
This further deteriorates the overall performance of the plant.
Our biggest challenge was economic shutdown of unit 2 for optimized
usage of available coal and other resources, as directed by the MERC
10/11/16
36more.
and non scheduling of unit 3 by LDC due to generation cost being

Station, Deepnagar
Coal supply by coal companies
Mahagenco has signed Fuel Supply agreements (FSAs) with different

subsidiaries of CIL viz WCL, MCL, SECL & SCCL for coal supply.
There is a major shortage of domestic coal supply.
The problem has been aggravated in the last few years and overall
materialization of coal is down by almost 30% to 34% as compared to
the required quantity.
Coal realization and shortage in last four years for BTPS is as below:
Year
2013-14
2014-15
10/11/16
2015-16
(upto Dec15)
Linkage
(LMT)
Receipt Materializatio Shortag

(LMT)
n (% )
e (%)
517628
8650000
59.84
40.16
4
570759
9430000
60.53
39.47
4
6105000
475870
5
77.95
22.05
37

Station, Deepnagar
Coal Company wise Percentage Materialization

Company
WCL
2013-14
2014-15
Linkage
4012000
3546000
2015-16
(till Dec15)
2113000
Receipt
2765908
3061421
2714860
68.94
86.33
128.48
Linkage
3646000
4623000
1662000
Receipt
1145702
1379913
851145
31.42
29.85
51.21
Linkage
1668000
Receipt
394143
195408
675564
% Materialization
Linkage
0.00
992000
0.00
1261000
40.50
662000
Receipt
870531
1070852
517136
87.76
84.92
78.12
Particulars
% Materialization
MCL
% Materialization
SECL
HGIC
% Materialization
10/11/16
38

Station, Deepnagar
Coal Company wise Percentage Materialization

%
10000
90
9000
80
8000
70
7000
60
6000
T
5000
4000
M
T
40
30
3000
2000
20
1000
10
10/11/16
50
2013-14
2014-15
2015-16 (upto Dec-15)
39
M
a
t
e
r
i
a
l
i
z
a
t
o
n

Station, Deepnagar
Creative
ideas
generation
BTPS performance shows a meteoric rise in performance in

the FY 2015-16 due to many decisive and concrete steps
taken at Corporate level and local management and
developing creative solutions.
10/11/16
Improvement in Coal Quality due to receipt of high GCV coal from SECL and
subsequent blending of coal with MCL coal resulting in a net GCV of 32003500kcal/kg. Better the coal GCV, better is the heat input and so better is the
performance. This has been possible due to continuous and rigorous correspondence
with the coal managers at the respective mines.
Improvement in Coal linkage and materialization again due to rigorous
communication and stringent corporate decisions in this aspect.
Proper coal management- Lower elevation coal mills i.e B& C mills are being fed
with coal of superior quality of SECL & imported coal with less ash content and
higher elevation mills are being fed with coal of inferior quality i.e MCL coal is fed to
top mills . This results in better heat absorption in the water wall zones and better
heat utilization and so improved heat rat
We have started third party sampling of coal at the colliery end and received
end for better coal quality receipt.
40

Station, Deepnagar
Creative
ideas
generation
10/11/16
Various State level Performance improvement

Committees formed like
BTL Task Force Committee
CHP Improvement Committee
Heat Rate Improvement Committee
Coal Mill Performance Improvement Committee
Electrical Protection Committee
Committee of Water Chemistry Monitoring &
Consumption Optimization
ESP & Ash Handling Plant Improvement Committee .
Dedicated HO expert services groups for each power
stations for O&M related issues
The Annual Overhauls of units 2 and 3 were carried out
which resulted in performance improvement
41

Station, Deepnagar
BFP Old
Cartridge.
Modified Energy Efficient New

10/11/16Cartridge during AOH of set.
42

Station, Deepnagar
BTPS BEST O&M PRACTICES
1.
2.
Steam, powder coal and DM water and compressed air zero

leakages maintained by adopting best O&M practices; hence
benefiting into maintaining optimum normative parameter.
Coal mill performance tests are regularly scheduled to identify
any deviation. Based on the results of the tests coal cycle

maintenance is carried out. This has benefited into minimum coal
mill reject & reduction in un burnt in Bottom/ Fly ash . Coal mill
reject for this FY is @ 0.50 % .
3.
By adopting best O&M practices SOC is minimized.
4.
By utilizing only good quality of available WCL coal, PLF of U-3 is

maintained @ 80%, resulting into variable cost reduction.
5.
At 210 MW units by online sulphuric acid dozing in controlled

manner once in a week to achieve pH range 7.8-8.3, the vacuum
is maintained at the required value, with single CW pump in
service. Benefited into reduction in Auxiliary consumption.
6.
At 210MW units - All CWCT fan of both the units solid FRP blades
replaced by new hollow FRP blades successfully. There is a
reduction in current @ 30 Amp per fan.
10/11/16
43

