527

529

First Prize Thermal Power Stations(Coal & Gas fired plants <100 MW Capacity)

CAPTIVE POWER PLANT ELECTROTHERM(INDIA) LIMITED

Kutch (Gujarat)

Unit Profile

Electrotherm (India) Limited, an ISO 9001:2015, ISO 14001:2015, BS OHSAS18001:2007 & EN ISO 50001:2011 certified, public limited company, was foundedin 1983 to cater to the needs of all segments of steel industry, foundries and heattreatment industry. Today, Electrotherm is a well-diversified conglomerate havingbusinesses in the field of Engineering & Projects catering to steel and foundryindustry; transformer manufacturing; steel making; ductile iron pipe making;manufacturing of battery operated vehicles; renewable energy; transmission linetower and education.

Electrotherm Kutch Plant is having a state of the art, well integrated 0.5 millionTPA capacity for manufacturing steel. The plant has five induction furnaces of 22Ton capacity, one LRF and two 2-Strand CCM and captive power plant of 30 MW,Two Rotary kilns having a capacity of 0.25 million TPA sponge iron, two Blastfurnace capacity of 0.18 million TPA and a unit producing Ductile iron pipes.

With the integration of Hans Ispat steel facility, plant now has a total capacity of0.6 million TPA, making us the largest producer of TMT in Gujarat.

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THERMAL POWER PLANT (30 MW/Hr Capacity)

Purpose - Purpose of TPP/CPP is to generate power through Rankine cycle.

Energy Consumption

Description Unit 2014-15 2015-16

Annual generation Million kWh 222.098 243.392

Auxiliary power consumption % 8.76 8.26

Overall station PLF % 84.51 92.62

Overall station gross heat rate Kcal/kWh 2390 2065

Overall station net heat rate Kcal/kWh 2619 2251

Energy Consumption Trend

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Energy Conservation initiatives taken in FY 2015-16

Achievement of Annual energy

savings in 2015 -16

Sr. Project D escription Electricity Coal Total Total

No. (Lakhs (MT) Savings investment

kWh) in in

Rs. Lakhs Rs. Lakhs

1 Installation of FRP blade with hub assembly instead of solid GRPblade and hub (CT Fan-1 & 3). 3.03 19.75 5.60

2 Installation of 4 Nos of sonic horn (Soot Blower) instead ofSteam soot Blower (2 nos. LRSB & 4Nos. RSB) in AFBC-1 0.02 2437.50 94.92 4.10

3 Installation of 4 Nos of sonic horn (Soot Blower) instead ofSteam soot Blower (2 nos. LRSB & 4Nos. RSB) in AFBC-2 0.02 2437.50 94.92 4.10

4 Installed 11 Nos of sonic horn (Soot Blower) instead of Steamsoot Blower (3 Nos. LRSB & 10 Nos. RSB) in WHRB-1 0.03 3991.00 155.24 11.00

5 Installed 9 Nos of sonic horn (Soot Blower) instead of Steam sootBlower (3 Nos. LRSB & 10 Nos. RSB) in WHRB-2 0.03 3991.00 155.24 11.00

6 Modification in AFBC Boiler Bed material feeding System andeliminated spreader and drag chain feeder motor. 0.08 0.53 0.50

7 Power saving by change in PLC Logic for BC-1 & BC-4 Magnet 0.44 2.85 0.00

8 Modification in raw water feeding line in DM plant and eliminatedPWR pump from feeding system. 0.14 0.88 0.00

9 Modification in AFBC-1 Economizer flue gas duct to increasearea to avoid pressure drop of flue gas. 0.26 1.71 0.12

10 Power saving by fabricate bed material hopper @ 2 MT at BC4(MHS) 0.22 1.42 0.10

11 Installing VFD in Coal Crusher 0.44 1080.00 44.86 4.00

12 Installing VFD in Cooling tower fan-2 3.27 21.30 2.50

13 Installing VFD in Instrument Compressor No.-2 1.87 12.17 0.05

14 Modification in Service air compressors air suction filter 0.22 1.40 0.05

15 CCWP VFD is under capacity so it was not able to increase VFDspeed more than 90%. For maintaining vacuum, it was requiredto run 3 CCWP, therefore they have replaced old drive to newone to run at 100% speed. 1971.00 76.67 0.10

16 Removed excess refractory on water wall in AFBC-1 from allfour side to generate more steam and to reduce stacktemperature. 272.25 10.59 0.50

17 In-place of metallic sheet , installed transparent sheet on boilerfield room & mechanical room roof to conserve energy by usingday light. 0.01 0.04 0.10

