527

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 OHSAS

18001:2007 & EN ISO 50001:2011 certified, public limited company, was founded
in 1983 to cater to the needs of all segments of steel industry, foundries and heat
treatment industry. Today, Electrotherm is a well-diversified conglomerate having
businesses in the field of Engineering & Projects catering to steel and foundry
industry; transformer manufacturing; steel making; ductile iron pipe making;
manufacturing of battery operated vehicles; renewable energy; transmission line
tower and education.

Electrotherm Kutch Plant is having a state of the art, well integrated 0.5 million
TPA capacity for manufacturing steel. The plant has five induction furnaces of 22
Ton 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 Blast
furnace 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 of
0.6 million TPA, making us the largest producer of TMT in Gujarat.

529
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

530
Energy Conservation initiatives taken in FY 2015-16

Achie vement of Annual e nergy

savings in 2015 -16

Sr. Project D escription El ectricity Coa l Total Total

No. (Lakhs (MT) Savings investment
kWh) in in

Rs. La khs Rs. Lak hs

1 Installation of FRP blade with hub assembly instead of solid GRP

blade and hub ( CT Fan-1 & 3). 3.03 19.75 5.60

2 Installation of 4 Nos of sonic horn (Soot Blower) instead of

Steam 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 of

Steam 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 Steam

soot Blower (3 Nos. LRSB & 10 Nos. RSB) in W HRB-1 0.03 3991.00 155.24 11.00

5 Installed 9 Nos of sonic horn (Soot Blower) instead of Steam soot

Blower (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 and

eliminated spreader and drag chain feeder motor. 0.08 0.53 0.50

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

8 Modification in raw water feeding line in DM plant and elim inated

PWR pump from feeding system. 0.14 0.88 0.00

9 Modification in AFBC-1 Economizer flue gas duct to increase

area 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 VFD

speed more than 90%. For maintaining vacuum, it was required
to run 3 CCW P, therefore they have replaced old drive to new
one to run at 100% speed. 1971.00 76.67 0.10

16 Removed excess refractory on water wall in AFBC- 1 from all

four side to generate more steam and to reduce stack
temperature. 272.25 10.59 0.50

17 In-place of metallic sheet , installed transparent sheet on boiler

field room & mechanical room roof to conserve energy by using
day 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

531
Integrated Management System Policy

532
First Prize Thermal Power Stations
(Coal fired plants >100 MW Capacity)

NABHA POWER LIMITED

Rajpura, 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 Punjab
State Power Corporation Limited (erstwhile PSEB) for a period of twenty five years
under a Power Purchase Agreement (PPA). The plant is built on super critical
technology of Mitsubishi, Japan. It is the first ‘Made in India’ supercritical power
plant to be commissioned and operational in the country.

The plant sources its fuel from South Eastern Coalfields Ltd. (Subsidiary of Coal
India Limited) under a 20 year Fuel Supply Agreement (FSA). The company also
secured approvals to arrange coal from alternative sources to make up for any
shortage in supply of coal under the FSA. Bhakra-Nangal distributary is the perennial
source of water for the plant under an allocation by the state irrigation. The plant is
operated by an in-house experienced team of operations and maintenance
professionals.

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

Commissioning Date : Unit #1: 24-Jan-2014, Unit #2: 06-July-2014

Commercial Operation Date : Unit #1: 01-Feb-2014, Unit #2: 10-July-2014

533
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 power

under safe working conditions. A policy on Quality, Environment, Health and Safety
has been put in place. Emphasis is laid on continual improvement of our processes
and practices to achieve improved environmental, health and safety performance.
Training on HSE for employees and stake holders is undertaken on a regular basis
to foster a culture of health and safety.

They have been certified with the following Management Systems

1. ISO 9001:2015
2. OHSAS 18001:2004
3. ISO14001:2008

The certifications have been received within a year of COD

534
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 in
daily operation. Auxiliary steam was therefore utilized for heating in tank matt coil,
pump suction heater and tracing line along the entire piping. Delay in ignition
stability during unit start-up with HFO increased loss of station availability. Complete
switchover 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

535
Implementation of modified unit start-up logic and start-up curve with consent of
OEM.
• 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 Operation

Additional 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 passing
of 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 certain
valves were replaced to overcome the daily heat losses from the system. Maintenance
job was carried out in 97 nos. of valves in both unit and the DM water consumption
reduced to 0.67%.

