485THERMAL PO THERMAL PO THERMAL PO THERMAL PO THERMAL POWER WER WER WER WER ST ST ST ST STA A A AATIONS TIONS TIONS TIONS TIONS THERMAL PO THERMAL PO THERMAL PO THERMAL PO THERMAL POWER WER WER WER WER ST ST ST ST STA A A AATIONS TIONS TIONS TIONS TIONS 486 487 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 of Punjab State Power Corporation Limited and is located 23 km short of Bathinda on National High Way No. 64 and is situated opposite Village Lehra Mohabbat. Total plant area is 1025 Acres. Basic fuel is coal and furnace oil. Stage-I consists of two units of 210MW each. Stage-II consists of two units of 250 MW each. GHTP Lehra Mohabbat 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 and 4-1-99 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 four successive years and is being operated at the lowest cost of generation amongst all PSPCL power plants despite having higher interest and depreciation. This plant has shown excellent performance and huge savings have been made in terms of earning incentives by performing better than PSERC targets through meticulous planning. 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. 489 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 Year No. 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 98.86 100.38 factor 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 8.23 Consumption 7 Sp. Coal Kg/kWh 0.551 0.589 0.601 0.601 Consumption 8 Sp. Oil ml/kWh 0.327 0.228 0.802 0.367 Consumption 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/cm 2 to 0.4Kg/cm 2 . 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. 491 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 COMBINED CYCLE POWER STATION RELIANCE INFRASTRUCTURE LIMITED Samalkot, 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 Gas Authority of India Ltd. (GAIL). The plant is also designed to use Naphtha as main fuel and HSD as backup fuel. Raw water is drawn from Samalkot irrigation canal and pumped to the in-plant open water reservoir by RINFRA. An Intake Pump House has been set up by RINFRA near the intake point for this purpose. The power generated by the Gas Turbine and the Steam Turbine generators are stepped up to 220KV and fed to a 220KV outdoor substation. The power is evacuated by APTransco through overhead transmission lines. RINFRA has necessary agreement with APTransco for this purpose. The project has been executed by the consortium of Ansaldo Energia, Italy and RINFRA, on a turnkey basis. The Gas Turbine Generator, Heat Recovery Steam Generator and Steam Turbine Generator along with their respective auxiliaries has been designed and supplied by Ansaldo. 493 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 for implementation of several energy conservation activities in the plant. For the year 2009-10 initiatives are listed below, S. Energy Conservation Power Annual Annual Implemen- Annual No Activities Saving Energy Saving tation Energy (kW) Saving INR - Cost Saving kWh Lakh Lakhs Lakh kWh 1 Replacement Of GRP 128.95 1129602 25.42 20.005 11.2960 solid cell fan blade with Epoxy Coated Hollow Energy Efficient Fan Blade 2 Modifying Cooling Tower 22.80 199728 4.49 2.844 1.9973 makeup system from Motor driven pumping to Gravity system. 3 HPBFP VFD Pressure 30 262800 5.91 0.000 2.6280 Optimization 4 LPBFP VFD Pressure 3 25404 0.57 0.000 0.2540 Optimization 5 Illumination System: 1.33 11651 0.26 0.189 0.1165 Building Replacement of FL lamps (40W) with CFL (20W) lamps at non essential area. 6 Standby Closed cooling 4.6 40296 0.91 0.000 0.4030 water PHE isolated from ACW as well as CCW 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 day activities calculate own energy consumption as follows, Aux Power Consumption in MU’s= (Gas Turbine Generator + Steam Turbine Generator) – Export Energy Meter Reading Energy Meter Reading Aux Power Consumption in % = (Aux Power Consumption in MU’s x 100)/ (Station Generation in MU’s) 494 Station Auxiliary % Reduction Capacity Power in MU's Million Units In Percent MW 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 & efficient operation of the station, station could achieve ~ 7.21 % reduction in auxiliary power 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 effective power generation. Monthly review meeting on Energy conservation projects is being conducted in the presence of Unit Head. Reward & Recognition scheme are at place at corporate level to motivate Employees in view of Energy Conservation. During the period several best practice initiatives were undertaken for overall improvement 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 conserve energy. The Energy Management cell of SPS consists of qualified energy managers and auditors 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. 