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THERMAL POTHERMAL POTHERMAL POTHERMAL POTHERMAL POWERWERWERWERWER

STSTSTSTSTAAAAATIONSTIONSTIONSTIONSTIONS

THERMAL POTHERMAL POTHERMAL POTHERMAL POTHERMAL POWERWERWERWERWER

STSTSTSTSTAAAAATIONSTIONSTIONSTIONSTIONS

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487

First Prize Thermal Power Stations

GURU HARGOBIND THERMAL PLANT Lehra Mohabbat, Distt. Bathinda (Punjab)

Unit Profile

Guru Hargobind Thermal Plant is the third and the latest of the thermal plants ofPunjab State Power Corporation Limited and is located 23 km short of Bathinda onNational High Way No. 64 and is situated opposite Village Lehra Mohabbat. Totalplant area is 1025 Acres. Basic fuel is coal and furnace oil. Stage-I consists of twounits of 210MW each. Stage-II consists of two units of 250 MW each. GHTP LehraMohabbat comprises of two stages. Unit-1 & 2 of stage-I were synchronized on 29-12-97 & 16-10-98 and the units started commercial operation w.e.f. 26-6-99 and4-1-99 respectively. Unit-3 & 4 of stage-II are generating electricity w.e.f 05.02.2008& 11.10.2008 and these units started commercial operation w.e.f. 16.10.2008 &25.01.2010 respectively.

GHTP has surpassed its own records of highest generation during previous foursuccessive years and is being operated at the lowest cost of generation amongstall PSPCL power plants despite having higher interest and depreciation. This planthas shown excellent performance and huge savings have been made in terms ofearning incentives by performing better than PSERC targets through meticulousplanning.

488

During 2009-10, GHTP Lehra Mohabbat known for its performance has surpassed

another milestone by generating 75152 Lac units (Including 14729 Lac Units

generated by Unit-4 during stabilization period before its commercial operation)

against the target of 65790 Lac units set by Central Electricity Authority, New

Delhi. The plant load factor of 96.44% for commercial operation is the highest ever

plant load factor in PSPCL. The plant has surpassed its own previous highest record

of 95.10% plant load factor achieved during the year 2007-08. This plant load

factor of 96.44% achieved during 2009-10 is even higher than the plant load

factor of 95.99% which was achieved by GHTP Stage-I units and was the highest

amongst all state sector power plants during 2008-09.

The plant utilization factor of GHTP remained more than 100% at an ever highest

value of 100.38% during 2009-10. The auxiliary consumption during this year

remained at its lowest ever value of 8.23% against a PSERC target of 9.00%, thus

saving Crores of rupees, which speaks of high plant performance at which the

plant is being operated. The oil consumption remained at 0.373 ml/ kWh against

the set target of 1.0ml/kWh.

GHTP has achieved the highest ever monthly generation of 7065 Lakh units at a

plant load factor of 103.21% during March 2010 which is highest ever monthly

plant load factor at any plant of PSPCL.

GHTP Unit 1 has run continuously from 28.02.2009 to 12.09.2009 (195.4 days)

without any interruption. This is a new record of longest continuous run by any unit

of PSPCL.

The relentless pursuit of excellence has helped to make GHTP a trend-setter, leader

and a light house in Punjab State Power Corporation Limited by achieving high

plant performance and economy. GHTP has taken a lead in cutting down its capital

overhauling period from traditional practice of 45 days to as low as 28.5 days and

annual overhauling period from 20 days to less than 14 days resulting into savings

of Crores of rupees by PSPCL in terms of purchase of power. This had been possible

due to lust of excelling continuously prevailing amongst GHTP engineers and staff.

In the year 2009-10, annual maintenances of unit no. 1 & 2 were carried out in less

than 29 days against approved shut down period of 40 days. The units were brought

on bar 11.12 days ahead of schedule; thereby an extra generation of 560 Lac units

saving Rs. 30 Crores approx. was done in terms of power purchase.

The new records set by GHTP Lehra Mohabbat during 2009-10 are as under:

Annual plant load factor: 96.44% Better than the All India

State Sector

National highest 95.99%

achieved by GHTP Stage-I

units during 2008-09.

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2009-10 previous record

(Actual)

Highest ever annual generation: 7515.2 MU 5610.09MU in 2008-09

Highest ever annual plant 96.44% 95.10% in 2007-08

load factor:

Highest ever annual plant utilization factor: 100.38% 100.31% in

2007-08

Highest ever annual deemed plant load factor 97.53% 97.07% in

2003-04

Lowest ever annual Auxiliary Cons. (%): 8.23% 8.71% in

2008-09

Plant performance and energy consumption

Sr. Operating Unit YearNo. parameters 2006-07 2007-08 2008-09 2009-10

1 Actual Gen. MU 3443.172 3508.587 4441.92 6042.262

2 Plant Avail. Factor % 94.33 94.81 95.98 96.07

3 Plant Utilization % 99.21 100.31 98.86 100.38factor

4 Plant load factor % 93.58 95.10 94.89 96.44

5 Deemed PLF % 95.31 95.65 96.05 97.53

6 Auxiliary % 8.80 8.87 8.71 8.23Consumption

7 Sp. Coal Kg/kWh 0.551 0.589 0.601 0.601Consumption

8 Sp. Oil ml/kWh 0.327 0.228 0.802 0.367Consumption

9 Heat Rate Kcal/kWh 2440 2446 2459 2421

10 Thermal Efficiency % 35.25 35.15 34.97 35.52

Energy Conservation

The following benefits have been accrued to GHTP as a result of implementation of

innovations / best practices to improve the energy efficiency of GHTP:

GHTP has achieved thermal efficiency of 35.52% during 2009-10 against a

target of 34.40% set up by Punjab State Electricity Regulatory Commission.