18 Modification in AFBC boiler secondary air nozzle (used old bed

coil sleeve bend) 1734.00 67.45 0.10

532

Integrated Management System Policy

533

First Prize Thermal Power Stations(Coal fired plants >100 MW Capacity)

NABHA POWER LIMITEDRajpura, Dist. Patiala (Punjab)

Unit Profile

Nabha Power Limited is a 2X700 MW supercritical thermal power plant at Rajpura,Punjab. This is the first development project and the first power plant to be owned& operated by L&T. Entire power generated from this plant is contracted with PunjabState Power Corporation Limited (erstwhile PSEB) for a period of twenty five yearsunder a Power Purchase Agreement (PPA). The plant is built on super criticaltechnology of Mitsubishi, Japan. It is the first �Made in India� supercritical powerplant to be commissioned and operational in the country.

The plant sources its fuel from South Eastern Coalfields Ltd. (Subsidiary of CoalIndia Limited) under a 20 year Fuel Supply Agreement (FSA). The company alsosecured approvals to arrange coal from alternative sources to make up for anyshortage in supply of coal under the FSA. Bhakra-Nangal distributary is the perennialsource of water for the plant under an allocation by the state irrigation. The plant isoperated by an in-house experienced team of operations and maintenanceprofessionals.

Both the units were successfully commissioned within 48 and 54 months andcommenced commercial operations in 2014. Supercritical Boiler & Turbine has beenmanufactured indigenously by the JV of L&T-MHPS at Hazira, Gujarat.

Commissioning Date : Unit #1: 24-Jan-2014, Unit #2: 06-July-2014Commercial Operation Date : Unit #1: 01-Feb-2014, Unit #2: 10-July-2014

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Significant Milestones & Initiatives

Plant Availability:

FY 2014-15: 84.15% (Availability loss due to coal shortage- 8.97%)FY 2015-16: 91.79%

Some of the major highlights on efficiency front of the plant are as follows:

� Supercritical technology utilised for higher efficiency and reduced emission.� Usage of Washed Coal to meet the environment guidelines� Around 100 % Dry Fly Ash utilisation is being achieved on sustained basis� Zero Liquid discharge plant� Utilisation of NDCT and TDBFP for reduced Auxiliary Power Consumption.� State-of-the-art automation of complete operations including Copal rake

Unloading through Wagon Tipplers� Specific Oil consumption is much less than the normative value

Health Safety & Environment (HSE)

Nabha Power is committed to generate reliable and environment friendly powerunder safe working conditions. A policy on Quality, Environment, Health and Safetyhas been put in place. Emphasis is laid on continual improvement of our processesand practices to achieve improved environmental, health and safety performance.Training on HSE for employees and stake holders is undertaken on a regular basisto foster a culture of health and safety.

They have been certified with the following Management Systems1. ISO 9001:20152. OHSAS 18001:20043. ISO14001:2008

The certifications have been received within a year of COD

535

Energy Performance Indicators:

Station Heat Rate (kcal/KWhr)

Details of Energy Conservation Measures implemented

Project � 1: Complete Switchover from HFO to LDO

HFO being viscous in nature requires heating source, to be kept in live condition indaily operation. Auxiliary steam was therefore utilized for heating in tank matt coil,pump suction heater and tracing line along the entire piping. Delay in ignitionstability during unit start-up with HFO increased loss of station availability. Completeswitchover was therefore taken from HFO to LDO with the existing system.

Benefits:� Smoother start-up of unit with LDO improved unit start-up time.� Reduced DM water consumption.

Project � 2: Optimization of Unit Cold Start-up Operation

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Implementation of modified unit start-up logic and start-up curve with consent ofOEM.� Turbine cold start-up rolling pressure revised from 85 � 60 ksc

Mill advance operation prior to synchronization with consent of OEM� LDO firing in CD & EF elevation� Air Pre-heater flue gas inlet temp (> 220 deg C), Hot PA header temp. >185

deg C� Pre-heating of primary air by charging SCAPH for mill warming (Mill outlet temp.

55 to 60 deg C)� Second mill into service after charging of HP & LP heaters (Mill sequence D,E,C,B)

Benefits:� Reduced secondary oil consumption for start-up

Project � 3: Optimization of Unit Cold Start-up OperationAdditional make-up water is given to balance the losses through evaporation,sampling, soot-blowing and line heating which is generally 0.5% of the steam-water cycle. Above this range the additional make-up can be attributed to passingof energized valves. After stabilization of both units the DM consumption was 0.95%.During planned outage of the units the passing valves were attended and certainvalves were replaced to overcome the daily heat losses from the system. Maintenancejob was carried out in 97 nos. of valves in both unit and the DM water consumptionreduced to 0.67%.