496 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 has conducted third party plant energy audit in Sep’09. Station has implemented SAP package in 2004 for preventive maintenance activity and corrective maintenance activity. After implementation of SAP package historical data 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, vibration analysis of all critical equipments, current signature analysis on electrical equipments, 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 Tower GRP solid cell fan blade with Epoxy Coated Hollow Energy Efficient Fan Blade: The CW system is open re-circulating type with an induced draft cooling tower. Circulating water pumps’ discharge is led to the condenser. Outlet is returned to the cooling tower for cooling. There are total ten numbers cooling tower cells which are fitted with individual fans. During design, fans were made up of GRP solid fan blades. During ENCON activity and vendor discussion it was revealed that, energy conservation opportunity is available and all cell fan blades are replaced with Epoxy Coated Hollow Energy Efficient Fan Blade. These cell fan blades are with reduced weight and designed for same air flow with higher efficiency. Total investment : INR. 20, 00,533 /- First year energy cost savings : INR. 25, 41,605/- Power saving of 128.95 kW is achieved. 498 2. Modifying Cooling Tower makeup system from Motor driven pumping to Gravity system. For maintaining cooling tower basin level, Clarified water from the clarified water reservoir is pumped by Cooling Tower make-up pumps and fed to the cooling tower basin to maintain normal level in Cooling Tower basin For maintaining cooling tower basin level, two Cooling Tower makeup motors of 30 kW are installed, at a time only one pump is in service. As an energy conservation measure, system study is done for modifying existing system 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 reducing pressure by 2-Bar, temperature margin of @ 9.0 Deg Cent is observed, which is above saturation temperature for avoiding economizer steaming. So by reducing 2 Bar pressure, power consumption of HPBFP reduced by @ 30.00 kW Total investment : NIL First 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 water is pumped by two LPBFP Pumps (one working & one stand-by). System study revealed that by reducing pressure by 0.7 Bar, we are having saturation temperature margin of @ 6.0 Deg Cent which is sufficient for maintaining temperature above economizer steaming. 499 So by reducing pressure by 0.7 Bar, power consumption of LPBFP reduced by @ 3 kWh, Annual energy saving of 26280 kWh First year energy cost savings, Rs. 57,159/- Investment is: NIL. 5. Illumination System: Building. Replacement of FL lamps (40W) with CFL (20W) lamps at non essential area As energy conservation activity Rinfra-SPS has replaced existing FL tubes at non essential area with CFL. Total 133 nos FL tubes were replaced with CFL lamps. Existing FL tube power consumption was 40 W & CFL lamp power consumption is 20 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 water PHE isolated from ACW as well as CCW side The closed cooling System supplies CCW Water to the various coolers of auxiliary equipment like lube oil coolers of GT, ST; HP/LP feed pumps etc. CCW water pumps are used to supply the CCW water after cooling in the PHE (plate type heat exchanger) where CCW water is cooled by rejecting Heat to the ACW (Auxiliary cooling water). Standby PHE isolated from CCW as well as ACW side. It has been observed that both the ACW motor current reduced. Total investment : NIL First year energy cost savings : Rs. 90,666 /- Power Saving is 4.6 KW. 500 7. Wind Ventilators At Rinfra-SPS at different locations depending on the heat load, motor operated ventilation systems are installed. For adopting renewable energy technologies, Rinfra - SPS has evaluated several methodologies. After evaluating site requirement, it was decided to change motor driven ventilation system 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 energy utility in the world. Our mission is to use all energy resources most efficiently and thereby minimizing the impact of our operations on environment and conserving the scarce natural resources. 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. 501 Environment & Safety Reliance Energy believes in sustainable development and aims at preservation and promotion of environment in all its activities. SPS has qualified ISO14001 & OHSAS 18001 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. 