Energy - Generation

Progressive Energy Generation

The dream of building a prosperous future for our country demands our considerable contribution in the power sector. The past three decades have seen the demand for energy rise at an average rate of 3.6%. The energy demand is expected to grow even further to 5.2% to incorporate the GDP growth rate of 8% to 10% in the coming years.

The power sector of India is rapidly transforming from a nascent to a developing market. The private sector currently accounts for 17.88% of the total installed capacity of 156,783.98 MW. The 941 MW of electricity generated from our five power stations is a starting step towards the estimated power requirement of 400,000 MW by 2020.




The Generation Division : Engineering Power

Generation forms the first phase of making power available for your use. We also have direct involvement in the ensuing phases of transmission and distribution. This further accelerates our objective of stepping into the world of tomorrow.

Our generation division focuses on every single aspect of coal based & combined cycle power projects including designing, engineering, erection, installation, commissioning, operations and maintenance. The division is well equipped to successfully carry out in-house power projects as well as support ventures of our associate companies.




Our Five Power Projects : Energy Generation and Conservation

The entire capacity of the generation division stems from the five power stations located in Maharashtra, Andhra Pradesh, Kerala, Karnataka and Goa. All of them employ the latest technological advancements which promote enhanced performance along with better environment and safety standards. Well recognized on the national and international scale with many revered awards including IEEMA power awards and Golden Peacock awards, they are our source of inspiration to completely address the power demand of our envisioned world of tomorrow.


     Dahanu Thermal Power Station

Dahanu Thermal Power Station

Dahanu Thermal Power Station (DTPS), consisting two units of 250 MW, is one of the best power generation plants in the country, which commenced its commercial operations in January 1996. Recognized with innumerable awards, this power plant is known for its distinctive features that set it apart from others in terms of technological innovation, superior performance and continuous sustainability for a longer period. DTPS is located around 120 km north of Mumbai along Mumbai-Ahmedabad rail line.

The plants utilise a mix of Indian washed coal and imported coal as fuel. The general blending ratio is 80 : 20. The indigenous fuel is received from SECL (Korba) and also imported from various countries such as Indonesia and South Africa among others.

Dahanu Thermal Power Station has implemented integrated management systems (IMS) in its processes and is certified for quality management, environment management, occupational health and safety assessment studies, social accountability management, information security management, energy management and accreditation for DTPS coal testing laboratory.

Dahanu

  • The first power station in the country with two units of 250 MW.
  • Commercial operation started in January 1996.
  • Employs a blend of washed coal and imported coal as its source of fuel.

 
 

Plant Performance :

Here's an insight into the year-on-year performance of the plant :


DTPS Plant Performance
Parameters Units FY 09-10 FY 10-11 FY 11-12 FY 12-13 FY 13-14* FY 14-15*
PLF % 102.33 101.00 101.35 100.04 93.82 91.261
Availability % 97.18 96.48 97.48 96.67 95.87 91.60

Note* Due to low load demand, MSLDC instructs generation backing down of power plants based on Merit Order Dispatch(MOD)ranking



Recognitions:

DTPS has received Copyright for three innovative works from Copyright Office of Government of India, New Delhi.

  • Reduction in Overhauling Time - Implementation of Work procedure has ensured considerable reduction in overhauling period to 15 days. Thereby saving of Generation revenue equivalent to at least 10 to 15 days.
  • Energy Deviation Report - An effective tool for energy consumption monitoring and optimization. This helps operation personnel to utilize energy efficient equipments to cater economical generation
  • Improvement of Coal Mill Performance by Auto Operation - Software developed by DTPS team by studying the correlation between air and coal flow .This logic has helped to avoid undue variation in load and other process parameters even during very heavy rain.

