7.5 MW Biomass Power Plant VishnuVidyuthIndiaLtd

VISHNU VIDYUTH INDIA LIMITED
NARASINGAPALLI
VISHNU VIDYUTH INDIA LTD VISAKHAPATNAM
VISHNU VIDYUTH INDIA LIMITED

(7.5MW BIOMASS POWER GENERATING UNIT)
BRIEF DETAILS OF THE PROJECT
The project activity comprises of one steam generator(Boiler) and one power generator(Steam turbine) with
capacities of 32TPH, 66 Kg / Sqcm, 485 Deg C, Installed Capacity of 7.5MW at Narasingapalli village of Kasimkota
Mandal in Viskahapatnam District, Andhra Pradesh,India.The main purpose of the project activity is generation
of electricity by using biomass residues such as paddy husk, pamoline fibre, baggasse, causrina branches,
groundnut shells,poultry litter, woody biomass etc and exports the generated electricity to the state owned
power utility company named Andhra Pradesh Transmission Company(APTRANSCO), ie APEPDCL.
The 11KV generated power from the unit stepped up to 11/33 KV and evacuated to 132KV Narasingapalli
substation which is 0.4 km away from the power plant. In this process there are no green house gas emissions
or burning of any fossil fuels.
The 7.5 MW power project was synchronized with grid on 26th Dec 2012 and in operational standby.
Biomass fuel and its availability
• The rice husk is being used as a main fuel. Seasonal agro residues like baggasse ,saw dust, ground nut shells, casuarina
branches ,Jamoil skin, Palmoline fibre etc.,.The fuel on receipt in the plant premises is weighed at the Electronic weighbridge
installed at the plant main gate at National Highway -16, , unloaded in the fuel yard and stacked properly. The type of fuel,
quantities, vehicle No., etc are recorded by weighbridge staff and the same was certified by the fuel yard staff and security
personnel.
Technology
The technology(Rankin cycle) or power generation process using biomass fuels is converting the kinetic energy
available in the steam into mechanical energy using steam turbines and then to electrical energy using
alternators. The generated power will be transferred to match the nearest grid substation for proper
interconnection and smooth evacuation of power.
VISHNU VIDYUTH INDIA LIMITED Page 2

Other Benefits:
Operational success and business case
In and around of 100 Kms from the plant we are getting paddy husk from the rice millers and small
farmers. The rice husk is being used as a main fuel. Seasonal agro residues like baggasse, saw dust,
ground nut shells, pamoline fibre, casuarinas branches etc., were also used according to the
availability.
Financial viability of plant
a. Capex : capital expenditure – approximately Rs.55 Crores

b. O&M cost - Rs.4.69 /per unit
c. Revenue streams and Applicable tariffs : Rs. 6.47/unit approximately from AP TRACSCO
Andhra Pradesh Transmission Corporation
d. Project IRR – 15.63%
e. Balance Payback period – 7 years
f. Key sources of financing – 1. Equity shares 2. Retained earnings and
3. Bank finance.
g. Challenges and Outlook for biomass based energy
As the plant is being operating depending on the agriculture bio mass residual fuels procurement
and preparation of almost seven thousand tons fuel per month is a big challenge. Efficient
combustion of the multi fuels needs more attention and operational skills to reduce unburnt carbon
losses as these fuels differ in moisture and calorific values. Drying of chopped fuel difficult as some
variety of fuels will have almost 50% total moisture.
There is a drastic change in the industrial scenario lot of small and middle scale industries like
solvent oil extraction plants, ethanol plants and Beverages plants are grown up and utilizing paddy
husk as an idle fuel. Due to this the price of the rice husk escalated.
Lot of land agriculture land converted for real-estate and commercial use which resulting shortage of
paddy husk creating more demand, the drastic change in environment also leads for shortage of
paddy husk.
The abnormal escalation of fuel price contributing major role attributing to run the plant without
economical viability.
Viewing the above there is no any further planning to enhance the capacity of the plant