Benefits:� Reduction in OPEX (reduced DM generation and coal consumption)

Project- 4: APC reduction in Fan PowerTo optimize the fan loading pro-active initiative was taken to identify the air ingressand leakage points in Air & Flue Gas ducting through soap bubble test and planningwas carried out for arresting the same by welding all the joints during plannedoutage of units. Duct to duct, duct to bellow, duct to dampers and duct linings werewelded. Total running length welding carried out in Unit #1 � 4050m.

Benefits:� APC reduction of 697 kWh

Project-5: Stopping of one nos. of Cooling Water pumps during winterseason4 x 100% CW pumps is kept in service as per design to meet the cooling waterrequirement in both units i.e. two nos. of pump per unit. With lowering of ambienttemperature during winter season (November to March) and during prolonged partload operation, one nos. of CW pump is stopped and interconnection line is utilizedto meet cooling water requirement in both the units.

Benefits:� Reduction in APC (4270 KW � one CW power consumption)

537

First Prize Thermal Power Stations(Gas fired plants >100 MW Capacity)

GUJARAT INDUSTRIES POWERCOMPANY LIMITED

(Baroda Operation), Vadodara (Gujarat)

Unit Profile

Gujarat Industries Power Co. Ltd., Vadodara, Gujarat was incorporated on1st June, 1985 under Company�s Act 1956 under the auspices of Govt. of Gujaratand promoted by leading State PSU like Gujarat Alkalies & Chemicals Ltd.,(GACL),Gujarat State Fertilizer Co. Ltd. (GSFC), Gujarat Urja Vikas Nigam Limited (GUVNL)(former GEB) & Petrofils. M/s. GAIL (India) Limited; LPG Waghodia Plant is one ofthe customers for GIPCL.

1. Present Installed Capacity of Vadodara Gas Based Station

538

2. Present Installed Capacity of Gujarat Industries Power Co. Ltd.

Energy Consumption (Electrical & Thermal) in F.Y. 2015 � 2016F.Y. 2014 - 2015

539

Energy Conservation Measures F.Y. 2015-16

1. MODIFICATION by Installation of Blower assist model - Oil Mist Eliminator withVariable Frequency Drive to recover Oil Mist carry over to atmosphere fromVent of Lube Oil Tank of 32 MW Capacity; Gas Turbines

Annual Energy Saving: 0.75267 Lakhs KWh

2. MODIFICATION by Retrofitting of new small Bowl assembly with new tapercolumn pipe and shaft to fit assembly with EXISTING column pipe in CondenserCooling Water Pump and to couple with SAME High Tension Induction Motor ofCapacity 355 KW

Annual Energy Saving: 3.68928 Lakhs KWh

3. MODIFICATION by designing & installing Demand based illumination system in132 KV; outdoor type Switch yard to reduce energy consumption of energyintensive HPSV lighting

Annual Energy Saving: 0.23610 Lakhs KWh

4. MODIFICATION by replacement of 70 Watts HPSV & 250 Watts general lightingsystem by 23 Watts retrofitting type, spiral & screw type mounted CFL lightingin total plant area

Annual Energy Saving: 0.34707 Lakhs KWh

5. Arrest of Compressed Air Leakages in plant area network as a PRUDENTmaintenance practice

Annual Energy Saving: 0.34600 Lakhs KWh

6. REPLACEMENT of ELECTRICAL ENERGY operated Ventilator Fan by RENEWABLEENERGY operated Turbo Ventilator in Main Plant Machines, Material Store,Chemical & Laboratory BUILDINGS

Annual Energy Saving: 0.95046 Lakhs KWh

7. REDUCTION in Cooling Load by relocation of EPABX exchange

Annual Energy Saving: 0.07000 Lakhs KWh

540

Energy Policy

541

Second Prize Thermal Power Stations(Coal & Gas fired plants < 100MW capacity)

PUDUCHERRY POWERCORPORATION LIMITED

(Puducherry)

Unit Profile

The Puducherry Power Corporation was incorporated with the objective ofgenerating 32.5 MW of Electricity (22.9 MW from Gas Turbine and 9.6 MW fromSteam Turbine) at Karaikal which is one of the outlying regions of Puducherry. Therequired gas is obtained from the Gas wells at Narimanam in the Cauvery basinunder an agreement with the Gas Authority of India Ltd. The Corporation hadreceived the entire cost of Rs. 133.04 crores as Share Capital from the Govt. ofPuducherry till 1999-2000 and the same has been utilized for the execution of theProject.

The first and prestigious gas based power plant was set up at T.R. Pattinam,Karaikal to cater to the power demand of Karaikal region. The plant on Open Cycle(22.9 MW Gas Turbine) was synchronized during October 1999. The plant wasdedicated to the nation by the Hon'ble Prime Minister of India on 25.05.1999.