490

Auxiliary consumption of GHTP remained at its lowest ever value of 8.23%.

At GHTP, differential pressure across feed control valves of Boiler feed pump

has been reduced from its normal value of 6.0Kg/cm2 to 0.4Kg/cm2. This has

resulted in reduction of nearly 13 Amperes of current on 6.6 KV on each running

BFP.

One no. CW pump of 975 KW for Unit 1 & 2 is being stopped in winter by

running 3 no. CW pumps in parallel for two units against normal running of 2

no. CW pumps for each unit separately.

Two no. TACW pumps of 110 KW each are being stopped in winter by running

one no. TACW pump against normal running of 2 no. TACW pumps for each

unit.

As DM water make up is very low, so one no. hot well make up pump has been

put into operation for two units against running of one no. separate pump for

each unit.

125 Watt Mercury vapour lamps have been replaced with 70 watt Sodium

vapour lamp, wherever possible.

The deviation in all the parameters affecting efficiency of the plant have been

made available online to the operators. Alarm signals are generated in all such

cases to take corrective actions by the operator.

Start up of auxiliaries has been optimized.

Providing energy efficient PA fans during erection of GHTP Stage-II units.

Providing VFDs on ID fans during erection of GHTP Stage-II units.

GHTP has declared its Energy Management Policy as under:

Energy Management Policy

Team of engineers and staff of GHTP Lehra Mohabbat are committed to evolve,

improve and sustain in energy conservation through:

Improved plant utilization.

Benchmarking specific energy consumption with the best norms in country.

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Monitoring of energy consumptions to identify the areas for improvements.

Optimum Utilisation of auxiliaries for optimization of energy consumption.

Promoting energy awareness and encouraging employee participation for energy

conservation.

The team of engineers and officials of GHTP are fully committed and motivated to

bring more laurels to PSPCL and the state of Punjab. Suggestions for improvement

keep pouring in, are encouraged, discussed and implemented. In house interactions

and training sessions help in not only sharing experiences but also to appreciate

the efforts & contribution of each individual in achievements of the GHTP team.

492

First Prize Thermal Power Stations

220 MW SAMALKOT COMBINEDCYCLE POWER STATION

RELIANCE INFRASTRUCTURE LIMITEDSamalkot, Distt. East Godavari (Andhra Pradesh)

Unit Profile

Samalkot Combined Cycle Power Plant has been developed by RINFRA at Samalkot,Andhra Pradesh. The main fuel for the plant is natural gas being supplied by GasAuthority of India Ltd. (GAIL). The plant is also designed to use Naphtha as mainfuel and HSD as backup fuel. Raw water is drawn from Samalkot irrigation canaland pumped to the in-plant open water reservoir by RINFRA. An Intake PumpHouse has been set up by RINFRA near the intake point for this purpose. Thepower generated by the Gas Turbine and the Steam Turbine generators are steppedup to 220KV and fed to a 220KV outdoor substation. The power is evacuated byAPTransco through overhead transmission lines. RINFRA has necessary agreementwith APTransco for this purpose. The project has been executed by the consortiumof Ansaldo Energia, Italy and RINFRA, on a turnkey basis. The Gas Turbine Generator,Heat Recovery Steam Generator and Steam Turbine Generator along with theirrespective auxiliaries has been designed and supplied by Ansaldo.

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Energy Consumption

220 MW Samalkot Combined Cycle power station is commissioned in year 2002.As a responsible and foreseeing the energy demand, station has taken initiative forimplementation of several energy conservation activities in the plant. For the year2009-10 initiatives are listed below,

S. Energy Conservation Power Annual Annual Implemen- AnnualNo Activities Saving Energy Saving tation Energy

(kW) Saving INR - Cost SavingkWh Lakh Lakhs Lakh

kWh

1 Replacement Of GRP 128.95 1129602 25.42 20.005 11.2960solid cell fan blade withEpoxy Coated HollowEnergy Efficient FanBlade

2 Modifying Cooling Tower 22.80 199728 4.49 2.844 1.9973makeup system fromMotor driven pumping toGravity system.

3 HPBFP VFD Pressure 30 262800 5.91 0.000 2.6280Optimization

4 LPBFP VFD Pressure 3 25404 0.57 0.000 0.2540Optimization

5 Illumination System: 1.33 11651 0.26 0.189 0.1165Building Replacementof FL lamps (40W) withCFL (20W) lamps atnon essential area.