PROJECT LOCATION OF THE PLANT
Location
The Vishnu Vidyuth India Ltd was located at Narasingpalli village, Etcherla Mandal, Srikakulam District, Andhra
Pradesh State, in India. The geographical coordinates are 18031’N and 8309’E
General Details
1 Name of the project VISHNU VIDJTY IDDIA LIMITED
& NARASINGABILLI VILLAGE, KASIMKOTA MANDAL
Registered office address YELAMANCHILI,VISAKHAPATNAM - 531055
2 Location and address of the project NARASINGABILLI VILLAGE, KASIMKOTA MANDAL
YELAMANCHILI,VISAKHAPATNAM - 531055
3 Name of the authorized person CH.CHINASANYASIRAJU
Designation DIRECTOR
Phone no and STD code 08924-
Fax
E-mail Vishnuvidyuth.technical@gmail.com
Mobile
5 License capacity of the plant(MW) 7.5MW
6 Installed capacity of the plant 7.5 MW
7 Operating days in a year 300
8 Date of synchronization 2012 DEC 26
9 Date of Commercial Operation 2012 DEC 26
10 Total Project cost in Rs Crores 55 crore
Land 22.5 acres
Civil Work
Plant & Machinery
Miscellaneous Equipment
Pre-operative expenses and others ( inc IDC) Allocated to Project Cost components.
11 Means of Financing i) 18.270 Cr from IREDA, New Delhi,
ii) 0.25 Cr from MNES as Subsidy
iii) 16.13 Cr from Promoters as promoter’s
contribution.
12 Financial Institutions involved in funding of i) Term Loan- IREDA
the Project and for operations. ii) Working Capital loan from ING VYSA BANK
(Rs.1.50 Cr) – Presently Andhra bank
13 Project basic Technology Power Generation using Biomass direct

combustion
14 Project Consultant S.V.CHALAPATHIRAO

15 How was the Project Implemented In-House

(Turnkey/EPC/in-house ..etc)
16 Any other social/economic improvement in Direct and indirect employment of local, agri
the area of the project residues will have commercial value and formers
will gain extra income.

A. Plant and Equipment Details
A Boiler
1 Make of Boiler WALCHANDNAGAR INDUSTRIES LIMTED
2 Type of Boiler Bidrum. Water tube. Travelling
grate Biomass fired. Natural
circulation , Bottom supported,
balanced draught boiler
3 Capacity TPH 32
4 Design Pressure Kg/Cm2 66
5 Temperature Deg C 485
6 Heating surface Square M 2053
area
6 Type of Chimney RCC
Height of Mtr 60
Chimney

B ESP (Electro Static Precipitator)

1 Make THERMEX LTD
2 Model TE - 1
1 Inlet dust gm/Nm³ 10.5

concentration at
MCR
2 Gas flow cu. m /Hr 108000
3 Inlet Gas density Kg/Cu M 0.846
4 No of Fields. 3
5 Design: SPM mg/Nm3 <50
6 Transformer KV /MA ESP 1 & 2 -
rectifier Rating 120/200, ESP – 3
,120/300
7 Collecting Thk X Length X width in 1.5 X 6.75 X 650
electrodes mm
8 Emitting Thk in mm X No of turns 2.5 X 55
electrode (ss)


C Turbine
1 Make HCTC
2 Type Fully condensing – FC, Back pressure –BP,
Extraction cum condensing – EC, Extraction with
back pressure - EB
3 Capacity MW 7.5
4 Inlet Steam ATA 66
Pressure
5 Inlet Steam Deg. C 485
Temperature
6 Inlet Steam Flow TPH 32
7 Turbine Speed RPM 3000

E ALTERNATOR
1 Type QF1/WU7.5/2
2 Type of BRUSHLESS
Excitation system
3 Continuous rated MW/MVA 7.5/ 9.375
output
4 Rated Speed RPM 3000
6 Voltage Kvolts 11
7 Full Load Current Amps 492
8 No. of Poles 2


F Exciter
1 Type of exciter BRUSH LESS
TFL 380/150-6
2 Output kW 80
3 Voltage Volts 265
4 Current Amps 300
5 Frequency Hz 50
6 Revolutions RPM 3000
7 Excitation Volts 93.08
voltage
8 Excitation current Amps 2.81
9 No. Phases 3
10 No. of Poles 2
11 Power Factor 0.8
12 Insulation class F


G Surface Condenser
1 Manufacturer CICB-Chemicon Pvt
Ltd
2 Type PARALLEL FLOW,TWO
PASS
3 Quantity of Steam T/hr 30.11
4 Enthalpy of condensing steam 576

Kcal/Kg
5 Cleanliness factor 0.75
6 Size of tube mm
7 Total Number of Tubes
8 Cooling Surface area Sq 55722.000

mm
9 Quantity of cooling water Cu 758.43
m/Hr
10 Cooling Water inlet /outlet 0
C 32/42
Temperature
11 Velocity of cooling water m/Sec 1.83

12 No of water side passes 2
13 Water Chambers Divided

14 Water Chamber Design Atg 11

Pressure
15 Steam side Design Pressure Atg 0.92 Vaccum
16 Steam side Test Pressure Atg Hyd Fill