Station, Deepnagar
BTPS BEST O&M PRACTICES
Building of dry coal Stock before monsoon:
The coal received in monsoon season is generally too wet which
causes choke up and heavy oil consumption. To overcome this, all
the available coal stacked in trapezoidal shape and covered with
tarpaulin. This dry coal is blended with the received wet coal to
minimized the problems due to wet coal.
10/11/16
44

Station, Deepnagar
Innovative Design, Erection and Commissioning of new conveyor belt of
17m/500TPH capacity by Quality Circle Team of BTPS
SAAHAS QC TEAM WITH ALL SECTION HEADS
10/11/16
45
45

Station, Deepnagar
Coal Handling Plant (CHP) plays a vital role in thermal power station, main
objectives being
Coal received through railway wagon from collieries viz.
MCL,WCL,SECL and
Imported Coal.
Coal Wagons unloaded at Wagon Tippler and through apron feeder

conveyed to crusher, to Crushed up to 20mm size, free from foreign
material and fed to coal bunkers through series of conveyor belts.
Creating coal stock at Stacker/ Reclaimer yard during emergencies
and when no wagons are available for unloading .
Unloading Coal rake in free time (06hrs) to avoid the demurrage
charges.
Maximum bunker level at all the time for maximum MW generation.
BTPS
Coal Handling Plant has designed, erected and
commissioned a new conveyor of 17m/ 500TPH capacity utilizing
steel material and spares from scrap to address the problem of
frequent unavailability of reclaiming stream through the
medium
of Quality Circle
10/11/16
46
46

Station, Deepnagar
BTPS Best O&M Practices

C&I 500 MW AHP Improvement:
1. Pneumatics cylinder of
Ash intake valve below
ESP hoppers having
Bore 63mm x Stroke 152
mm replaced with new
cylinder having Bore 80
mm x Stroke 152mm
which helps effective
evacuation.
10/11/16
2. Modification of ALI
sensors by replacing
old sockets with new
SS flange due to
which reliability of
level sensor
indication improved.
47

Station, Deepnagar

AHP 500 MW: Dry Ash Extraction System
Sr
No
1
10/11/16
Major Issue
Inadequate
closing of
pneumatic ash
valves below
ESP hoppers
since
commissioning
Poor fluidizing /
poor ash flow
Action Taken
Replacement of
old 6 mm valve
springs with new
7 mm diameter
valve spring.
Benefits
Positive closing of
ash intake valves
which prevent ash
leakages & ash line
choke ups.
1)Replacement of Easy ash flow

existing
without poking.
fluidizing hoses
with new to
hoses.
2)All fluidizing pad
leakages attended
48

Station, Deepnagar

Sr
No
3
10/11/16
Major Issue
Action Taken
Buffer Hopper
frequent bags
failure.
1)All collar type

bags replaced
with snap type
bags.
2)Hopper
modified with bag
arresting screen.
3)Locking ring
provided at bag
holding mother
plate.
4) Purging lines
equipped with
Benefits
1)Slipping out &
falling of bags
almost prevented.
2)In case of bags
falling, it get
collected in upper
zone only & thus
prevented from
getting choke up of
buffer hopper.
3) Slipping out &
falling of bags
almost prevented.
4) Filter bags &
49

Station, Deepnagar

Sr
No
4
10/11/16
Major Issue
Vacuum pumps
failure.
Action Taken
Air washery units

provided before
vacuum pumps.
Fluidizing valve Uplifting of
frequent failure fluidizing line
& inconvenient along with valves
to
and valve position
maintenance.
changed.
Buffer hopper
Purging solenoid
purging
valves provided
solenoid valve
with 40 NB
leakage
modified isolating
attending
valves.
problems
Branch
1 Ash draining
isolating
valve incorporated
Benefits
Ensured clean air in
the vacuum pumps
Valve failure
minimized & became
easy for
maintenance.
No need to isolate
ESP pass for
attending leakages.
Ease of maintenance
with reduced
maintenance time.
Smooth operation of
50
the valve,