The plant was put into commercial operation w.e.f 3rd January 2000. The entirepower generated from the Karaikal Gas Power Plant is supplied to the ElectricityDepartment, Karaikal. The plant is performing extremely well till date.

The power generated by both the gas and steam turbines are distributed at 11 KVlevel and distributed to local industries and consumers. Some of the power isexported to 110 kV level to nearby 110 kV sub-station.

The Power Station consists of 1 No. Gas Turbine Unit of capacity 22.9 MW, 1 No.HRSG and 1 No. Steam Turbine Unit of capacity 9.6 MW. The total capacity of thePower Plant is 32.5 MW.

542

List of Energy Conservation Measures:

Energy Conservation measures implemented in PPCL as recommendedby AEA Consultants

Sr. Energy Saving Proposal Annual Energy Annual Energy Investment SimpleNo. Saving Cost Saving (Lakh Rs.) Payback

(Lakh kWh) (Lakh Rs.) Period(Months)

Energy Saving measures within the year 2015-16

1 By arresting dumping steam to condenser & its 16.000 65. 12 Ni l Immediatespray passing. Useful steam was saved. Also (Gen. Increase)reduced heat load occurred on condenser andthereby improved vacuum.

2 Gland steam excess return control valve 8.000 32.56 Nil Immediatepressure setting calibrated properly to maintain (Gen. Increase)Gland steam supply header pressure. Usefulsteam was saved. Also reduced heat loadoccurred on condenser and thereby improvevacuum.

3 Stopping of Hogger / Starting ejector 4 .585 18.66 Nil Immediateenhanced generation by steam saving (Gen. Increase)

Brief Description of Energy Conservation Measures implemented:

The brief description of the above list of energy savings measures are presentedbelow:

Project-1 By arresting dumping steam to condenser and spray passing, themeasure improved Power generation. Also the condenser heat load got reducedand improved vacuum.

Passing of steam was stopped by closing isolation valves of dumping &spray line which increased generation of 200 kW (avg.).

543

Illustration:When dumping steam passing was identified, screenshot was taken from the DCSbefore isolating dumping & spray line isolation valves. Snapshot after isolation wasalso taken.

Before taking rectification After taking rectification

The above screenshot was taken which reveals that STG generation is 9.4 MWcorresponding to GT load 21.4 MW. At this stage dumping passing steam wasidentified. The second screenshot of DCS was taken after rectification in terms ofarresting dumping steam. By arresting dumping steam STG generation wasincreased to 9.7 MW corresponding to same GT load 21.4 MW.

Conclusion: It can be concluded that Generation was increased by 200 kW(200kW) by arresting dumping steam.

Techno Economic:

Potential for generation increase = 200 kWAnnual operation time = 8000Annual energy generation increase = 1600000 kWh

Energy cost = Rs. 4.07Annual monetary gain = Rs. 6512000Investment = NegligibleSimple Pay back = Immediate

Project-2: Gland steam excess return control valve pressure setting calibratedproperly to maintain Gland steam supply header pressure to arrest air ingressfrom LP gland and thereafter gland steam excess return to condenser was arrestedthereby reducing condenser heat load and increase in power generation.

Based on the above observation, actions were taken for some corrective works

1. Excess return steam from gland supply header to condenser arrested.2. To stop bypass through manual control valve of gland steam supply controlvalve was isolated.By taking corrective actions following were achieved:

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1. Gland steam supply header pressure developed.2. Turbine LP gland air ingress stopped3. Condenser heat load reduced4. Improved vacuum and ultimately generation increased.

From the above illustration, it can be noticed that on an average 100 kWgeneration was increased for same vacuum by stopping excess returnsteam

DCS Screenshot

Techno Economic:

Potential for generation increase = 100 kW Annual operation time = 8000

Annual energy generation increase = 800000 kWhEnergy cost = Rs. 4.07Annual monetary gain = Rs. 3256000Investment = Nil

Simple Pay back = Immediate

Project-3: Stopping the Hogger / Starting ejector will enhance generation bysteam saving as well as other loss reduction. It was found that the Hogger wasput in line along with service ejector to maintain condenser vacuum. Hogger isgenerally used temporarily at initial vacuum pulling and at emergency condition.Air ingress also identified through LP gland due to low gland steam supply pressure.Hogger was taken out from the system after correcting gland steam supplypressure and proper gland sealing. Motive steam temperature was found runninglow (193 0C at 13 kg/cm2g) than design (210 0C at 10kg/cm2g). From theabove observation, it can be concluded that the motive steam was not superheatedand therefore, unable to extract sufficient air from condenser.