17 Water side Design 0
C 60
Temperature
18 Steam side Design 0
C 120
Temperature
19 Test Temperature 0
C Ambient
20 Hotwell capacity (NWL to Min 6
LLWL)

H Cooling Tower
1 Type of Cooling Tower COUNTER FLOW INDUCED

DRAFT
2 No of cells 3
3 Flow through each cell M3/Hr 975
4 Total Flow M3/Hr 1950
5 Hot water Temperature Deg C 42
6 Cold water Temperature Deg C 34
7 Design wet bulb temperature Deg C 29
8 Range Deg C
9 Approach Deg C
10 Cell Length M 7.53
11 Cell Width M 7.41

12 Cell Height(from FGL to desk level) M 6.4
13 Stack Height M 8.0
14 Air Inlets No/Cell 3
15 Air inlet Height M 2.25
16 Basin Dimensions (L X W X H) M 22.7 X 7.9 X 2.5
17 Cold Water sump Dimensions M 22.2 X 7.4 X 2.0
18 Material of fan Blades / number of blades FRP / 6

19 Fan diameter mm 4.25
20 Fan air flow rate per cell Cu.m/hr 413856
21 Gear box model / Type B 120 / Single Reduction

22 Reduction ratio 5.615 : 1
23 Out put speed Rpm 288
1 Make
Industrial systems and Equipment Ltd
ID Fan Flow (M3/Sec) at MCR 25
Pressure mmwc 215
Temperature Deg C 150
Fan speed (RPM) 990
Motor Make SIEMENS
Motor Rating KW 150

2 Make
FD Fan Flow (M3/Sec) at MCR 15
Pressure mmwc 225
Fan speed (RPM) 1480
Motor Make SIEMENS
Motor Rating KW 55

3 Make
SA Fan Flow (M3/Sec) at MCR 5.0
Pressure mmwc 30
Fan speed (RPM) 1480
Motor Make SIEMENS
Motor Rating KW 55

I.I Boiler Feed Water Pump

1 Make KSB PUMPS LTD
2 Model HAD 65/15 Multi stage
centrifugal pump
3 Type of Motor INDUCTION
4 Capacity M3/hr 40
5 Head Mwc 950
6 Drive Power (kW) KW 200
7 Motor Speed RPM 2983
8 No of Stages 15
9 Minimum Flow M3/hr 8.7


I.II Deaerator
1 Type Horizontal spray cum tray
type
2 Capacity T/Hr 35.5
3 Heating Steam Quantity MT/Hr 503
4 Heating Steam Pressure Kg/Cm2
5 Operating Pressure Kg/Cm2 1.46
6 Design Pressure Kg/Cm2 4.5
7 Inlet Water Temperature °C 35
8 Out let Water Temperature °C 108

TURBINE AUXILIARIES
J Turning Gear
1 Motor rating KW 2.2
2 Speed Rpm 1730
3 Load Amps 4.5
4 Mounting Flange
J.I Ejector (Main)

1 Manufacturer
2 Working Steam Pressure kg/Cm2g 10
3 Working Steam temperature 0
C 350
4 Steam Consumption kg/hr 250
5 Suction Pressure kg/Cm2 (a) 0.035
6 Capacity of dry Air kg/hr 10.2
7 Suction mixture (Dry air + Water vapor) kg/hr 32.65

J.II Condensate Extraction Pumps

1 Motor Rating Kw 18.5
2 Speed RPM 2930
3 Type CPK GCM /50-250
4 Capacity M3/h 32
5 Discharge Pressure Kg/cm2 8
J.III Oil Coolers (1 X 100%) SHELL SIDE TUBE SIDE

1 Make BHEL BHEL
2 Medium Oil Cooling Water
3 Design pressure (Kg/Cm2(g)) 9 6
3 Design Temperature (Deg .C) 100 80

5 Test pressure (Kg/Cm2(g)) 11.7 7.8

6 Test Temperature (Deg .C) Ambient Ambient
7 Flow Quantity ((m3/Hr) 38.32 100
8 Inlet Temperature (Deg .C) 45 35
9 Outlet Temperature (Deg .C) 59.5 37.2
10 No .of passes 1 4
11 No. of Tubes --- 776
12 Tube size (OD X Thk) mm Mm Ǿ 15.875 X 1.24
13 Pressure Drop (Kr/cm2) 0.2 0.3
14 Surface Area (m2) 84

J.IV Auxiliary Oil Pump (AOP)

1 Motor Rating Kw 30
2 Speed RPM 1470
3 Capacity l/s 16.67
4 Discharge Pressure Kg/cm2 8.5


J.V Emergency Oil Pump (EOP)