6 Standby Closed cooling 4.6 40296 0.91 0.000 0.4030water PHE isolatedfrom ACW as well asCCW side

7 Wind Ventilators 4.3 224431 5.05 3.206 2.2443

Station Energy Consumption Performance Report

Power Plant for its own operation has many equipment, station in day to dayactivities calculate own energy consumption as follows,

Aux Power Consumption in MU’s=(Gas Turbine Generator + Steam Turbine Generator) – Export Energy Meter ReadingEnergy Meter Reading

Aux Power Consumption in % =(Aux Power Consumption in MU’s x 100)/ (Station Generation in MU’s)

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Station Auxiliary % ReductionCapacity Power in MU's

Million Units In PercentMW MU's kWhr/kWhr %

Year 2008-09 220 33.1659 3.2780 Base Year

Year 2009-10 220 30.7755 1.9749 7.21

Auxiliary Power Consumption in Million Units

29

30

31

32

33

34

Auxiliary Power Consumption in MU's

2008-09

2009-10

Auxiliary Power Consumption in %

0

0.5

1

1.5

2

2.5

3

3.5

Auxiliary Power Consumption in %

2008-09

2009-10

Above data revels that, due to several energy conservation measures & efficientoperation of the station, station could achieve ~ 7.21 % reduction in auxiliarypower consumption in the period of 2009-10.

Energy Conservation Commitment, Policy and Set-Up

SPS considers energy conservation as its major objective to achieve cost effectivepower generation. Monthly review meeting on Energy conservation projects is beingconducted in the presence of Unit Head. Reward & Recognition scheme are at placeat corporate level to motivate Employees in view of Energy Conservation.

During the period several best practice initiatives were undertaken for overallimprovement in all round performance.

495

1. Improve the Heat Rate.

2. Reduce the Auxiliary power consumption

3. Reduction in consumption of Resources (i.e. Water, prcess chemicals)

Energy Management Cell

PLANT HEAD(RINFRA-SPS)

ENERGY MANAGER

Senior. Manager(Mech. Maint.)

Asst. Manager(Operation)

Asst. Manager(C&I Maint.)

Asst. Manager(Elect. Maint.)

Energy Conservation & Efficiency Improvement

At SPS there are state-of-art maintenance techniques and strategies to conserveenergy.

The Energy Management cell of SPS consists of qualified energy managers andauditors who ensure adherence to constantly evolving energy efficiency standards.The various energy conservation measures that have been put into practice are:

Installation of VFD in HPBFP, LPBFP, Raw Water Pumps

De-staging of CEP

Modification In DD Hydraulic Oil System

Wind Turbo Ventilators

Normal FL lamps & ballast are replaced by High Lumen Lamps & HF Ballast.

Corrocoating of CW / ACW Pumps

Installation of Energy Efficient Epoxy Coated Cooling Tower Cell Fan Blades.

Modification of motor driven Cooling Tower Makeup system to Gravity System.

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Draining of Abnormal sump Water by gravity to common monitoring basin.

Plant Compressor Air System pressure set point reduced from 8.5 Bar to 7.5

Bar

Steam & Water Analysis System (SWAS) drain water recovery to reserve feed

water tank.

During Summer Bypassing of Pretreatment plant.

Energy saver installed in MLDB.

Dosing Of Alum in Pretreatment plant by gravity

Dosing Of H2 SO4 in Circulating water System by gravity

Dosing Of H2 SO4 in Effluent Treatment Plant by gravity

Illumination System : Building

Replacement of FL lamps (40W) with CFL (20W) lamps at non essential area

Illumination System : Street Lights

Replacement of HPSV lamps (270W) with CFL (75W) lamps

Steam Turbine Condenser Bullet Cleaning is practiced during opportunity.

For improving steam turbine & HRSG performance, Evaporator section chemical

cleaning is practiced.

As a proactive, after implementation of many energy saving program Station hasconducted third party plant energy audit in Sep’09.

Station has implemented SAP package in 2004 for preventive maintenance activityand corrective maintenance activity. After implementation of SAP package historicaldata of the plant is maintained in the server and is readily available for any analysis.

For efficient operation of the station, predictive maintenance is done on plant assets,as transformer dissolve gas analysis, plant equipment thermography, vibrationanalysis of all critical equipments, current signature analysis on electricalequipments, Tan delta test on electrical system.

497

Year Station PLF Station Avail.% %

2003-04 66.19 94.33

2004-05 61.00 98.30

2005-06 45.28 89.39**

2006-07 50.46 97.40

2007-08 60.67 97.41

2008-09 52.50 97.08

2009-10 80.86 90.25**

Plant Performance (PLF/AVL) up to last financial year

Note: ** Station was under Major Overhaul.

Energy Conservation Activities

1. Replacement of Cooling TowerGRP solid cell fan blade withEpoxy Coated Hollow EnergyEfficient Fan Blade:

The CW system is open re-circulating typewith an induced draft cooling tower.Circulating water pumps’ discharge is ledto the condenser. Outlet is returned to thecooling tower for cooling. There are totalten numbers cooling tower cells which arefitted with individual fans. During design,fans were made up of GRP solid fan blades.During ENCON activity and vendor discussion it was revealed that, energyconservation opportunity is available and all cell fan blades are replaced with EpoxyCoated Hollow Energy Efficient Fan Blade.