An evaluation was done how generation can be improved if Hogger is taken outfrom the system.

545

Saving calculation due to Hogger stoppage

Sl.No. Parameters Unit Value Basis

1 Aux. Steam pressure kg/cm2 10 Design

2 bar 9.81 Calculated3 Aux. Steam temp 0C 210 Design

4 Aux. enthalpy kCal/kg 681.61 Calculated

5 Aux. steam flow through hogger kg/hr 350 Design

6 Spray water pressure kg/cm2 75 Design7 bar 73.55 Calculated

8 Spray water temperature 0C 132.88 Design

9 Spray water enthalpy kCal/kg 134.60 Calculated

10 Spray water flow kg/hr 43.29 Calculated11 MS pressure kg/cm2 42 Measured

12 bar 41.19 Calculated

13 MS temp 0C 385 Measured14 MS enthalpy kCal/kg 758.83 Calculated

15 MS flow kg/hr 306.71 Calculated

16 MS saving due to Hogger stoppage TPH 0.307 Calculated

17 Spray water saving Hogger stoppage TPH 0.043 Calculated

18 m3/ hr 0.046 Calculated19 Design STG output MW 9.6 Design

20 Design MS flow at TG inlet TPH 48 Design

21 Design sp. Steam consumption TPH / MW 5.00 Calculatedof Turbine

Saving Calculation-1

22 Generation increase due to kW 61.4 CalculatedHogger stoppage

23 Aux. Power Consumption % 6 Assumed

24 Extra generation feed to grid kW 57.72 Calculated

25 Extra Generation per Annum kWh 457111Saving Calculation-2

26 BFP sp. Energy consumption kWh/m3 3.74127 BFP power saving kW 0.174

28 BFP energy saving per Annum kWh 1376.35

29 Total Saving/Generation quantified kWh 458487 Sl. No 25 +28

30 Energy Sale Cost Rs/kWh 4.0731 Annual Energy Cost saving Rs 1866042

32 Investment Rs. Nil

33 Payback Months Immediate

Apart from the above mentioned saving, some other quantifiable saving can alsobe achieved mentioned below:

Per annum 2772 TON DM water can be saved @ 350 kg/hr [as in Sl. No.5] Respective chemical cost can be saved. Water saving as CBD loss can be saved.

546

Second Prize Thermal Power Stations(Coal fired plants >100 MW Capacity)

BUDGE BUDGE GENERATING STATION(West Bengal)

Unit Profile

CESC Limited established in 1897, a flag-ship company of RP-SG group is a morethan hundred year old Power utility operating within a licensed area of 567 squareKm in the city of joy, Kolkata. Its consumer base is approx. 3 millions. Companyhas 3 Generating Stations whose combined capacity is 1,125 MW.

Budge Budge Generating Station (BBGS) is committed to provide cheap, efficientand reliable power in line with the vision of the company. The formally articulatedVision, Mission and core values act as the guiding force propelling the organizationto global standards.

Budge Budge Generating Station is a 750 MW (3*250MW) Thermal Power Plant. Ithas 3 Units of 250 MW each and have been certified with ISO 9001:2008, ISO14001:2004 and OHSAS 18001:2007 by TUV Nord. Unit-1 and Unit-2 wascommissioned in 1997 and 1999 whereas Unit-3 has been commissioned in 2010.Budge Budge Generating Station (BBGS) is spread over an area of 225 Acres.BBGS is the most modern power plant of CESC. Unit no 1 & 2 are similar in make,Turbine is of Parson�s, whereas Boiler and BOP is ABL make. Unit 3 is a completeset of B-T-G from BHEL. All boilers are pulverized fuel fired.

547

Performance Trends:

Plant performance and Energy use trends

Energy Conservation Measures:

Some of the major innovative projects that are being carried out in the last 3 yearsin BBGS mainly to reduce their carbon footprints and to conserve energy are:

a. Modification of Hydraulic fluid coupling of BFP of Unit-1 & Unit-2 to save powerconsumption.

b. Refurbishment of Air heater of Unit-1

c. Use of Variable speed drives in PA fans of Unit-1&2.

d. Use of LT VFDs.

e. Reduction of throttling loss at Unit-3 Feed Control Station by reduction ofdifferential pressure.

f. Stage binding (De-staging) of Condensate Extraction Pump of Unit-1&2.

g. Optimization of PA flow for reduction of Un-burnt % of coal in ash.

h. Modification of flue gas ducting by CFD study to lower ID Fan power consumption.

i. Replacement of LT motors with energy efficient motors.

j. Revamping of Cooling Tower & use of carbon shaft for CT fans.