Major Milestones :

  • Unit no. 1 was synchronised on 6th January 1995
  • Unit No. 2 was synchronised on 29th March 1995
  • The power station commercially commenced its operation in 1996
  • FGD Unit I and II commissioned in October 2007
  • World's First Power Plant to get ISO 50001 : 2011, certification for Energy Management
  • ISO 9001 : 2008 - Quality Management System
  • ISO 14001 : 2004 - Environment Management System
  • BS OHSAS 18001 : 2007 - Occupational Health and Safety Assessment Studies
  • SA 8000 : 2008 - Social Accountability Management System
  • ISO 27001 : 2013 - Information Security Management System
  • ISO / IEC 17025 : 2005 - Accreditation for DTPS coal testing laboratory by National Accreditation Board of Laboratory (NABL)


Special Features :

Many features distinguish the Dahanu plant as India's one of the finest power generation plants. These include :


  • The CW Systems are equipped with concrete volute pumps to facilitate the smooth functioning of Sea water condenser cooling system.
  • Complete automatic control & monitoring of the three cylinders reheat condensing turbine, boiler and auxiliaries by Digital Distributed Control, Monitoring and Information System (DDC-MIS) to maintain trouble free output.
  • Highly advanced Supervisory Control and Data Acquisition (SCADA) system for complete centralized control over transmission and distribution.


In a bid to ensure minimization of plant's adverse environmental impact, the DTPS has installed :


  • A chimney of 275.3 mtrs height for proper emission/ dispersion of boiler exhaust
  • An Electronic Electrostatic Precipitator (ESP) of 99.9% efficiency to collect fly ash with In-house developed Ammonia dosing system to improve collection efficiency.
  • Four ambient air quality monitoring stations to measure hazardous gases such as PM10, PM2.5, SO2 and NOx
  • Flue gas Desulphurization unit of 100% capacity having efficiency greater than 90%, for removal of Sulphur and its oxides.
  • Advanced air pollution monitoring system
1 Plant Capacity : : 2 X 250 MW
2 Land for Plant : 351.58 hectares
3 Land for Ash disposal area : 370.00 hectares
4 Total Coal (Washed + Imported) : 2.6 Million tons
5 Sea Water (Condenser Cooling) : 84,000 (M3/Hr.)
6 Sweet Water : 300 (M3/Hr)

Energy Conservation :

DTPS has made remarkable achievements on parameters of average unit heat rate, Auxiliary power consumption (APC), Specific Oil Consumption & DM water consumption by consistently maintaining them lower than the national average for a generation unit of this size.


DTPS has proactively adopted following energy conservation measures...

  • Replacement of old HP module with refurbished module which has improved efficiency
  • Monitoring of Computer idling time and Optimization of computer operation by introducing software developed by DTPS engineers thereby saving of energy
  • Installation of Variable Frequency Drive in Condensate Extraction Pumps, Coal Mill Seal Air Fans, PA Fan.
  • Vapour Absorption Air Conditioning systems.
  • Energy Efficient Lighting systems.
  • Solar street lighting.
  • Corrocoating of CW Pumps & ACW Pumps.

The Energy Management Cell at DTPS consists of qualified Energy Managers and Auditors, who continuously drive the energy conservation agenda with defined energy policy, procedures and work instructions. Internal and external energy audits of various systems carried out at regular interval.

Environment Safeguards :

The organization's social responsibility towards the environment is evident in the adaptation of clean technology and stringently following the environmental safety guards :

To prevent Air Pollution

  • ESP of 99.9% efficiency for collection of fly ash from flue gases.
  • Online monitoring of emission levels of SO2, NOx, and TPM in Flue gas.
  • Four Ambient air quality monitoring Stations to measure PM10, PM2.5, SO2 and NOx.
  • Along with one meteorological station for weather monitoring.
  • Ban on use of plastic bags inside the plant and colony. Cloth bags are provided at the colony gate
  • Appointment of stewards for building to maintain cleanliness of their buildings and surrounding area and cleaning schedule for housekeeping of colony and plant surrounding area is being followed rigorously.
  • Renovation of Sewage Treatment Plant (STP) was undertaken this year.
  • Environment management and awareness programmes taken for various school and college students. Around 670 students benefitted from this program
  • In house production of organic fertilizer is used for cultivation of vegetable and fruits
  • Plantation of varieties of flowers - 600 Nos with 6 varieties, Medicinal and Herbal garden having 45 species,

Ash Disposal

  • Ash utilization is more than 100 percent and also preparing ash bricks to help local people by providing them bricks for their construction work
  • Four ash ponds for disposal of ash slurry.
  • Dry Fly Ash collection System for maximising ash utilization as per MOEF notifications.
  • Arranged visits for local ash brick and tiles manufacturer plants and organized a seminar on Pond Ash utilization