These cell fan blades are with reduced weight and designed for same air flow withhigher efficiency.

Total investment : INR. 20, 00,533 /-First year energy cost savings : INR. 25, 41,605/-Power saving of 128.95 kW is achieved.

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2. Modifying Cooling Tower makeupsystem from Motor driven pumpingto Gravity system.

For maintaining cooling tower basin level,Clarified water from the clarified water reservoiris pumped by Cooling Tower make-up pumpsand fed to the cooling tower basin to maintainnormal level in Cooling Tower basin

For maintaining cooling tower basin level, two Cooling Tower makeup motors of 30kW are installed, at a time only one pump is in service.

As an energy conservation measure, system study is done for modifying existingsystem to gravity system & system is taken in service from Feb 15, 2010.

Total investment : Rs. 2,44,444 /-First year energy cost savings : Rs. 4, 49,388/-Power saved is 22.8 kW.

3. HPBFP VFD Pressure Optimization

DP across FRS was maintained at 7.0 Bar.

After reducing DP to 5.0 Bar, i.e. by reducingpressure by 2-Bar, temperature margin of @9.0 Deg Cent is observed, which is abovesaturation temperature for avoiding economizersteaming.

So by reducing 2 Bar pressure, powerconsumption of HPBFP reduced by @ 30.00 kW

Total investment : NILFirst year energy cost savings : Rs.5, 91,300/-Power Saving is 30 kW.

4. LPBFP VFD Pressure Optimization

For maintaining LP drum level, boiler feed wateris pumped by two LPBFP Pumps (one working& one stand-by).

System study revealed that by reducingpressure by 0.7 Bar, we are having saturationtemperature margin of @ 6.0 Deg Cent whichis sufficient for maintaining temperature aboveeconomizer steaming.

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So by reducing pressure by 0.7 Bar, power consumption of LPBFP reduced by @ 3kWh,

Annual energy saving of 26280 kWhFirst year energy cost savings, Rs. 57,159/-Investment is: NIL.

5. Illumination System: Building.Replacement of FL lamps (40W)with CFL (20W) lamps at nonessential area

As energy conservation activity Rinfra-SPS hasreplaced existing FL tubes at non essential areawith CFL.

Total 133 nos FL tubes were replaced with CFLlamps.

Existing FL tube power consumption was 40 W & CFL lamp power consumption is20 W.

Energy saving of 35,460 kWh per annum achieved.

Total investment : Rs. 18,900 /-First year energy cost savings : Rs. 26,214.3 /-

6. Standby Closed cooling waterPHE isolated from ACW as well asCCW side

The closed cooling System supplies CCW Waterto the various coolers of auxiliary equipmentlike lube oil coolers of GT, ST; HP/LP feed pumpsetc. CCW water pumps are used to supply theCCW water after cooling in the PHE (plate typeheat exchanger) where CCW water is cooledby rejecting Heat to the ACW (Auxiliary cooling water).

Standby PHE isolated from CCW as well as ACW side. It has been observed thatboth the ACW motor current reduced.

Total investment : NILFirst year energy cost savings : Rs. 90,666 /-Power Saving is 4.6 KW.

500

7. Wind Ventilators

At Rinfra-SPS at different locations dependingon the heat load, motor operated ventilationsystems are installed.

For adopting renewable energy technologies,Rinfra - SPS has evaluated severalmethodologies.

After evaluating site requirement, it was decided to change motor driven ventilationsystem with wind driven ventilators.

Wind ventilators operating working principle is on thermo-siphon.

Total investment : Rs. 3,20,645 /-First year energy cost savings : Rs. 5, 04,970/-Power saving of 4.27 KW per fan.

Energy Management Policy

Reliance Energy Limited is committed to be the most efficient integrated energyutility in the world.

Our mission is to use all energy resources most efficiently and thereby minimizingthe impact of our operations on environment and conserving the scarce naturalresources.

This we plan to achieve by,

Adopting appropriate energy efficient and clean technologies in process design,

procurement, implementation and also continually upgrade our performance

Managing efficient use of all forms of energy by adopting industry wide best

practices

Continually benchmarking our energy performance against the best in the

world and improving our competitiveness by training and knowledge sharing.

Creating awareness about efficient use of energy and conservation methods

amongst all our stakeholders

Carrying out regular energy audits to identify areas for improvement

Complying with all relevant state regulatory and statutory requirements on

energy management.

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Environment & Safety

Reliance Energy believes in sustainable development and aims at preservation andpromotion of environment in all its activities. SPS has qualified ISO14001 & OHSAS18001 since Dec’2005 & committed to follow all the guidelines as per ISO standards.Following major improvements have been made during last three years:

Zero discharge is continuing since May 2006.

Water Consumption & Chemical Consumption reduced by Maintaining COC up

to 12.

Continuous monitoring of Stack Emission through CEMS & modern in-house

Environment Analysis Laboratory and confirm Air, water, emission, hazardous

waste, noise parameter within target limit.

Annual Third party Safety audit against naphtha leakage, fire, lightening arrester

completed in Aug’09.