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k. Optimization of Transformer loadings.

l. Use of low speed seal air fans

m. Use of energy efficient lighting (LEDs) for outdoor and indoor lighting, Timercircuit has been incorporated to control outdoor lighting.

Energy Conservation projects implemented

1. Speed optimization of Unit-1 & 2 BFP Hydraulic Couplings:

The Project was taken up for execution as it had huge potential for energy savings.Alongside the trend shows the Specific energy consumption trends of the last 3financial years. The target for SEC for FY 2015-16 was 8.1%, the quest for loweringSEC led us to explore serious possibilities to lower their own consumption.

Unit-1&2 are 250 MW sets having sub-critical double down shot fired boilers. Themajor energy consuming drive in a thermal power plant is Boiler feed pump whichrecirculates by taking suction from De-aerator and pumping the water at very highpressure to Boiler for superheated steam generation which is the prime mover ofthe turbine in a thermal power plant. BFP consumes around 30-35% of the totalPlant energy consumption.Unit-1&2 have 2 boiler feed pumps each with 2*100%capacity.

Reasons for selecting thisproject:

Achieving GlobalBenchmark Figure onSpecific EnergyConsumption.

BFP being a big ticket itemconsuming about 34% oftotal SEC.

Opportunity to reduce SECby 0.12 %

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Challenges faced before deployment/implementation

The main challenge was risk evaluation and mitigation of the same. The associatedrisks was that in case of abnormal lowering of grid frequency, the modified pumpwill not be able to cater full load demand and this situation demands running of thestandby pump. Under the present grid discipline this is a remote possibility, howeverunder any circumstances the new modified Gear set can be reverted back to oldoriginal set with minimum downtime.

Process Followed for deployment/implementation

The Boiler feed pump of both Unit-1&2 was such initially designed so as to providea max pump speed of 5730 RPM at 47.5 Hz frequency of Input power. At full loadcondition the output pump speed of 5300 RPM is sufficient to feed the boiler. Nowsince the operating frequency in the grid is around 50 Hz, to keep the output speedat 5300 RPM there was a loss of around 1148 KW in the hydraulic coupling as oilwas being drained from the coupling to reduce the speed to the required value of5300 RPM.

Plant envisaged to reduce this coupling loss which was occurring in the hydro-coupling. By optimizing gearing ratio , plant designed the coupling such that theoutput speed of the pump is 5350 RPM which is sufficient to feed the boiler at fullload at an input frequency of 50 Hz.

Comparison of the pre-deployment with post-deployment scenario

Below are the status before and after modification:

550

The graphs below shows the energy consumed by BFP vis-à-vis PLF along themonths in 2014 and 2015, before and after implementation of the project respectively

551

Savings:

In FY 2015-16 we ended with a SEC % of 8.05 as compared to 8.21 in FY2014-15.

Actual Electricity Savings after Modification= 12.06 Million KWhActual Coal Savings after Modification=7201 Tonnes

1. Refurbishment of Unit-1 Air Heater

Leakages in Air Heater tubes resulted in intermixing of fresh air and flue gas therebyincreasing the ID Fan Ampere drawl.

Bulk replacement of air heater tubes resulted in reduction of ID Fan Ampere therebysaving energy.

Air heater leakage % which is measured every alternate month helped us to reachthe conclusion that mass replacement of heat exchange tubes will give us intendedbenefits.

Air heater Leakage as measured Leakage as measuredon 8/12/15 on 19/04/16

(Pre-replacement) (Post-replacement)

SAH-A 17.66 5.00

SAH-B 9.88 2.49

PAH 12.14 3.33

Savings:

Actual Electricity Savings after Modification= 2.45 Million KWh/yearActual Coal Savings after Modification=1464 Tonnes/year

552

Second Prize Thermal Power Stations(Gas fired plants >100 MW Capacity)

PRAGATI POWER STATIONPragati Power Corporation Limited (New Delhi)

Unit Profile

Pragati Power Corporation Limited is an undertaking of Government of NCT ofDelhi. It was incorporated on 9th January, 2001 to undertake power generationactivities for supplying power to Delhi. It is one of the leading Undertakings ofGNCTD, generating profits since inception and paying dividends regularly. It ispresently having capital base of 2,019 Cr and asset base of 3,319 Cr. The projectedasset base and revenue income of Company in the near future are 6,000 Cr and5,000 Cr respectively.