502 Second Prize Thermal Power Stations GMR VEMAGIRI POWER GENERATION LIMITED 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 of 388.5 MW at Vemagiri village, Kadiyam Mandal of East Godavari District Andhra Pradesh between latitudes 160 55' & 170 and longitude 810 45' & 810 50'. The site which is about 7-8 km south east of Rajahmundry town The Vemagiri project consists 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 heat recovery steam generator (HRSG) all capable of operating in combined cycle mode. The combined cycle system is an optimized and matched system of high technology power generation equipment, software and services configured for convenient integration with the balance of the plant to form an economical power plant. Economical performance of function, either power generation or power and thermal energy production with an efficiency of around 55 - 58%, is the outstanding characteristic of combined-cycle systems 503 Energy Consumption With the implementation of various energy conservation projects and the conversion of HSS pot lines to Pre-Baked pots, there is a substantial reduction of energy consumption. There is steady decline of specific energy consumption in the last two 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 1825.31 504 Energy and resource conservation during the project stage Case study GVPGL has taken many proactive measures to ensure that its activities do not have adverse impacts on the environment. Towards this end, it has taken up many projects involving process improvement or modification and installation of latest energy 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 or injecting steam along with the fuel. This method involves consumption of natural resources like water, power, additional fuel, and chemicals, and, in turn, needs pollution control measures. The alternative latest technology for controlling NOx emissions is using DLN burners, which do not use DM water or steam and maintain the NOx levels at less than 20 PPM (parts per million). NOx (oxides of nitrogen) are the main air pollutants emitted from the facility. DLN (dry low- NOx) burners have been installed in the facility to control NOx emissions The dry low NOx II (DLN-2) control system regulates the distribution of fuel delivered to a multi-nozzle combustor arrangement. The fuel flow distribution to each combustion chamber fuel nozzle assembly is a function of combustion reference temperature (TTRF1) and IGV temperature control mode. Diffusion, piloted premix, and premix flame are established by changing the fuel flow distribution in the combustor. By a combination of fuel staging and shifting of burning modes from diffusion at ignition through full pre-mix at high load, dramatically lower NOx emissions can be achieved above 40% load than with conventionally controlled and fired combustion systems 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 secondary stage only. This mode of operation is achieved at and near the combustion reference temperature design point. Optimum emissions are generated in premix mode 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 for their new plants. Now during the operational stage the NOx values maintained are as below 507 And continues Emission Monitoring system is installed online which monitors the flue gas parameters. 400 KV Switch Yard A 400 KV switchyard with one and half beaker switching scheme is provided for evacuation of power generated in the plant through two nos 400 KV transmission lines to APTRANSCO sub stations due to which the line current is minimum and hence transmission losses are minimize hence forth distribution losses are minimized. Energy and resource conservation during the operational stage In compliance with requirements (process improvement/modification) Tuning of IGV Angle The gas turbine compressor air flow is regulated by IGV (Inlet guide vane) The DLN-2.0+ combustor emission performance is sensitive to changes in fuel to air ratio. The DLNx combustor was designed according to the airflow regulation scheme used with IGV Temperature Control The IGVs open from their minimum value as the turbine increases load while on the exhaust temperature control curve until they reach a maximum at Base L Operation of the gas turbine. During the performance review GVPGL decided to change the operating range of the Inlet Guide vane from 26°C - 82°C to an operating range of 26°C- 86 °C. 1. "Increasing the maximum operating angle of IGV to 86 degrees has reduced the pressure drop across the compressor and a lower in resultant temperature depression of air flow. The compressor ratio was increased from 14.2 kg/cm2 to 14.6 kg/cm2 which have significantly improved compressor efficiency and GT / Plant output. 