SPS has got distinction for zero accident free hours till end of this financial

year 2008-09.

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Second Prize Thermal Power Stations

GMR VEMAGIRI POWER GENERATIONLIMITED

Vemagiri Village, Distt. East Godavari (Andhra Pradesh)

Unit Profile

GMR Vemagiri Power Generation Ltd., promoted by GMR Group of companies,established a natural gas based power generation unit with an installed capacity of388.5 MW at Vemagiri village, Kadiyam Mandal of East Godavari District AndhraPradesh between latitudes 160 55' & 170 and longitude 810 45' & 810 50'. Thesite which is about 7-8 km south east of Rajahmundry town The Vemagiri projectconsists of one advanced class industrial heavy-duty type Gas Turbine with generator(GE's PG 9351 FA), one steam turbine with generator, one triple pressure heatrecovery steam generator (HRSG) all capable of operating in combined cycle mode.The combined cycle system is an optimized and matched system of high technologypower generation equipment, software and services configured for convenientintegration with the balance of the plant to form an economical power plant.

Economical performance of function, either power generation or power and thermalenergy production with an efficiency of around 55 - 58%, is the outstandingcharacteristic of combined-cycle systems

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Energy Consumption

With the implementation of various energy conservation projects and the conversionof HSS pot lines to Pre-Baked pots, there is a substantial reduction of energyconsumption. There is steady decline of specific energy consumption in the lasttwo years, which is evident from the table and graphs, which are mentioned below:

Unit 2009-10 2008-09

Annual Generation MU 3011.2 678.2

Total Electrical Energy

Consumption MU 94.0 29.6

Fuel Consumption MMSCM 568.8 128

Specific energy Consumption (Billion kCal/ year) 5.12 1.24

Heat Rate kCal/kWh 1700.82 1825.31

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Energy and resource conservation during the project stage

Case studyGVPGL has taken many proactive measures to ensure that its activities do nothave adverse impacts on the environment. Towards this end, it has taken up manyprojects involving process improvement or modification and installation of latestenergy saving equipment to save natural resources like water, mitigate pollution,and conserve energy.

1. Rainwater Harvesting

� The objective of the rain water

harvesting is recharging groundwater.

The rain water collected from the roof of

buildings is channelized through the rain

water down comers and routed to the

garland drain around the buildings. These

garland drains are connected to the plant

storm water drainage network system all

around the plant. Several recharge wells

will be located at strategic.

505

locations within the plant and will be interconnected to the storm water drainage

system.

� The storm water drain will be finally connected to the Guard Pond. The

surplus water received in the Guard Pond will be diverted to Kadiyam ava

drain

2. DLN -Dry Low Nox combustion

� Natural gas is used as a fuel in the GVPGL facility, which emits NOx.Conventionally, NOx emissions are controlled by using pure DM water orinjecting steam along with the fuel. This method involves consumption ofnatural resources like water, power, additional fuel, and chemicals, and, inturn, needs pollution control measures.

� The alternative latest technology for controlling NOx emissions is usingDLN burners, which do not use DM water or steam and maintain the NOxlevels at less than 20 PPM (parts per million). NOx (oxides of nitrogen) arethe main air pollutants emitted from the facility. DLN (dry low- NOx) burnershave been installed in the facility to control NOx emissions

� The dry low NOx II (DLN-2) control system regulates the distribution offuel delivered to a multi-nozzle combustor arrangement. The fuel flowdistribution to each combustion chamber fuel nozzle assembly is a functionof combustion reference temperature (TTRF1) and IGV temperature controlmode. Diffusion, piloted premix, and premix flame are established bychanging the fuel flow distribution in the combustor. By a combination offuel staging and shifting of burning modes from diffusion at ignition throughfull pre-mix at high load, dramatically lower NOx emissions can be achievedabove 40% load than with conventionally controlled and fired combustionsystems

506

Mode/Operating Range

� _ Primary - Fuel to the

primary nozzles only. Flame

is in the primary stage only.

This mode of operation is

used to ignite, accelerate

and operate the machine

over low- to mid-loads, up

to a pre-selected

combustion reference

temperature.

� _ Lean-Lean - Fuel to

both the primary and

secondary nozzles. Flame is

in both the primary and

secondary stages. This mode of operation is used for intermediate loads between

two pre-selected combustion reference temperatures.

Secondary - Fuel to the secondary nozzle only. Flame is in the secondary zone

only. This mode is a transition state between lean-lean and premix modes.

This mode is necessary to extinguish the flame in the primary zone, before

fuel is reintroduced into what becomes the primary premixing zone.

Premix - Fuel to both primary and secondary nozzles. Flame is in the secondarystage only. This mode of operation is achieved at and near the combustionreference temperature design point. Optimum emissions are generated in premixmode

� GVPGL is the only plant in INDIA with DLN 2+ (advance technology of DLN)technology with a NOx level less than 25 ppm.

� Now the upcoming gas based power plants are adopting this technology fortheir new plants.

� Now during the operational stage the NOx values maintained are as below

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And continues Emission Monitoring system is installed online which monitors theflue gas parameters.