1 Motor Rating Kw 3.7
2 RPM RPM 1500
3 Type 110 V DC Motor
4 Capacity l/s
J.VII Oil Vapor Extraction Fan (OVEF)

1 Make FLAKWOOD
2 Type HD-4-20A-H2-1213
3 Capacity M3/Sec 0.11
4 Motor Rating HP 1.5
5 Speed Rpm 2750

K RO Plant
1 Inlet Flow m3/hr 9
2 Output Flow m3/hr 5
3 Reject Water /Hr m3/hr 2
K.I DM Plant
1 Inlet Flow m3/hr 7
2 Output Flow m3/hr 5
3 Effluent Water Flow (in 3 days) m3/hr 7
K.II RAW WATER PUMPS

1 Make KSB
2 Type MEGA G 40-160
3 Capacity M3/Hr 4.5
4 Motor Rating KW 3.7
5 Speed Rpm 2880
K.III D.M.TRANSFER PUMPS

1 Make KSB
2 Type MEGA CHEM C 20-200
3 Capacity M3/Hr 5
5 Speed Rpm 2840

K.III M.G.F. PUMPS

1 Make KSB
2 Type MEGA G 40-160
3 Capacity M3/Hr 4.5
5 Speed Rpm 2900

K.II Recirculation cooling water pumps

1 Motor Rating Kw 132
2 Speed RPM 1490
3 Capacity M3/h 1000

K.IV Raw Water System

1 Storage Tanks Nos. 1
2 Total Capacity KL 2100000
3 Capacity ( M3 / Hr ) 2100

Fire Fighting System
MATERIAL HANDLING SYSTEM
L Biomass Material Handling System

1 Material BIOMASS
2 Bulk Density –(Cotton Stalk & Coal) Kg/m3 0.8
3 Conveyor Width (Belt Width) /Thickness Mm 800 /8
4 Belt material M24 GRADE NYLONE /
NYLONE 4Ply
5 Conveyor Dev. Length M 250
6 Gear Box Type U – 700,30:1 -2No’s
U – 600,30:1 -1Nom
7 Belt Speed M/sec 0.8
8 Motor Capacity KW 11
9 Motor Speed RPM 1440

Belt Conveyor – 1 = 200 meters
Belt Conveyor – 2 = 80 meters
ASH HANDLING SYSTEM
M Ash Handling System

1 Material FINE ASH
2 Bulk Density T 0.6
3 PNEMUTIC : Capacity TPH 5
4 Conveyor Width (Belt Width) /Thickness mm 600 / 8
5 Belt Speed M/SEC 0.8
6 Belt Width MM 650
7 Motor Rating HP 5
8 Speed RPM 1440
9 Gear Box Type U – 400 30:1
10 Total belt length mtrs 150

M.I Submerge Belt Conveyor

1 Material WET ASH
2 Conveyor Width (Belt Width) /Thickness mm 900/ 10
3 Bulk Density Kg / Cu M 0.6
4 Conveyor: Capacity TPH 4
5 Belt Speed M/SEC 0.5
6 Gear Box Type U - 400 30:1
7 Motor Speed Rpm 1430
8 Motor Rating HP 3

ELECTRICAL SYSTEM
N HT Side Switchyard 33 KV S/s

1 33 KV Lightning Arrestor for Line Make LAMCO
2 33 KV Lightning Arrestor for Transformer Make LAMCO
3 33 KV VCB Circuit Breaker line Make AREVA
5 33 KV Line Current Transformer Make LAKSHMI ENGINEERS
6 33 KV Main Transformer Current Make LAKSHMI ENGINEERS
Transformer
7 33 KV Line C & R Panel Make PASCAL SWITCH CARE
LTD
8 RTCC Panel (Make) Make KIRLOSKER
N.I ABT Meter details
ABT Meter as per APGENCO Norms Serial No 16268048
MAIN METER
1 Make ELSTER ALFA 1800
2 Type Alfa 1800, 3PH, 4 WIRE
3 Class & Accuracy 0.2
4 Power Factor 0.8-1
ABT Meter as per APGENCO Norms Serial No 16268049
CHECK METER

1 Make ELSTER ALFA 1800

2 Type Alfa 1800, 3PH, 4 WIRE
3 Class & Accuracy 0.2
4 Power Factor 0.8
N.II 33 KV Side Breaker

1 Make AREVA
2 Type VCB
3 Rated Voltage Kv 36
4 Full Load Amps 1250
5 Bus Bar Rating KA 25
11 KV Side Breaker
N.III
1 Make ABB
2 Type VCB
3 Rated Voltage Kv 12
5 Bus Bar Rating KA 26.3


