EBERGY CONSERVATION BACK PRESSURE TURBINE

VARIABLE COST OF UP & UTTARAKHAND

SL NO. Station Paisa/ Unit Station Paisa/ Unit 1 SALAL HPS 48.00 CHIBRO (YAMUNA) 27.00

2 URI HEP 81.00 KHATIMA HPS 30.00

3 CHAMERA HEP 107.00 KULHAL HPS 31.00

4 TANAKPUR HEP 115.00 CHILLA HPS 34.00

5 SASAN 128.50 KHODRI HPS 34.00

6 SINGARAULI STPS 131.00 DHAKRANI HPS 36.00

7 SIGARAULI STAGE III 136.60 RAMGANGA HPS 37.00

8 VISHUNUPRAYAG 140.00 DHALIPUR HPS 40.00

9 RIHAND STAGE II 143.70 SALAL HPS 102.00

10 DHAULI GANGA HEP 145.00 SINGARAULI STPS 131.00

11 NATHPA JHAKRI (SJVNT) 146.00 MANERI BHALI-II 134.00

12 CHAMERA -II HEP 169.90 RIHAND STAGE -III 136.60

13 URI-II HEP 169.90 RIHAND STAGE -II 143.70

14 SEWA HEP 170.00 URI HEP 169.00

15 OBRA B 171.50 CHAMERA HEP 169.90

16 ANPARA B 181.50 RIHAND 184.60

17 OBRA A 184.30 KAHALGAON-II 249.50

18 RIHAND-I 184.60 UNCHAHAR-III TPS 252.10

19 ANPARA A 213.00 UNCHAHAR-II TPS 252.20

20 CHAMERA-III 220.00 UNCHAHAR-I TPS 257.20

21 KOTESHWAR HEP 220.00 NARORA APS 259.00

22 KAHALGAON-II 249.50 TANAKPUR HEP 260.00

23 UNCHAHAR-III TPS 252.10 NAPTHA JHAKRI (SJVNL) 283.00

24 UNCHAHAR-II TPS 252.20 CHAMERA -II HEP 294.00

25 UNCHAHAR-I TPS 257.20 DHAULI GANGA HEP 306.00

26 KAHALGAON 257.40 ANTA G 314.00

27 ANPARA-C (Lanco) 258.00 URI-II HEP 326.00

28 TEHRI HYDRO 260.00 DADRI STAGE -II 327.00

29 FARAKKA 261.40 DADRI G 327.30

30 NARORA APS 277.40 RAPP © 340.40

31 TANDA 278.60 KOTESHWAR HEP 342.00

32 HARDUAGANJ Ext 295.30 JHAJJAR 361.80

33 DILHASTI HEP 306.40 CHAMERA-III HEP 373.00

34 RAPP (B) 306.40 AURAIYA G 373.30

35 NATA G 314.00 RAPP (B) 373.90

36 DADRI STAGE - II 327.20 SEWA HEP 453.00

37 DADRI G 327.30 TEHRI HYDRO 538.00

38 DADRI NCTPS 348.90 DULHASTI HEP 560.00

39 PARICCHA Ext 361.30 DADRI L 706.20

40 JHAJJAR 361.80 ANTA L 808.20

NTPC TANDA OUTAGE

PROFITABILITY

A CHALLENGE INTRODUCTION ECT DESCRIPTION TANDA POTENTIAL PRDS CASE STUDY LIMITATIONS CONCLUSION

UNIT#1 OUT FOR 94 DAYS, UNIT#2 OUT FOR 90 DAYS-NTPC MAUDA

349.438 MUS LOST DUE TO BACKING DOWN/RESERVE SHUT DOWN-NTPC TANDA

32.983 % OF TOTAL LOSS DUE TO BACKING DOWN/RESERVE SHUT DOWN-NTPC DADRI

17.66% OF TOTAL LOSS DUE TO BACKING DOWN/RESERVE SHUT DOWN-NTPC UNCHAHAR

FROM 01ST APRIL 2015 TO 30TH MARCH 2016

PC SHARP

UNDER THE GUIDANCE OF

SHRI RAKESH BAJAJ (AGM MM)

TEAM

T RAMCHANDRAN (SR MGR-FQA) AMIT KR NAYAK (MGR-TMD)

PRAVEEN PRAJAPATI (DY MGR-BMD) RAVI PAL SINGH (DY MGR-OPN)

KNOWLEDGE SHARING BY SHARP

SL. NO TIME THEME/TOPIC SPEAKER EVENT

1 SEPTEMBER, 2015 ENERGY EFFICIENT CARTRIDGE AMIT NAYAK तकनिकी गोष्ठी

2 APRIL, 2015 THERMO DYNAMICS AND THERMAL ENGINEERING RAVI PAL SINGH KNOWLEDEG SHARING

3 FRBRUARY, 2015 BREAKDOWN IN ROTARY PART PRAVEEN PRAJAPATI BOILER KT MEET

4 NOVEMBER, 2015 UT AND DPT TECHNOLOGY T RAMCHANDRAN KNOWLEDGE SHARING

5 FEBRUARY, 2016 STUDY OF 03 MW BACK PRESSURE TURBINE ALL 04 MEMBERS BABHNAN CHINI MILL

INTRODUCTION ECT DESCRIPTION TANDA POTENTIAL PRDS CASE STUDY LIMITATIONS CONCLUSION

ACCOLADES OF SHARP


FOUNDED IN JANUARY, 2011.