� 400 KV Switch Yard

A 400 KV switchyard with one andhalf beaker switching scheme isprovided for evacuation of powergenerated in the plant through twonos 400 KV transmission lines toAPTRANSCO sub stations due to whichthe line current is minimum and hencetransmission losses are minimizehence forth distribution losses areminimized.

Energy and resource conservation during the operational stage

In compliance with requirements (process improvement/modification)

� Tuning of IGV AngleThe gas turbine compressor air flow is regulated by IGV (Inlet guide vane)The DLN-2.0+ combustor emission performance is sensitive to changes infuel to air ratio. The DLNx combustor was designed according to the airflowregulation scheme used with IGV Temperature Control The IGVs open fromtheir minimum value as the turbine increases load while on the exhausttemperature control curve until they reach a maximum at Base L Operationof the gas turbine. During the performance review GVPGL decided to changethe operating range of the Inlet Guide vane from 26°C - 82°C to an operatingrange of 26°C- 86 °C.

1. "Increasing the maximum operating angle of IGV to 86 degrees has reducedthe pressure drop across the compressor and a lower in resultanttemperature depression of air flow. The compressor ratio was increasedfrom 14.2 kg/cm2 to 14.6 kg/cm2 which have significantly improvedcompressor efficiency and GT / Plant output.

2. This change in IGV angle has significantly reduced the attemperation waterconsumption in the superheated of HRSG. Attemperation reduced to 23MT as against 40 MT earlier thereby improving the Heat Rate of the Plant.

� Provision of Re heaters in HRSG

GVPGL is provided with condenser preheaters which will heat the feed waterand release the burnt flue gases at a minimum temperature of around 89 deg Cwhich improves the HRSG efficiency and also reduces the environmental effects.Reheater is provided on exhaust of High pressure system which gets heated in

508

HRSG and come as Hot reheat steam which enters as IP-steam to steam turbineand expands due which the overall efficiency of Plant increasesBeyond compliance to statutory requirements (proactive practices)

� Process modification in the auxiliary cooling water system of thesteam turbine

The cycle of concentration was increased from 6 to 8 in the auxiliary coolingwater system of the steam turbine. This reduced effluent generation, chemicalconsumption, and load of effluent treatment.

GVPGL designed to operated in Combined cycle mode always in view of this no By-pass stack is envisaged, hence forth GVPGL cannot operate in simple cycle whichminimizes the environmental impact effects and saves the fuel energy.

� ELECRTICAL SYSTEM

a. Lighting voltage optimization: The voltage supply level for the plantlighting is more. It was proposed to change the tap positions intransformer. After changing the tap positions voltage and current arereduced.

b. Dedicated lighting transformer installedc. For discharge lighting, optimum voltage is around 210Vd. For every 1% increase in voltage above optimum level, energy

consumption increases by 1%e. About 10% of total saves found by optimization of voltage. Nil investmentf. Annual savings - Rs 4.00 Lakhs

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Sl. No. Energy Saving Description Savings Investment paybackActions period

1 HP-BFP ARV passing Install multistage 100 kW 25 Lakhs 7 monthspressure reductiondrag valves Pressureis reduced in manystages (13 - 40)avoiding the highpressure differenceacross the valve andthereby reducing thefurther erosion of itsseat

2 Maintain a Optimum Reduced pressure 40 KW NIL 0DP across the feed drop across CVstation gradually Target to 6

bar and operate theCVs at maximumopening

3 Using of the IA 1.) Estimates the 7.6 Lakhs 0.5 1 monthinstead of CPD for header pressure dropthe inlet air pulsation during the IA pulsation

& according action planto be determined

4 Use of Both PHE in Operation of both NIL 0parallel operation PHE's in parallel

operation hasdecreased the DPacross Heat exchanger

5 Optimizing the air Established optimum NIL 0pressure pressure required for

the control valves andmaintained optimumheader pressure whichdecreased thecompressor loadingrate

6 Lighting Transformer Optimum voltage 10% NIL NilOptimum voltage maintained in line with

the safe equipmentperation by changingap position to adjustthe voltage to 210V inlighting transformer

510

Environmental Profile

The company has an Environmental Policy at both corporate and facility levels. Italso has an environment Environmental Management Plan

Environmental Management Plan

Environmental risk Management is in Place and the Objective of the Environmentalrisk management is "To determine the risk of major hazards having damage potentialto environment, life & property and provide a scientific basis to assess safety levelof the facility and preventive measures against failure occurrence".

Detailed characterization of various environmental components Viz Air, water, Noise,Land and Socio-economic were studied and measures were determined. An dedicatedambient Air Quality Monitoring station is in place for continuous monitoring ofambient air quality consists ting of suspended particulate Matter (SPM) and gaseouspollutants like oxide of Nitrogen (NOX) and sulphur Dioxide (SO2)

Environment Policy

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Second Prize Thermal Power Stations

DR. SHYAMA PRASAD MUKHARJEE THERMALPOWER STATION, CSPGCL

Korba-East (Chhattisgarh)

Unit Profile

Chhattisgarh State Power Generation Co. Ltd. is a fully integrated utility engaged

in generation of electricity. 2X250MW DSPM TPS KORBA (EAST) is one of the

company's best generating facilities at Korba. Power generated from DSPM is

transmitted through State Load Dispatch Center.