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

Project- 4: APC reduction in Fan Power

To optimize the fan loading pro-active initiative was taken to identify the air ingress
and leakage points in Air & Flue Gas ducting through soap bubble test and planning
was carried out for arresting the same by welding all the joints during planned
outage of units. Duct to duct, duct to bellow, duct to dampers and duct linings were
welded. 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 winter

season
4 x 100% CW pumps is kept in service as per design to meet the cooling water
requirement in both units i.e. two nos. of pump per unit. With lowering of ambient
temperature during winter season (November to March) and during prolonged part
load operation, one nos. of CW pump is stopped and interconnection line is utilized
to meet cooling water requirement in both the units.

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

536
First Prize Thermal Power Stations
(Gas fired plants >100 MW Capacity)

GUJARAT INDUSTRIES POWER

COMPANY LIMITED
(Baroda Operation), Vadodara (Gujarat)

Unit Profile

Gujarat Industries Power Co. Ltd., Vadodara, Gujarat was incorporated on

1st June, 1985 under Company’s Act 1956 under the auspices of Govt. of Gujarat
and 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 of
the customers for GIPCL.

1. Present Installed Capacity of Vadodara Gas Based Station

   


   

 

    
 
 

 
 
   
 
  

537
2. Present Installed Capacity of Gujarat Industries Power Co. Ltd.

Energy Consumption (Electrical & Thermal) in F.Y. 2015 – 2016

F.Y. 2014 - 2015

538
Energy Conservation Measures F.Y. 2015-16

1. MODIFICATION by Installation of Blower assist model - Oil Mist Eliminator with

Variable Frequency Drive to recover Oil Mist carry over to atmosphere from
Vent 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 taper

column pipe and shaft to fit assembly with EXISTING column pipe in Condenser
Cooling Water Pump and to couple with SAME High Tension Induction Motor of
Capacity 355 KW

Annual Energy Saving: 3.68928 Lakhs KWh

3. MODIFICATION by designing & installing Demand based illumination system in

132 KV; outdoor type Switch yard to reduce energy consumption of energy
intensive HPSV lighting

Annual Energy Saving: 0.23610 Lakhs KWh

4. MODIFICATION by replacement of 70 Watts HPSV & 250 Watts general lighting

system by 23 Watts retrofitting type, spiral & screw type mounted CFL lighting
in total plant area

Annual Energy Saving: 0.34707 Lakhs KWh

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

maintenance practice

Annual Energy Saving: 0.34600 Lakhs KWh

6. REPLACEMENT of ELECTRICAL ENERGY operated Ventilator Fan by RENEWABLE

ENERGY 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

539
Energy Policy

540
Second Prize Thermal Power Stations
(Coal & Gas fired plants < 100MW capacity)

PUDUCHERRY POWER
CORPORATION LIMITED
(Puducherry)

Unit Profile

The Puducherry Power Corporation was incorporated with the objective of

generating 32.5 MW of Electricity (22.9 MW from Gas Turbine and 9.6 MW from
Steam Turbine) at Karaikal which is one of the outlying regions of Puducherry. The
required gas is obtained from the Gas wells at Narimanam in the Cauvery basin
under an agreement with the Gas Authority of India Ltd. The Corporation had
received the entire cost of Rs. 133.04 crores as Share Capital from the Govt. of
Puducherry till 1999-2000 and the same has been utilized for the execution of the
Project.

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 was
dedicated 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 entire
power generated from the Karaikal Gas Power Plant is supplied to the Electricity
Department, Karaikal. The plant is performing extremely well till date.

The power generated by both the gas and steam turbines are distributed at 11 KV
level and distributed to local industries and consumers. Some of the power is
exported 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 the
Power Plant is 32.5 MW.

541
List of Energy Conservation Measures:

Energy Conservation measures implemented in PPCL as recommended

by AEA Consultants

Sr. Energy Saving Proposal Annual Energy Annual Energy Investment Simple
No. Saving Cost Saving (Lakh Rs.) Payback
(Lakh kWh) (Lakh Rs.) Period
(Months)

Energy Saving measures within the year 2015-16

1 By arresting dum ping steam to condenser & its 1 6 .0 0 0 6 5. 1 2 Nil Im mediate

spray passing. Useful steam was saved. Also (G en. Increase)
reduced heat load occurred on condenser and
thereby improved vacuum .