This plant consists of 2 x 104 MW Frame 9-E Gas Turbine Units commissioned in2002 and 1 x 122 MW STG Unit commissioned in May�2003. Gas supply has beentied up with GAIL through HBJ Pipeline. The Combined Cycle Power Plant (CCPP)station is comprised of a 2x104 MW Gas Turbines of GT Frame-9E and 1 x 122 MWSteam Turbine. The Waste Heat flue gases emanating from the gas turbines isbeing utilized to generate HP & LP steam in respective Waste Heat Recovery Boilers(WHRBs / HRSGs) and generate power via a 122 MW steam turbine. The hot gasesof 570o C with a mass flow of approx. 14000 MT/hr is passed through 2 Nos. wasteheat recovery boilers to generate steam.

Plant is certified with ISO certifications of ISO9001, ISO 14000, ISO 18000, aswell.

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Fuel:

The primary fuel for gas turbine is natural gas being supplied by M/s GAIL. The gasis received at GAIL Terminal installed in the vicinity of the power station. M/s GAILis committed to supply 1.75 MCMD of gas on daily basis. The caloric value ofnatural gas being received for power generation is in the band of 8200-8500kilocalories on NCV basis.

Raw Water :

Raw water requirement is met through Sewage treated water being drawn fromSen Nursing Home and Delhi Gate Sewage Treatment Plant. The de-mineralizedwater requirement for steam generation is met up through sewage treated waterby treating this through RODM (reverse osmosis de-mineralized) process. Theproduction of cooling water requirement for condenser and other equipment is alsomet through STW after processing through Lime softening system. The plant effluentis discharged to river Yamuna after naturalizing and thus the effluent discharge isbetter than sewage water. In fact cleaner water is being discharged to River, makingthe project more eco-friendly.

Emission Control :

In order to have control on flue gas emission particularly NOx, a special emphasisbeing given. To control NOx, State of art, Dry Low NOx. (DLN) Burners have beeninstalled on gas turbines. At present the value of NOx. is in order on 17-18 ppm onbase load. The allowable limit of NOx. approved by DPCC (Delhi Pollution ControlCommittee) is 35 ppm. This is the first plant in India with a facility to control NOxemissions by use of dry low Nox technology (DLN) and is an eco-friendly powerstation.

Operating ParametersAnnual Operating Parameters FY 2014-15 & 2015-16

DESCRIPTION UNIT 2014-15 2015-16

Gross Gen. MU 1847.368 1539.471

PLF % 63.91 53.11Station Heat Rate Kcal/Kwh 2046 2008Aux Power Consumption MU 48 41

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Energy Conservation Initiatives:

Pragati Power Station is certified with ISO 50001:2011 for effective implementationof Energy management system (EnMS) covering all the O&M departments of theplant including water treatment.

� A dedicated Energy management team is constituted for energy conservationstudy in the plant and to meet the PAT target being dedicated consumer.

� Pragati Power Station is the first power company of GNCTD certified with ISO50001

� Energy conservation is brought up among all level of staff� Energy Management system (EMS) is connected up to low voltage areas though

metering.

Major Energy Conservation Activities Carried out during 2015-16:

During the year 2015-16, arppox 16 nos of energy saving projects were implementedincluding electrical and thermal.

1) Replacement of HT Condensate preheat recirculation pump (CPHRC)with Low capacity , LT pump with VFD.

PPS-1 consists of three nos of CPHRCP pump. The pumps are integral part ofcondenser preheat circuit. These pumps are used to recirculate the hot water fromde-aerator to maintain the fixed temperature at the inlet of the Condensate preheater.There was a control valve (CV#6) which is opened around 5 % only. To overcomethe throttling loss, the CV was replaced with new CV of low capacity in first phaseand further pump with lower head and LT motor is replaced. Also for fine tunecontrol, VFD is also installed on the pump and huge amount of energy is saved.Total investment :48.51 lacsTotal Savings :161 KW-Payback :Less than 1.5 year.

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2) Changing of cooling tower blades with new profile and shaft withnew carbon shaft:

PPCL consists of induced draft cooling tower having 8 no of cells . Old profile of thefan blade studied and it was found that it can be changed with new profile whichwill conserve energy , further the motor shaft are also replaced with light carbonshaft to enhance the savings. Presently the project has been implemented on 4 CTfans.

Total Investment : 28.51 lacsTotal savings : 66 kwPayback : less than 1.6 years

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3) Dry Ice blasting of HRSG-II:

During inspection of HRSG �II it was observed that the tubes needs cleaning forbetter heat transfer at the surface of the tubes. Dry ice blasting carried out duringmajor overhauling of GT #2 and a decrease in back pressure by 25mm Wc observed,Which further increased the load on GT by 136 kw .

Total investment : 12 lacsTotal Kw saved : 136 KwPay back period : Less than 4 months.