DSPM units are the 2X250MW sets supplied by BHEL INDIA and are in operation

since March-2008. Since commissioning DSPM is performing well and presenting

example of best operation and maintenance practices.

DSPM units are maintaining very high level of Plant Load factor (PLF) when compared

to national average.

Unit I came into operation on dated 21/10/2007 where as Unit II put into operation

dated 20/03/2008. Taking minimum period of stabilization both units have started

performing well and during 2008-2009 the PLF of DSPM reached up to 84.8% and

during the year 2009-2010 the PLF of DSPM increased up to 87.65% At Present

the DSPM TPS is performing best with a PLF of 94.93% up to Oct. 2010.

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Energy Consumption

Overall station generation during 2008-09 and 2009-10 is as follows

Secondary station fuel oil consumption and station auxiliary power consumption ofthe plant during 2008-09 and 2009-10 is as follows.

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Average station heat rate of the plant is as follows

Overall station PLF of the plant is as follows

Energy conservation & savings details

After commissioning during 2008-09, DSPM units with a minimum period ofstabilization achieved annual PLF of 84.8% with overall generation of 3714.07 MU.The gross heat rate was 2577 kCal/kWh.

By the time 2009-10 by best operation and maintenance practices, as mentionedabove our PLF improved from 84.8% to 87.65%with a generation of 3838.93MU.

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By reducing unnecessary tripping by best operation and maintenance activitiesstation reduced its specific oil consumption from 1.358 to .756 ml/kWh .

By operating the unit at optimum parameter and minimum deviation from designeddata, station improved its heat rate from 2577 kCal/kWh to 2481.43 kCal/kWh.

Activities implemented by the station to achieve Energy Saving

1. By operating unit at designed parameter overall efficiency of plant is improved.

2. Reduction in partial loading results in higher PLF hence improvement and

electrical energy saving.

3. Reducing partial losses.

4. Avoiding idle running hours of CHP.

5. Utilizing max capacity of conveyor Belts of CHP.

6. Proper switching control of lighting load.

7. Reduction in specific oil/coal cons results in saving in aux power cons.

8. Utilizing max capacity of existing aux by operating at full load.

9. Proper up keeping of running aux reduces outage of aux and consequently

unwanted outages of units.

10. Reducing various steam, water, coal and air leakages.

Future Energy Reduction Targets

1. Secondary fuel consumption below 0.70 Ml/Kwh.

2. Specific coal consumption below 0.70 Kg/Kwh.

3. Auxiliary power consumption below 7.7%.

4. DM water make up below 1.0 %.

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Certificate of Merit Thermal Power Station

ULTRATECH CEMENTS LIMITEDUNIT BIRLA WHITE

7.5 MW THERMAL POWER PLANTJodhpur (Rajasthan)

Unit Profile

Birla White is the 7th largest White Cement plant in the world and largest in Indiain Plant capacity. Birla White has moved from a single commodity premium productto a multi specialty product company with market leadership position and exportingto 26 countries in 6 continents.

TPP has Atmospheric fluidized bed Combustion (AFBC) steam Boiler - capacity 38TPH and is designed to fire multi fuels as below.

1. F-grade coal - 100%

2. Lignite - 100%

3. Combination of Pet coke & F grade coal in ratio of 60:40

Birla White commissioned its 7.5 MW capacity Thermal Power Plant in the month ofMarch 2007. This plant is a multi-fuel plant done on an EPC basis. The supply of 38TPH boiler is from CVPL Trichy and Turbine is from HTC China. Enhanced capacityof Thermal Power Plant 7.5MW to 8.0MW by modification in Boiler and Turbine inthe month of August, 2010.

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Thermal Power Station Design Details

Thermal Power Station Operating Details

S N Particulars Current completed Previous completedDesign details financial year financial year

2009-10 2008-09

(a) Capacity of the station (MW) 8.00 7.5

(b) Average Station Gross Heat Rate 3650 3650on GCV basis of the fuel used,(kcal/kWh)

(c) Station Net Heat Rate on 2800 2800GCV basis of the fuel used,(kcal/ kWh)

(d) Station Auxiliary Power 10 10Consumption (%)

(e) Station Secondary Fuel Oil NA NAConsumption (ml/kWh)

S N Annual Operating Parameters Current completed Previous completedfinancial year financial year

2009-10 2008-09

1 Overall Station Generation (MillionkWh/year) 62.34 54.8

2 Overall Station PLF (%) 95 84

3 Coal/ Lignite/ Pet coke Consumption (Million Metric Tonne)(Please specify the name of Fuel used)

Overall Station fuel consumption(Coal/ Lignite/BiomassConsumption) (Million MetricTonne/ year) 0.33

Average Gross Calorific Value(GCV)of fuel (kcal/kg) 7215 4142

Overall Thermal energy used inthe station due to the use ofabove fuel(Billion kcal/ year) 23764.34 20013.68

Gross Heat Rate on GCV basis(kcal/ kWh)

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1 Overall Station Gross Heat Rateon GCV basis (kcal/ kWh) 3300 3637

2 Net Heat Rate on GCV basis(kcal/ kWh)

Overall Station Net Heat Rate onGCV basis (kcal/ kWh) 2766.09 2750

3 Auxiliary Power Consumption ofGross Energy Generated (%)

Overall Station Auxiliary PowerConsumption (%) 8.2 9.5

Raw material Consumption during last 2 years. (MT per year)

S. N. Name 2008-09 2009-10

1 Pet coke 6844.97 2931

2 Coal 11121.31 213

3 Lignite 32480.46 0

Energy Conservation Commitment, Policy and Organizational Set-Up

� The management of Birla White is committed to reduce energy

consumption.