2 Gland steam excess return control valve 8 .0 0 0 3 2 .5 6 N il Im mediate

pressure setting calibr ated properly to maintain (G en. Increase)
Gland steam supply header pressure. Useful
steam was saved. Also reduced heat load
occurred on condenser and thereby improve
vacuum .

3 Stopping of Hogger / Starting ejector 4 .5 8 5 1 8 .6 6 N il Im mediate

enhanced generation by steam saving (G en. Increase)

Brief Description of Energy Conservation Measures implemented:

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

Project-1 By arresting dumping steam to condenser and spray passing, the

measure improved Power generation. Also the condenser heat load got reduced
and improved vacuum.

Passing of steam was stopped by closing isolation valves of dumping &

spray line which increased generation of 200 kW (avg.).

542
Illustration:
When dumping steam passing was identified, screenshot was taken from the DCS
before isolating dumping & spray line isolation valves. Snapshot after isolation was
also taken.

Before taking rectification After taking rectification

The above screenshot was taken which reveals that STG generation is 9.4 MW
corresponding to GT load 21.4 MW. At this stage dumping passing steam was
identified. The second screenshot of DCS was taken after rectification in terms of
arresting dumping steam. By arresting dumping steam STG generation was
increased 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 kW

Annual operation time = 8000
Annual energy generation increase = 1600000 kWh
Energy cost = Rs. 4.07
Annual monetary gain = Rs. 6512000
Investment = Negligible
Simple Pay back = Immediate

Project-2: Gland steam excess return control valve pressure setting calibrated
properly to maintain Gland steam supply header pressure to arrest air ingress
from LP gland and thereafter gland steam excess return to condenser was arrested
thereby 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 control
valve was isolated.
By taking corrective actions following were achieved:

543
1. Gland steam supply header pressure developed.
2. Turbine LP gland air ingress stopped
3. Condenser heat load reduced
4. Improved vacuum and ultimately generation increased.

From the above illustration, it can be noticed that on an average 100 kW

generation was increased for same vacuum by stopping excess return
steam

DCS Screenshot

Techno Economic:

Potential for generation increase = 100 kW

Annual operation time = 8000
Annual energy generation increase = 800000 kWh
Energy cost = Rs. 4.07
Annual monetary gain = Rs. 3256000
Investment = Nil
Simple Pay back = Immediate

Project-3: Stopping the Hogger / Starting ejector will enhance generation by

steam saving as well as other loss reduction. It was found that the Hogger was
put in line along with service ejector to maintain condenser vacuum. Hogger is
generally 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 supply
pressure and proper gland sealing. Motive steam temperature was found running
low (193 0C at 13 kg/cm2g) than design (210 0C at 10kg/cm2g). From the
above observation, it can be concluded that the motive steam was not superheated
and therefore, unable to extract sufficient air from condenser.

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

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 Saving calculation due to Hogger stoppage

Sl.No. Parameters Unit Value Basis

2
1 Aux. Steam pressure kg/cm 10 Design
2 bar 9.81 Calculated
0
3 Aux. Steam temp C 210 Design
4 Aux. enthalpy kCal/kg 681.61 Calculated
5 Aux. steam flow through hogger kg/hr 350 Design
2
6 Spray water pressure kg/cm 75 Design
7 bar 73.55 Calculated
0
8 Spray water temperature C 132.88 Design
9 Spray water enthalpy kCal/kg 134.60 Calculated
10 Spray water flow kg/hr 43.29 Calculated
11 MS pressure kg/cm2 42 Measured
12 bar 41.19 Calculated
0
13 MS temp C 385 Measured
14 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
3
18 m / hr 0.046 Calculated
19 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 Calculated
of Turbine
Saving Calculation-1
22 Generation increase due to kW 61.4 Calculated
Hogger stoppage
23 Aux. Power Consumption % 6 Assumed
24 Extra generation feed to grid kW 57.72 Calculated
25 Extra Generation per Annum kWh 457111
Saving Calculation-2
26 BFP sp. Energy consumption kWh/m3 3.741
27 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 4.07
31 Annual Energy Cost saving Rs 1866042
32 Investment Rs. Nil
33 Payback Mont hs Immediate

Apart from the above mentioned saving, some other quantifiable saving can also
be 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.