Station, Deepnagar
ESP AREA
BEFORE
MODIFICATIONS
10/11/16
AFTER MODIFICATIONS
51

Station, Deepnagar
TRAINING AND SKILL DEVELOPMENT OF EMPLOYEES
10/11/16
At Training Sub Centre, we are

conducting Refresher Courses for Plant
engineers/Technicians/office/Security/Ho
spital/Administration and Accounts/ Fire
Fighting Staff of 210MW and 500MW , 32
Weeks On Job Induction Level Training
for Engineers and 34 Weeks OJT for
Technicians as per Annual Training
Calendar as well as External Training
Courses, where trainees are deputed to
other reputed Training Institutes like
ESCI Hyderabad, NITIE, CLI- Mumbai,
52
NPC, workshop on PAT etc.

Station, Deepnagar
We have also imparted training to

Chemists
on
Laboratory
Quality
Management and Internal Audit which
assumes a lot of significance
as
laboratory accreditation Standard ISO
17025 : 2005 for general testing Lab
emphasize on Quality Assurance and
decisions are made based on the test
report of laboratories. We have a Coal
Testing Laboratory at BTPS wherein coal
samples are tested for their quality /
compositions by Proximate and Ultimate
10/11/16 analysis methods and to acquire NABL
53

Station, Deepnagar
Separate energy meter has been

installed at TSC supply (incoming
feeder). At TSC, we are following the
policy of going green by initiating
the energy saving activities
We have replaced 14 Nos of previously
used fluorescent
tubes consuming
60W per tube
with LED tubes
resulting in energy saving 957.6KWh
in the last 6 months and also saving
the environment from CO2 pollution
10/11/16
54

Station, Deepnagar
10/11/16
TSC
is
also
regularly
preparing
manuals and handbooks for technical
as well as personality empowerment
of the engineers and allied staff
working in the plant and offices.
Recently
a
handbook
on
Plant
Performance
Optimization
and
Stress Management was prepared by
TSC which was lauded by all and won
recognition by the MD and was
awarded with cash incentive of Rs
2000/- and Certificate of Appreciation
55
by CGM (Technical), Mumbai

Station, Deepnagar
A significant milestone in the achievements of
TSC is in the area of Quality Circles . TSC took
the initiative to set up and establish 15 QCs in
BTPS.
At the 26th Chapter Convention Quality Concept
2015 Nagpur Chapter held on 13th September
2015.
Team Co-ordinator
Ms Shoba Subramaniam Dy.EE (TSC) has won the
BEST Quality Circle Poem Award 2015.
PRAYAS QC Won the following Awards
Gold Award in CCQC Nagpur chapter 2015 on
topic Water Saving
Mahindra & Mahindra Rolling Trophy for Best
QC in CCQC-2015 Nagpur Chapter
10/11/16
56

Station, Deepnagar
Best QC Award in Inter-Mahagenco QC competition

held at Koradi Training Centre in Nov 2015 with cash
prize of Rs 31,000/ Excellence Award at NCQC-2015
Some of the awards received by our other QCs are
Team Aqua Won the Gold Award in CCQC Nagpur
chapter 2015 on topic High Turbidity in non DM
sump due to filter backwash turbid water mixing in
raw water inlet.
Jan 2015- 2nd Prize in BTPS competition
QPRO-2015 at Institute of Engineers, Nagpur
presentation case study first Par Excellent
10/11/16
SANKALP QC Won the Gold Award in CCQC Nagpur

chapter 2015 on topic Frequent Failure of ASH level
Sensor at TPS
57

Station, Deepnagar
Inauguration of POG Handbook at HO, Mumbai by Dir

(Op) and CE, BTPS
10/11/16
58

Station, Deepnagar
Felicitation of PRAYAAS QC team on winning the 2nd Best QC award

at Koradi Training Centre in Nov 2015. TSC, BTPS was coordinator
and guide for the event, news report in local newspaper
10/11/16
59

Station, Deepnagar
Felicitation of PRAYAAS QC team on winning the Mahindra and

Mahindra Rolling Trophy award for best QC at CCQC, Nagpur
Chapter in Sept 2015. Ms Shobha Subramaniam, DyEE, BTPS was
team coordinator for the event, news report in local newspaper
10/11/16
60

Station, Deepnagar
Gold Award presented to SANKALP QC, BTPS team at CCQC,

Nagpur Chapter . Ms Shobha Subramaniam, DyEE, BTPS was
team
coordinator
for
the
event
10/11/16
61