2. This change in IGV angle has significantly reduced the attemperation water consumption in the superheated of HRSG. Attemperation reduced to 23 MT 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 water and release the burnt flue gases at a minimum temperature of around 89 deg C which 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 turbine and expands due which the overall efficiency of Plant increases Beyond compliance to statutory requirements (proactive practices) Process modification in the auxiliary cooling water system of the steam turbine The cycle of concentration was increased from 6 to 8 in the auxiliary cooling water system of the steam turbine. This reduced effluent generation, chemical consumption, 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 which minimizes the environmental impact effects and saves the fuel energy. ELECRTICAL SYSTEM a. Lighting voltage optimization: The voltage supply level for the plant lighting is more. It was proposed to change the tap positions in transformer. After changing the tap positions voltage and current are reduced. b. Dedicated lighting transformer installed c. For discharge lighting, optimum voltage is around 210V d. 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 investment f. Annual savings - Rs 4.00 Lakhs 509 Sl. No. Energy Saving Description Savings Investment payback Actions period 1 HP-BFP ARV passing Install multistage 100 kW 25 Lakhs 7 months pressure reduction drag valves Pressure is reduced in many stages (13 - 40) avoiding the high pressure difference across the valve and thereby reducing the further erosion of its seat 2 Maintain a Optimum Reduced pressure 40 KW NIL 0 DP across the feed drop across CV station gradually Target to 6 bar and operate the CVs at maximum opening 3 Using of the IA 1.) Estimates the 7.6 Lakhs 0.5 1 month instead of CPD for header pressure drop the inlet air pulsation during the IA pulsation & according action plan to be determined 4 Use of Both PHE in Operation of both NIL 0 parallel operation PHE's in parallel operation has decreased the DP across Heat exchanger 5 Optimizing the air Established optimum NIL 0 pressure pressure required for the control valves and maintained optimum header pressure which decreased the compressor loading rate 6 Lighting Transformer Optimum voltage 10% NIL Nil Optimum voltage maintained in line with the safe equipment peration by changing ap position to adjust the voltage to 210V in lighting transformer 510 Environmental Profile The company has an Environmental Policy at both corporate and facility levels. It also has an environment Environmental Management Plan Environmental Management Plan Environmental risk Management is in Place and the Objective of the Environmental risk management is "To determine the risk of major hazards having damage potential to environment, life & property and provide a scientific basis to assess safety level of 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 dedicated ambient Air Quality Monitoring station is in place for continuous monitoring of ambient air quality consists ting of suspended particulate Matter (SPM) and gaseous pollutants like oxide of Nitrogen (NOX) and sulphur Dioxide (SO2) Environment Policy 511 Second Prize Thermal Power Stations DR. SHYAMA PRASAD MUKHARJEE THERMAL POWER 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. 512 Energy Consumption Overall station generation during 2008-09 and 2009-10 is as follows Secondary station fuel oil consumption and station auxiliary power consumption of the plant during 2008-09 and 2009-10 is as follows. 513 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 of stabilization 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 mentioned above our PLF improved from 84.8% to 87.65%with a generation of 3838.93MU. 514 By reducing unnecessary tripping by best operation and maintenance activities station reduced its specific oil consumption from 1.358 to .756 ml/kWh . By operating the unit at optimum parameter and minimum deviation from designed data, 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 %. 