545
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 more

than hundred year old Power utility operating within a licensed area of 567 square
Km in the city of joy, Kolkata. Its consumer base is approx. 3 millions. Company
has 3 Generating Stations whose combined capacity is 1,125 MW.

Budge Budge Generating Station (BBGS) is committed to provide cheap, efficient

and reliable power in line with the vision of the company. The formally articulated
Vision, Mission and core values act as the guiding force propelling the organization
to global standards.

Budge Budge Generating Station is a 750 MW (3*250MW) Thermal Power Plant. It

has 3 Units of 250 MW each and have been certified with ISO 9001:2008, ISO
14001:2004 and OHSAS 18001:2007 by TUV Nord. Unit-1 and Unit-2 was
commissioned 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 complete
set of B-T-G from BHEL. All boilers are pulverized fuel fired.

546
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 years
in 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 power
consumption.
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 of
differential 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.

547
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, Timer
circuit 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 3
financial years. The target for SEC for FY 2015-16 was 8.1%, the quest for lowering
SEC 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. The
major energy consuming drive in a thermal power plant is Boiler feed pump which
recirculates by taking suction from De-aerator and pumping the water at very high
pressure to Boiler for superheated steam generation which is the prime mover of
the turbine in a thermal power plant. BFP consumes around 30-35% of the total
Plant energy consumption.Unit-1&2 have 2 boiler feed pumps each with 2*100%
capacity.

Reasons for selecting this

project:

 Achieving Global
Benchmark Figure on
Specific Energy
Consumption.

 BFP being a big ticket item

consuming about 34% of
total SEC.

 Opportunity to reduce SEC

by 0.12 %

548
Challenges faced before deployment/implementation

The main challenge was risk evaluation and mitigation of the same. The associated
risks was that in case of abnormal lowering of grid frequency, the modified pump
will not be able to cater full load demand and this situation demands running of the
standby pump. Under the present grid discipline this is a remote possibility, however
under any circumstances the new modified Gear set can be reverted back to old
original 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 provide
a max pump speed of 5730 RPM at 47.5 Hz frequency of Input power. At full load
condition the output pump speed of 5300 RPM is sufficient to feed the boiler. Now
since the operating frequency in the grid is around 50 Hz, to keep the output speed
at 5300 RPM there was a loss of around 1148 KW in the hydraulic coupling as oil
was being drained from the coupling to reduce the speed to the required value of
5300 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 the
output speed of the pump is 5350 RPM which is sufficient to feed the boiler at full
load at an input frequency of 50 Hz.

Comparison of the pre-deployment with post-deployment scenario

Below are the status before and after modification:

549
The graphs below shows the energy consumed by BFP vis-à-vis PLF along the
months in 2014 and 2015, before and after implementation of the project respectively

550
Savings:

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

2014-15.

Actual Electricity Savings after Modification= 12.06 Million KWh

Actual 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 thereby
increasing the ID Fan Ampere drawl.

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

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

Air heater Leakage as measured Leakage as measured

on 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/year

Actual Coal Savings after Modification=1464 Tonnes/year

551
Second Prize Thermal Power Stations
(Gas fired plants >100 MW Capacity)

PRAGATI POWER STATION

Pragati Power Corporation Limited (New Delhi)

Unit Profile

Pragati Power Corporation Limited is an undertaking of Government of NCT of

Delhi. It was incorporated on 9th January, 2001 to undertake power generation
activities for supplying power to Delhi. It is one of the leading Undertakings of
GNCTD, generating profits since inception and paying dividends regularly. It is
presently having capital base of 2,019 Cr and asset base of 3,319 Cr. The projected
asset base and revenue income of Company in the near future are 6,000 Cr and
5,000 Cr respectively.