Corporate Social Responsibility

  • Entrepreneurship program - Tailoring classes ongoing for rural ladies in Dahanu Taluka. Earlier, automobile training given to local youth
  • Educational kit distribution for school students
  • Distribution of notebooks at concessional rates
  • Best Teacher's Awards - Awarding 5 best teacher's in Dahanu Taluka every year during Teacher's day
  • Under Rain water harvesting, the borewells are recharged through rain water

 

MoEF Clearance Letter for Pipe Conveyor System Construction


Environmental Reports



     BSES Kerala Power Station
bses

 

The BSES Kerala Power Limited

The BSES Kerala Power Company Limited, popularly known as BKPL, was initially promoted as a Joint Venture between the then BSES Limited, which was later on rechristened as Reliance Energy Limited (REL) and the Kerala State Industrial Development Corporation Limited, a Govt. of Kerala enterprise. This is a 165 MW combined cycle power station located at Kochi.


In year 2006 the company became a wholly owned group company of erstwhile Reliance Energy Limited, (now Reliance Infrastructure Limited).


165 MW combined cycle power station, Kochi, Kerala.


The power station, fully dedicated to the State of Kerala, operates in close coordination with the Kerala State Electricity Board Limited (KSEBL). It uses Naphtha as its fuel. Both, the BKPL and KSEBL have signed and executed a long term Power Purchase Agreement.


Today, the BKPL is completely a system driven entity. It has not only ensured the operational efficiencies, but also has demonstrated its performance in the field of environment consciousness, energy conservation, health and safety & security. To ensure this, the Power Station has adopted the Integrated Management Systems and received Certification for the following systems:-


1. ISO 14001: 2004 Environment Management System
2. OHSAS 18001: 2007 Occupational Health and Safety Management System
3. ISO 9001:2008 Quality Management System
4. ISO 50001:2011 Energy Management System

The power station's performance was duly recognized by Energy Management Center, Kerala and Dept. of Factories and Boilers, Govt. of Kerala.



Plant Performance:


Given below is a year-on-year analysis of the plant's performance.


Parameters Units FY 09-10 FY 10-11 FY 11-12 FY 12-13 FY 13-14 FY 14-15
PLF % 41.3 16.2 3.4 9.4 24.37 10.80
Availability % 86.5 88.6 95.9 98.5 98.73 95.78

Low PLF is on account of lesser off take by KSEBL because of high cost of power generated using Naphtha. The plant has nevertheless maintained high availability consistently.



Major Milestones and Achievements:


1. 31 Oct, 1997: Land development activities started
2. 3 May, 1999: Combined cycle PPA signed with KSEBL
3. 23 Nov, 2001: Declared Commercial operation of the plant in combined cycle mode


Technical Specifications :

The setup at BKPL reveals a technical conglomerate of both international & domestic pioneers.

The Power Station consists of three General Electric (GE) make LM 6000 PC series, state-of- the-art aero derivative Gas Turbines Generators (GTGs), apt for dual-fuel operation. The gas turbines are fitted with inlet air chilling systems whereby the ambient air is cooled to 9 Degree C before it enters the gas turbine. Because of the inlet air chilling system, gas turbines maintain steady output irrespective of fluctuations in ambient temperature.

The GTGs and auxiliaries have been packaged, supplied and set up by Stewart & Stevenson, USA.

Thermax Babcock & Wilcox Limited has supplied the three dual pressure (45 TPH HP & 12 TPH LP) Heat Recovery Steam Generators (HRSGs).

39MW Steam Turbine Generator (STG) and auxiliaries have been supplied, erected and commissioned by Bharat Heavy Electricals Limited (BHEL).

Energy Conservation & Efficiency Improvement :

The Power Station has formulated an Energy Cell which keeps a stringent check on energy conservation activities and initiatives. This cell comprises of skilled energy managers and auditors, who continuously drive the agenda of energy conservation with a set of defined policies. Furthermore there are regular internal and external energy audits of various systems to ensure the optimal efficiency standards. The various energy conservation measures that have been implemented are:

1. Additional Make Water Heater Modules in HRSGs
2. Vacuum Pump for improvement in STG Vacuum
3. Reduction in the LP steam injection pressure to avoid the throttling losses control valve
4. Up rating of main and auxiliary Cooling water pumps
5. De staging of CEP & LPBFP
6. Improvement of MCW performance by Corrocoating the impellers
7. Replacement of CT fan blades by more efficient hollow FRP blades
8. Installation of lighting transformer with energy saver option
9. Energy Efficient lighting system
10. Replacement of instrument air compressor
11. Installation of solar lamps


     Samalkot Power Station
Samalkot

 

Samalkot Power Station

Plant Performance :

A 220 MW combined cycle Samalkot Power Plant (SPS) is located at Samalkot in Andhra Pradesh.


