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BUDGE BUDGE GENERATING STATION (West Bengal)

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BUDGE BUDGE GENERATING STATION (West Bengal) 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 Achievement of Annual energy savings in 2015 -16 Sr. Project D escription Electricity Coal Total Total No. (Lakhs (MT) Savings investment kWh) in in Rs. Lakhs Rs. Lakhs 1 Installation of FRP blade with hub assembly instead of solid 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 WHRB-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 Logic 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 CCWP, 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.
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