Station, Deepnagar
Mahindra & Mahindra Rolling Award presented to PRAYAAS QC,

BTPS team at CCQC, Nagpur Chapter . Ms Shobha Subramaniam,
DyEE, BTPS was team coordinator for the event
10/11/16
62

Station, Deepnagar
At NCQC-2015 BTPS TSC coordinator nominated as Judge for QC

teams
10/11/16
63

Station, Deepnagar
CSR Activities
Bhusawal TPS is committed towards contribution of

social and
economical
development of the project
affected communities.
Under this program regular CSR activities following

activities are taken:
10/11/16
Supply of drinking water and street lighting to

nearby villages.
Providing
approach
roads
to
the
affected
villages.
Felicitating 10th and 12th students of nearby
village.
Helping in renovating schools, Hospitals etc.
Training to the PAPs and BTRI under CSR
schemes.
Implementation of Swatch Bharat Abhiyan. 64

Station, Deepnagar
CSR Activities
10/11/16
65

Station, Deepnagar
Vardhapan day Celebrated at BTPS
10/11/16
66

Station, Deepnagar
Best Employee Award
To motivate the employees to implement their

innovative ideas/work for benefiting in the plant
performance the Best employee Award scheme has
been implemented from May-2015.
Under this scheme the Best Employee for the month

is selected and awarded during the monthly ORT
meeting.
10/11/16
67

Station, Deepnagar
10/11/16
68

Station, Deepnagar
Acknowledgements :
I express my sincere gratitude for the guidance, help and support of
Shri Harne Chief Engineer, BTPS
Shri Kothule - Dy.CE-210MW
Shri Kumarwar DyCE-500MW
Shri Masram -S.E(Admin)
Shri Petkar -SE(Trg)
Shri D.B.Jogdand (E.E-Trg)
Ms Neha Lohar-A.E-POG 210MW for furnishing all information in time.
Shri N.H.Deore-JE-POG 500MW for helping with all the data
10/11/16
69

Station, Deepnagar
THANK YOU
10/11/16
70

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Bhusawal Thermal Power

Bhusawal Thermal Power

BHUSAWAL THERMAL POWER

Bhusawal Thermal Power

Bhusawal Thermal Power

Bhusawal Thermal Power

Shri Vipinji Shrimali

Shri Vijay Singh

Shri C.S Thotwe

Bhusawal Thermal Power

Our young, dynamic and

Shri Abhay A Harne

Bhusawal Thermal Power

It has a generation capacity of 12077MW comprising 8640 MW

It is in process to install its prestigious and one of the largest Sewage

Bhusawal Thermal Power

Bhusawal TPS Credentials

Bhusawal Thermal Power

To achieve Generation Targets decided in

Bhusawal Thermal Power

Environment, Health & Safety

We, at Bhusawal Thermal Power Station of

Bhusawal Thermal Power

One of the oldest power station

Bhusawal Thermal Power

The water source is from Suryakanya Tapi River, one of

Bhusawal is one of the Major Railway Junction on

Bhusawal Thermal Power

Bhusawal TPS first unit of capacity 62.5 MW was

The current Installed capacity of Bhusawal TPS is

17th July 1968

Unit Retired -15th Dec 2010

Was under Economic Shutdown

4th May 1982

16th Nov 2012

3rd Jan 2014

Unit -3 was under shutdown from

Bhusawal Thermal Power

To Generate the Electricity, Bhusawal TPS use coal

Imported Coal used for 2 X 500 MW units only.

Daily coal requirement of 2 X210 MW coal is @

Bhusawal Thermal Power

BTPS Unit-2 Performance for last

APC % APC (%)

Bhusawal Thermal Power

PLF & APC

Unit-2 was under Economic Shutdown from date 13-09-2014 to 31-10-2015.

Bhusawal Thermal Power

BTPS Unit 3 Performance for last

Bhusawal Thermal Power

Bar Chart showing Generation, PLF and

PLF & APC

Bhusawal Thermal Power

BTPS Stage-II Performance for

Bhusawal Thermal Power

PLF & APC

After ESD & AOH Unit-2 synchronized on dated 31-10-2015

Bhusawal Thermal Power

BTPS 210 MW CV Vs PLF

Bhusawal Thermal Power

Stage II Performance FY 2015-16

Bhusawal Thermal Power

BTPS Unit 4 Performance for last