FIRST POSITION IN NOCET-2011, STATION LEVEL.

FIRST RUNNER UP IN NOCET-2011, REGIONAL LEVEL.

FIRST POSITION IN PC-2012, STATION LEVEL.

FIRST RUNNER UP IN PC-2012, REGIONAL LEVEL.

FIRST POSITION IN Q4E-2013, STATION LEVEL.

FIRST POSITION IN Q4E-2013, REGIONAL LEVEL.

SECOND RUNNER UP IN Q4E-2013, COMPANY LEVEL.

FIRST POSITION IN Q4E-2014, STATION LEVEL.

FIRST RUNNER UP IN Q4E-2014, REGIONAL LEVEL.


THE SOLUTION

MAKE THE PLANT AS ENERGY EFFICIENT AS POSSIBLE, PREFERABLY USING EXISTING RESOURCES


PRESSURE REDUCING VALVES

THE PRESSURE ENERGY (POTENTIAL ENERGY) IS CONVERTED TO USELESS TURBULENCE & NOISE IN THE PRV.

POTENTIAL OF ABOUT 3000 MW IN INDIA ITSELF, WHICH IS 1.2 % OF THE TOTAL INSTALLED CAPACITY

BY BUREAU OF ENERGY EFFICIENCY

ENERGY CONSERVATION TURBINE



LOSS

KW



• ECT IS A SMALL COGENERATION SYSTEM CATERING TO STEAM FLOW RATES FROM 1.5 T/HR AND UPWARDS.

• BACK PRESSURE STEAM TURBINE USED IN PARALLEL TO AN EXISTING PRESSURE REDUCING VALVE (PRV).

• STEAM IS EXPANDED IN THE ECT, THUS CONVERTING HEAT ENERGY (OF STEAM ) TO ELECTRICAL POWER.



ANTI VIBRATION MOUNTS

GENERATOR

LUBE OIL FILTER

TURBINE

LUBE OIL COOLER



• ALLOW THE STEAM FLOW VARIATION WHILE KEEPING THE PROCESS PRESSURE CONSTANT.

• INDUCTION GENERATORS CONTINUE TO OPERATE IN SPITE OF LARGE FLUCTUATIONS IN INLET PRESSURE.

• GREATER THAN 80% TURBINE EFFICIENCY. • COMPACT POWER PACKAGE • FITS IN CONGESTED EQUIPMENT ROOMS.

NTPC TANDA POTENTIAL

HP BY PASS VALVE LP BY PASS VALVE

APRDS CONTROL VALVE


HP BY PASS VALVE

INLET PRESSURE : 90 KG/CM2, 500 DEG C OUTLET PRESSURE : 6 KG/CM2, 300 DEG C STEAM FLOW : 130 T/H POWER POTENTIAL

11.76 MW


LP BY PASS VALVE

INLET PRESSURE : 6 KG/CM2, 300 DEG C OUTLET PRESSURE : 0.08KG/CM2, 40 DEG C, 90% DF STEAM FLOW : 150 T/HR POWER POTENTIAL

21.25 MW


APRDS CONTROL VALVE

INLET PRESSURE : 150 KG/CM2, 500 DEG C OUTLET PRESSURE : 13 KG/CM2, 350 DEG C STEAM FLOW : 60 T/HR POWER POTENTIAL

2.7 MW


VALVE HP BYPASS

VALVE

LP BYPASS

VALVE

APRDS CONTROL

VALVE

POWER IN MW 11.76 21.25 2.70

DURATION IN

MINUTES

10 10

60 X24X365

(5 TPH TO SJAE)

FEASABILITY

CASE STUDY

ECT AT APRDS CHARGED FROM MS-LINE WHAT IF CHARGED FROM CRH-LINE ??


CAPACITY OF APRDS

MP STARTUP STEAM FLOW 35 T/HR

F.O AUTOMISATION STEAM FLOW 25 T/HR

HP GLAND SEALING 2 T/HR

TO STEAM JET AIR EJECTOR 5 T/HR

TO D/A PEGGING FROM 6 ATA 21 T/HR

SCAPH 5 T/HR

APH SOOT BLOWING 1.25 T/HR

L.P SEALING 2 T/HR

AT MCR 5 TPH OF PERENNIAL ENTHALPY FLOW IN APRDS


ECT ~

APRDS MS LINE

TO APRDS 11 ATA HDR


APRDS MS LINE

STEAM FLOW : 5 TPH INLET PRESSURE : 150 KG/CM2, 500 DEG C OUTLET PRESSURE : 13 KG/CM2, 350 DEG C STEAM FLOW : 5 T/HR ECT EFFICEINCY : 95% 310 KW