� Monthly review on energy consumption by top management.

� Launching of Power Champion Scheme to encourage employees for energy

consumption and recognition of best performance teams.

� Monthly Review of Energy consumption on section wise on 2nd working

day of every month in Mass communication meeting.

� Up gradation of technology with low energy consumption, like installation

of RABH in place of ESPs, Installation of Vertical Roller Mill for Cement

Grinding etc.

� Explore the possibility of cheaper alternative fuel and waste products

(Like agro waste, Bio fuel etc.)

� At the project planning level, finalize only low energy consumption with

eco friendly technology.

� Continuous monitoring of energy consumption through ENERCON energy

system.

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Energy Conservation Achievements

Year ofCommissioning of the

projects

Projectdescription

Achievement of energy savings per year basis Investment

incurredon theproject

Rs.(Lakhs)

Electricity

(Kwh)

Fuels*

Coal(tonnes)

F.Oil(kL)

Gas(lakhNm3)

Total(fuel) in(MTOE)

Totalsavingsin (Rs.Lakhs)

2009-10 Modification in NA 5030 NA NA 1710boiler flue gaspath &refractoryinside theboiler toincrease thealternate fuelfiring otherthan Indiancoal Rs 2

Lakhs

Modification in 8.94 NA NA NAdischarge duct 0of Boiler &replaced theflap typedampers by Rs. 2plate type shut Lahsoff dampers toreduce thepressure dropin duct

Optimization of 2.44 NA NA NAauxiliary cooling 0water pump 249.85 Rs. 05operation to Lahsspeed mode byproviding VFDdrive

Modification in 1.22 NA NA NAdischarge duct 0of ID fan &replacement ofFlap typedampers to Rs. 0.4plate type shut Lahsoff dampers toreduce thepressure dropin duct

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Optimization of 0.48 NA NA NAcondensate 0extractionpump to speed Rs. 0.2mode by Lahsproviding VFDdrive

TPP plant 0.98 NA NA NAlighting circuit 0 Rs. 0.2modification Lahs

Optimization of 0.756 NA NA NAAsh handlingoperationbased upon theHooper levelsinstead ofcontinuousrunning NIL

Reduction in 0.24 NA NA NAboiler PA 0headerpressure byinstalling IGVdamper in PAfan duct NIL

Optimization of 0.33 NA NA NAcooling tower 0fan operationwithtemperaturedifference NIL

1. Automation of Ash Handling System. Prepared and Implement a group logicsequence of all the fourteen drives of ASH Handling System in DCS to run inautomatic mode for selected period of time set by the operator with start /stop alarm indication and the indication of run time and stop time. Preparethe tantalizer for calculating the total running hours and observe that systemis running for twelve hours a day. The power consumption of Ash HandlingSystem is reduced by 0.756 Lakhs kWh per annum

2. Auxiliary cooling water is operating on direct on line starter. During plantteam observation it was found that it is operating through throttling resultingin consuming of more power. Given supply to cooling tower motor throughvariable voltage variable frequency drive (VVVFD) and by maintaining, requiredflow and pressure by varying the speed of the motor, the power consumptionof Auxiliary cooling water pump is reduced by 2.44 Lakhs kWh i.e. saving ofRs 11.71 Lac per annum.

3. Plant was using 70 watt HPSV (High Pressure Sodium Vapor) fitting , whichwas replaced with 18 watt CFL fitting. The CFL fitting is giving the requiredillumination for path

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4. Firing of 100% Petcoke (Petroleum Industry waste) in AFBC boiler , a use ofalternative fuel over fossil fuel like Indian coal .Resulted in

� Conservation of coal energy.� Reduction in direct electrical energy by reduction in auxiliary power

consumption of power plant due to petcoke being a high heat value &low ash fuel.

5. Installed KVAR controller and HT capacitor and main RSEB Line

Environment and Safety

Major Environmental Projects taken during the year 2008- 10

The significant achievements and efforts of BW during 2009 are given below:� Tree plantation around 5000 during 2009 & 2010 at various location in Thermal

Power Plant, Cement plant, colony, school and near by villages.� There is zero effluents discharge from industry. Only domestic waste water

(sewage) is being treated at sewage treatment plant (STP) and consumed inPlant and Horticulture.

� Installed higher capacity bag house at crusher� Installed bag house at coal dump hopper

Safety

Birla White is an OHSAS 18001:2007, certified Unit, It continuously focus onBirla White has a structured Safety, Health & Environment (SHE) Subcommitteewhich comprising of the representation from the various functions.