515 Certificate of Merit Thermal Power Station ULTRATECH CEMENTS LIMITED UNIT BIRLA WHITE 7.5 MW THERMAL POWER PLANT Jodhpur (Rajasthan) Unit Profile Birla White is the 7th largest White Cement plant in the world and largest in India in Plant capacity. Birla White has moved from a single commodity premium product to a multi specialty product company with market leadership position and exporting to 26 countries in 6 continents. TPP has Atmospheric fluidized bed Combustion (AFBC) steam Boiler - capacity 38 TPH 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 of March 2007. This plant is a multi-fuel plant done on an EPC basis. The supply of 38 TPH boiler is from CVPL Trichy and Turbine is from HTC China. Enhanced capacity of Thermal Power Plant 7.5MW to 8.0MW by modification in Boiler and Turbine in the month of August, 2010. 516 Thermal Power Station Design Details Thermal Power Station Operating Details S N Particulars Current completed Previous completed Design 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 3650 on GCV basis of the fuel used, (kcal/kWh) (c) Station Net Heat Rate on 2800 2800 GCV basis of the fuel used, (kcal/ kWh) (d) Station Auxiliary Power 10 10 Consumption (%) (e) Station Secondary Fuel Oil NA NA Consumption (ml/kWh) S N Annual Operating Parameters Current completed Previous completed financial year financial year 2009-10 2008-09 1 Overall Station Generation (Million kWh/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/Biomass Consumption) (Million Metric Tonne/ year) 0.33 Average Gross Calorific Value (GCV)of fuel (kcal/kg) 7215 4142 Overall Thermal energy used in the station due to the use of above fuel (Billion kcal/ year) 23764.34 20013.68 Gross Heat Rate on GCV basis (kcal/ kWh) 517 1 Overall Station Gross Heat Rate on GCV basis (kcal/ kWh) 3300 3637 2 Net Heat Rate on GCV basis (kcal/ kWh) Overall Station Net Heat Rate on GCV basis (kcal/ kWh) 2766.09 2750 3 Auxiliary Power Consumption of Gross Energy Generated (%) Overall Station Auxiliary Power Consumption (%) 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. 518 Energy Conservation Achievements Year of Commissio ning of the projects Project description Achievement of energy savings per year basis Invest ment incurred on the project Rs. (Lakhs) Electri city (Kwh) Fuels* Coal (tonn es) F.Oil (kL) Gas (lakh Nm3) Total (fuel) in (MTOE) Total savings in (Rs. Lakhs) 2009-10 Modification in NA 5030 NA NA 1710 boiler flue gas path & refractory inside the boiler to increase the alternate fuel firing other than Indian coal Rs 2 Lakhs Modification in 8.94 NA NA NA discharge duct 0 of Boiler & replaced the flap type dampers by Rs. 2 plate type shut Lahs off dampers to reduce the pressure drop in duct Optimization of 2.44 NA NA NA auxiliary cooling 0 water pump 249.85 Rs. 05 operation to Lahs speed mode by providing VFD drive Modification in 1.22 NA NA NA discharge duct 0 of ID fan & replacement of Flap type dampers to Rs. 0.4 plate type shut Lahs off dampers to reduce the pressure drop in duct 519 Optimization of 0.48 NA NA NA condensate 0 extraction pump to speed Rs. 0.2 mode by Lahs providing VFD drive TPP plant 0.98 NA NA NA lighting circuit 0 Rs. 0.2 modification Lahs Optimization of 0.756 NA NA NA Ash handling operation based upon the Hooper levels instead of continuous running NIL Reduction in 0.24 NA NA NA boiler PA 0 header pressure by installing IGV damper in PA fan duct NIL Optimization of 0.33 NA NA NA cooling tower 0 fan operation with temperature difference NIL 1. Automation of Ash Handling System. Prepared and Implement a group logic sequence of all the fourteen drives of ASH Handling System in DCS to run in automatic mode for selected period of time set by the operator with start / stop alarm indication and the indication of run time and stop time. Prepare the tantalizer for calculating the total running hours and observe that system is running for twelve hours a day. The power consumption of Ash Handling System is reduced by 0.756 Lakhs kWh per annum 2. Auxiliary cooling water is operating on direct on line starter. During plant team observation it was found that it is operating through throttling resulting in consuming of more power. Given supply to cooling tower motor through variable voltage variable frequency drive (VVVFD) and by maintaining, required flow and pressure by varying the speed of the motor, the power consumption of Auxiliary cooling water pump is reduced by 2.44 Lakhs kWh i.e. saving of Rs 11.71 Lac per annum. 3. Plant was using 70 watt HPSV (High Pressure Sodium Vapor) fitting , which was replaced with 18 watt CFL fitting. The CFL fitting is giving the required illumination for path 520 4. Firing of 100% Petcoke (Petroleum Industry waste) in AFBC boiler , a use of alternative 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 in Plant 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 on Birla White has a structured Safety, Health & Environment (SHE) Subcommittee which comprising of the representation from the various functions.