@RS. 4/KWH RS. 1.08 CRORE PER ANNUM SAVINGS HEAT RATE REDUCED BY 7.71 KCAL/KWH


APRDS MS LINE-SPECS OF ECT

•DIMENSIONS : 6.5X4X3 (IN METERS) •NO. OF STAGES : 2 •POWER PACK SET WEIGHT (KG) 4500 KG. •TURBINE SPEED (RPM): 12000 – 14400 •OUTPUT (RPM) : 1500 / 1800 •PRECISION ROLLING ELEMENT BEARING. •PRESSURIZED OIL CIRCULATION SYSTEM. •FLEXIBLE COUPLING OF TURBINE AND GENERATOR. •MOUNTING SKID WITH ANTI-VIBRATION MOUNTS. •NO FOUNDATION REQUIRED.

BY TURBOTECH PRECISION ENGINEERING PRIVATE LIMITED BANGLORE


APRDS MS LINE-PROJECT COST

BY TURBOTECH PRECISION ENGINEERING PRIVATE LIMITED BANGLORE

DESCRIPTION (RS.IN LAKHS)

TURBINE GENERATOR 94

C.S.T(4%) 1.81

E.D(16.32%) 6.36

SUPERVISION OF ERECTION 8

FREIGHT 0.2

EXPANSION BELLOWS 0.6

TURBINE ERECTION 1

ELECTRIC CABLING 1

STEAM PIPING ETC. 2

CIVIL WORK 0.5

MISCELLANEOUS 1

LESS MODVAT 6.36

INVESTMENT 1.20 CRORE


APRDS CRH LINE

TO APRDS 11 ATA HDR

ECT ~


APRDS CRH LINE

STEAM FLOW : 5 T/HR INLET PRESSURE : 35 KG/CM2, 380 DEG C OUTLET PRESSURE : 13 KG/CM2, 350 DEG C STEAM FLOW : 5 T/HR ECT EFFICEINCY : 95% 100 KW

@RS. 4/KWH RS. 35.04 LAKH PER ANNUM SAVINGS HEAT RATE REDUCED BY 11.78 KCAL/KWH


APRDS CRH LINE-SPECS OF ECT

• SINGLE STAGE IMPULSE TYPE • DIMENSIONS : 5X4X4(IN METERS) • HIGH SPEED FLEXIBLE COUPLING • FREQUENCY: 50 HZ • VOLTAGE: 380V / 415V • INDUCTION GENERATOR WITH GRID EXCITATION SYSTEM • CONFIGURATION: BACK PRESSURE • POWER SET WEIGHT : 2000 KG

BY KESSELS TURBINE NEW DELHI


APRDS CRH LINE-PROJECT COST

BY KESSELS TURBINE NEW DELHI

DESCRIPTION (RS.IN LAKHS)

TURBINE GENERATOR 43.5

PANEL, SWITCH & CABLING 2.5

ERECTION , MODIFICATION 2.5

INVESTMENT 48.5

V ECT IN INDIA

• 300KW AT AMRUT DISTILLARIES LTD, KUMBALGOLD, BANGLORE BY TURBOTECH PRECISION ENGINEERING.

• 340 KW AT UNITED SPIRITS, POONAMALLEE, CHENNAI BY TURBOTECH PRECISION ENGINEERING.

• 1600 KW AT PHARMACEUTICAL INDUSTRY, HIMANCHAL BY SIEMENS.


V COMPARISON

• @ RS 2 CRORE, BFP ENERGY EFFICIENT CARTRIDGE, SAVINGS 300 KW PER BFP.

• @2.5 CRORE TG ROOF TOP SOLAR 450 KW FOR ONLY ~04 HRS PER DAY

@ RS 48 LAKH, 100 KW USING ECT AT APRDS

ECT AT APRDS


V


LIMITATIONS

OBLIVIOUS TO INSIGNIFICANT YET PERINNIAL LOSS IN PRVS.

FINANCIALLY NOT VIABLE FOR ALL PRVS.

APREHENSION TOWARDS RELIABILITY OF UNCHARTED INNOVATION.

V CONCLUSION


•GROWING DEMAND AND RISING PRICES MAKE INVESTMENT IN SMALL-SCALE TURBINES ECONOMICALLY VIABLE.

•USE PROVEN AND ESTABLISHED TECHNOLOGY AND CONSISTS OF CONTINUOUS TECHNICAL IMPROVEMENTS.

•RELIABLE SMALL-SCALE TURBINE WILL BE A PROFITABLE AND LASTING DECISION.

BABHNAN SUGAR MILLS LTD

GONDA

3MW BACKPRESSURE TURBINE FLOW :30 TPH

30 KG, 350 DEG C TO 2 KG 165 DEG C

Thank You

Transforming lives

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EBERGY CONSERVATION BACK PRESSURE TURBINE

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