1) Various other projects which resulted in significant energy savings atPPS -1:

In belief to the social and commercial cause persistent effort is made towardsenergy conservation and in tune with National Mission for Enhanced Energy Efficiencyand to reduce the carbon footprint in the atmosphere, PPS-1 implemented variousother projects such as:

a) Replacement of BA fans of both GT with lower capacity,b) Use of energy efficient motors on CT fans,c) Use of waste heat from CW return line in the central AC plants,

d) Winter heating through the return CW water from condenser.,e) VFD on CT fans,f) Impeller trimming of the ECW and CPHRCP pump,

g) Destaging of DGN pump ,h) Coating of SNH and DGN pump.i) Blade modification of Fin fans. Etc,

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Energy Policy

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Certificate of Merit Thermal Power Stations(Coal Fired Plants > 100 MW Capacity)

NAVA BHARAT VENTURES LIMITEDKhammam District (Telangana)

Unit Profile

Nava Bharat Ferro Alloys Limited, Paloncha started their first Ferro alloy furnace ofcapacity 16.5 MVA in the year 1975. Later, three more furnaces were installed inthe years 1979, 1983 & 2005 respectively. Presently total installed furnace capacityis 74.5 MVA and annual production capacity ranges from 1, 17,000 MT to 1, 44,000MT depending on the product mix.

In the year 1997 Nava Bharat Ferro Alloys Limited entered into the field of powergeneration by installing a thermal power plant (Unit-1) using coal as fuel, with acapacity of 30 MW. In the year 2000, unit-1 capacity was enhanced to 50 MW byadding another Boiler. Further, in the years 2006 & 2007, two new units each ofcapacity 32 MW were added. Present total installed capacity of Power Plant is 114MW. Surplus power available is sold, to different trading companies, after meetingthe captive and auxiliary requirements.

In the year 2006, organization�s name was changed to Nava Bharat Ventures Limitedfrom Nava Bharat Ferro Alloys Limited.

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Energy Consumption

Description Units 2013-14 2014-15 2015-16

Auxiliary power % 9.11 9.18 9.18

Plant load factor % 92.11 91.84 81.22

Plant heat rate kCal/kWh 3,177 3,216 3,078

Specific coal consumption kg/kWh 0.895 0.925 0.906

Grass calorific value of Coal kCal/kg 3,546 3,474 3,398

Generation and consumption details

Specific Energy Consumption

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Plant load factor

Energy Conservation Activities & Organizational Set Up

An energy conservation team was constituted in 2006 consisting of the engineersfrom all the sections. The team is led by Certified Energy Manager from Bureau ofEnergy Efficiency (BEE), Ministry of Power.

The responsibilities of this team are being framed.

a. identifying and creating awareness among all our employees and contractworkmen on the latest energy efficient technologies,

b. implementing appropriate energy efficient and clean technologies,c. continual improvement in energy conservation practices to achieve global bench

marks,d. constant monitoring and improving the performance of equipment,

e. organizing energy audits to identify areas for improvement,f. complying with applicable statuary requirement,g. encouraging competitive sprit among all our employees, contractors and their

workmen to generate innovative energy conservation ideas and rewarding thebest ideas,

h. sharing the best energy conservations practices among the various units of thecompany,

i. educating housewives and school children on energy conservation.

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Energy Conservation Neasures Implemented

Following are the energy conservation activities taken up by the plant:

Annual electrical energy savings;

S. Title of Energy Saving project implemented In MillionsNo kWh Rs

1 VFD provided for 50 MW, STG-1 condensateextraction pump. 0.153 0.46

2 New CEP with low seal water requirementwas installed. DM water consumption reduced by20 TPD. 0.022 0.07

3 After measuring the illumination lux levels, TGbuilding roof top lighting reduced from 10 pointsto 5 points. 0.02 0.06

4 Voltage level reduced at CHP-1 bus voltagefrom 425 V to 407 V. 0.049 0.15

5 VFD provided for air conditioning-Vaporabsorption system at PP office and CPP control room 0.005 0.02

6 Provided HT-VFD for unit-3 boiler feed pump toreduce the auxiliary power consumption. 0.738 2.26

7 TG-1 specific steam consumption reduced byUp-grading steam path internals. 1.18 3.64

8 Provided VFD to Drip pump in Unit -1. 0.035 0.11

Annual thermal energy savings;

S. Title of Energy Saving project implemented MT Rs inNo millions

1 By installing sonic soot blowers the heat pick upof waste heat recovery system was increased 5,584 14.27

2 TG-1 specific steam consumption reduced byUp-grading steam path internals. 14,100 31.33

Environment and Safety

Plant is certified for the following standards:� ISO 9001:2008 Quality management system.� ISO 14001:2004 Environmental management system� ISO 50001:2011 Energy management system� OHSAS 18001:2007 Occupational health and safety management system.