This plant consists of 2 x 104 MW Frame 9-E Gas Turbine Units commissioned in
2002 and 1 x 122 MW STG Unit commissioned in May’2003. Gas supply has been
tied 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 MW
Steam Turbine. The Waste Heat flue gases emanating from the gas turbines is
being 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 gases
of 570o C with a mass flow of approx. 14000 MT/hr is passed through 2 Nos. waste
heat recovery boilers to generate steam.

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

552
 Fuel:

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

Raw Water :

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

Emission Control :

In order to have control on flue gas emission particularly NOx, a special emphasis
being given. To control NOx, State of art, Dry Low NOx. (DLN) Burners have been
installed on gas turbines. At present the value of NOx. is in order on 17-18 ppm on
base load. The allowable limit of NOx. approved by DPCC (Delhi Pollution Control
Committee) is 35 ppm. This is the first plant in India with a facility to control NOx
emissions by use of dry low Nox technology (DLN) and is an eco-friendly power
station.

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

DESCRIPTION UNIT 2014-15 2015-16

Gross Gen. MU 1847.368 1539.471
PLF % 63.91 53.11
Station Heat Rate Kcal/Kwh 2046 2008
Aux Power Consumption MU 48 41

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Energy Conservation Initiatives:

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

• A dedicated Energy management team is constituted for energy conservation

study in the plant and to meet the PAT target being dedicated consumer.
• Pragati Power Station is the first power company of GNCTD certified with ISO
50001
• 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 implemented
including 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 of
condenser preheat circuit. These pumps are used to recirculate the hot water from
de-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 overcome
the throttling loss, the CV was replaced with new CV of low capacity in first phase
and further pump with lower head and LT motor is replaced. Also for fine tune
control, VFD is also installed on the pump and huge amount of energy is saved.
Total investment : 48.51 lacs
Total Savings : 161 KW-
Payback : Less than 1.5 year.

554
2) Changing of cooling tower blades with new profile and shaft with
new carbon shaft:

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

Total Investment : 28.51 lacs

Total savings : 66 kw
Payback : less than 1.6 years

555
3) Dry Ice blasting of HRSG-II:

During inspection of HRSG –II it was observed that the tubes needs cleaning for
better heat transfer at the surface of the tubes. Dry ice blasting carried out during
major 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 lacs

Total Kw saved : 136 Kw
Pay back period : Less than 4 months.

1) Various other projects which resulted in significant energy savings at

PPS -1:

In belief to the social and commercial cause persistent effort is made towards
energy conservation and in tune with National Mission for Enhanced Energy Efficiency
and to reduce the carbon footprint in the atmosphere, PPS-1 implemented various
other 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,

556
Energy Policy

557
Certificate of Merit Thermal Power Stations
(Coal Fired Plants > 100 MW Capacity)

NAVA BHARAT VENTURES LIMITED

Khammam District (Telangana)

Unit Profile

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

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

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

558
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

559
Plant load factor

Energy Conservation Activities & Organizational Set Up

An energy conservation team was constituted in 2006 consisting of the engineers

from all the sections. The team is led by Certified Energy Manager from Bureau of
Energy Efficiency (BEE), Ministry of Power.

The responsibilities of this team are being framed.

a. identifying and creating awareness among all our employees and contract
workmen 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 the
best ideas,
h. sharing the best energy conservations practices among the various units of the
company,
i. educating housewives and school children on energy conservation.

560
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 Millions

No kWh Rs
1 VFD provided for 50 MW, STG-1 condensate
extraction pump. 0.153 0.46
2 New CEP with low seal water requirement
was installed. DM water consumption reduced by
20 TPD. 0.022 0.07
3 After measuring the illumination lux levels, TG
building roof top lighting reduced from 10 points
to 5 points. 0.02 0.06
4 Voltage level reduced at CHP-1 bus voltage
from 425 V to 407 V. 0.049 0.15
5 VFD provided for air conditioning-Vapor
absorption system at PP office and CPP control room 0.005 0.02
6 Provided HT-VFD for unit-3 boiler feed pump to
reduce the auxiliary power consumption. 0.738 2.26
7 TG-1 specific steam consumption reduced by
Up-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 in

No millions
1 By installing sonic soot blowers the heat pick up
of waste heat recovery system was increased 5,584 14.27
2 TG-1 specific steam consumption reduced by
Up-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.

561