N.IV 415V Side Auxiliary Circuit Breaker

1 Make L&T
2 Type ACB
4 Rated Voltage V 500

N.V 415V Side Boiler Auxiliary Circuit

Breaker
1 Make L&T
2 Type ACB
4 Rated Voltage V 415

CONTROL SYSYEM EQUIPMENT
O Distributed Control system

1 Make ABB Automation
2 Analog input / output Modules No’s 136
3 Digital input / output Modules No’s 1072
6 Total number of channels No’s 1208

O.I Air Compressors

1 Make CHICAGO PNEMUTIC
2 Motor power Kw 18.5
3 Maximum Air Pressure bar 7.5
4 Free Air Delivery l/s 30.7
O.II Air Dryer
1 Make
2 Type

3 Capacity Kw
4 Ambient Temp Max / min Deg C 45 / 5
AIR COMPRESSORS

P Backup For relay panels

1 Make NAREEN EELVTRONICS
LTD
2 Capacity Volts 110

P.I Backup For DCS

1 Make DUBAS ENGG PVT LTD
2 Capacity Volts 240
3 Full Load Kva 2 X 6 KVA

P.III Diesel Generator

1 Make Kirloskar Cummins
2 Capacity Kva 250

3 Full load Capacity Amps 474.27

4 Speed Rpm 1500

CONTROL ROOM PANELS

33 Kv Control and relay panel AVR Panel

Generator control and synchronizing panel Generator Relay panels


11KV TRANSFORMER


33 KV TRANSFORMER WITH TAP CHANGER

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VISHNU VIDYUTH INDIA LIMITED

VISHNU VIDYUTH INDIA LIMITED

BRIEF DETAILS OF THE PROJECT

Biomass fuel and its availability

VISHNU VIDYUTH INDIA LIMITED Page 2

Operational success and business case

Financial viability of plant

a. Capex : capital expenditure – approximately Rs.55 Crores

g. Challenges and Outlook for biomass based energy

VISHNU VIDYUTH INDIA LIMITED Page 3

PROJECT LOCATION OF THE PLANT

13 Project basic Technology Power Generation using Biomass direct

VISHNU VIDYUTH INDIA LIMITED Page 4

15 How was the Project Implemented In-House

VISHNU VIDYUTH INDIA LIMITED Page 5

A. Plant and Equipment Details

VISHNU VIDYUTH INDIA LIMITED Page 6

B ESP (Electro Static Precipitator)

1 Inlet dust gm/Nm³ 10.5

VISHNU VIDYUTH INDIA LIMITED Page 7

VISHNU VIDYUTH INDIA LIMITED Page 8

VISHNU VIDYUTH INDIA LIMITED Page 9

VISHNU VIDYUTH INDIA LIMITED Page 10

VISHNU VIDYUTH INDIA LIMITED Page 11

VISHNU VIDYUTH INDIA LIMITED Page 12

VISHNU VIDYUTH INDIA LIMITED Page 13

4 Enthalpy of condensing steam 576

8 Cooling Surface area Sq 55722.000

11 Velocity of cooling water m/Sec 1.83

VISHNU VIDYUTH INDIA LIMITED Page 14

14 Water Chamber Design Atg 11

16 Steam side Test Pressure Atg Hyd Fill

VISHNU VIDYUTH INDIA LIMITED Page 15

1 Type of Cooling Tower COUNTER FLOW INDUCED

10 Cell Length M 7.53

11 Cell Width M 7.41

VISHNU VIDYUTH INDIA LIMITED Page 16

19 Fan diameter mm 4.25

20 Fan air flow rate per cell Cu.m/hr 413856

21 Gear box model / Type B 120 / Single Reduction

23 Out put speed Rpm 288

VISHNU VIDYUTH INDIA LIMITED Page 17

VISHNU VIDYUTH INDIA LIMITED Page 18

VISHNU VIDYUTH INDIA LIMITED Page 19

I.I Boiler Feed Water Pump

VISHNU VIDYUTH INDIA LIMITED Page 20

VISHNU VIDYUTH INDIA LIMITED Page 21

VISHNU VIDYUTH INDIA LIMITED Page 22

J.I Ejector (Main)

VISHNU VIDYUTH INDIA LIMITED Page 23

J.II Condensate Extraction Pumps

J.III Oil Coolers (1 X 100%) SHELL SIDE TUBE SIDE

VISHNU VIDYUTH INDIA LIMITED Page 24

5 Test pressure (Kg/Cm2(g)) 11.7 7.8

VISHNU VIDYUTH INDIA LIMITED Page 25

J.IV Auxiliary Oil Pump (AOP)

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VISHNU VIDYUTH INDIA LIMITED Page 27