The project was executed by the consortium of Ansaldo Energia, Italy and BSES Ltd., (EPC Business Group), India. The core machinery comprising of Gas Turbine Generator, Heat Recovery Steam Generator and Steam Turbine Generator along with their respective auxiliaries has been designed and supplied by Ansaldo.


The construction of the project was initiated in October 1999 and the commercial operation commenced in December 2002.


The Plant uses its primary fuel as natural gas, which is sourced from Gas Authority of India Limited (GAIL). It is also capable of using HSD / Naphtha as an alternative fuel. Raw water needed for the Plant is pumped to the in-plant open water reservoir from the Samalkot Irrigation canal.


The power generated from the Gas Turbine and the Steam Turbine generators are stepped up to 220 KV and fed to a 220 KV outdoor substation. This power is transported by APTRANSCO through overhead transmission lines.


The Samalkot Power Plant has an Integrated Management System across the following systems:-

  • ISO 9001:2008 Quality Management System
  • ISO 14001: 2004 Environment Management System
  • OHSAS 18001: 2007 Occupational Health and Safety Management System
  • SA 8000: 2001 Social Accountability Management System
  • ISO 27001: 2005 Information Security Management System


Plant Performance:

Given below is a year-on-year analysis of the plant's performance.


SPS Samalkot Plant Performance
Parameters Units FY 10-11 FY 11-12 FY 12-13 FY 13-14 FY 14-15
PLF % 75.96 68.39 37.48 25.53 08.92
Availability % 96.75 97.8 97.96 97.97 99.97

Note : Plant Availability remains consistently high. PLF is less due to less gas availability from GAIL.

Technical Features :

Power Block :

There is a single assembly comprising of one Gas Turbine Generating (GTG) Unit connected to its Heat Recovery Steam Generator (HRSG) and one Steam Turbine Generating (STG) Unit.

The Gas Turbine Generating unit is capable of delivering power in continuous operation and consists of two silo combustion chambers, starting system equipment, filtered air intake system, fuel systems, turbine & compressor wash system, AC generator & exciter, fire protection system, exhaust emission control arrangement, bypass stack, piping, necessary instrumentation and control, and other associated auxiliary system equipments.



GTG Unit
Manufacturer Siemens AG
Model 94.2
Fuel Natural Gas, Naphtha, HSD
Output 140512 KW with Natural gas at 29° C ambient
Natural gas flow 9.284 KG/sec at 19.0 KG/cm2

The HRSG is a dual pressure unit and generates high pressure and low pressure steam for the steam turbine generator from the GT exhaust gas.



STG Unit
Manufacturer Ansaldo
Type Single Cylinder, Condensing, Double Pressure
Output 80880 KW
Steam exhaust Horizontal


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
  • Energy Efficient Lighting system
  • Cora-coating of CW / ACW Pumps
  • Installation of Energy Efficient Epoxy Coated Cooling Tower Cell Hollow Fan Blades.
  • Modification of motor driven Cooling Tower Makeup system to Gravity System.
  • Installation of High Efficiency Illumination system.

     Windfarm Power Station
wind

 

Wind Farm project - Chitradurga, Karnataka

With focus on sustainable power supply to consumers, Reliance Infrastructure commissioned 2 Wind based renewable energy projects at Chitradurga district in Karnataka.

1. 7.59 MW Wind Farm Project, commissioned in Sept.1999
2. 1.8 MW Wind Farm Project, commissioned in June 2003

Project Location

Project is located at Jogimatti Wind Zone at Chitradurga district in Karnataka.

Project is spread over 80 Acres of land situated on 3 different hills about 950 Meters above MSL.

System Configuration

The Farm uses a total of 36 windmills to generate total power of 9.39 MW

230 KW : 33 nos.

  • Enercon make type E -30 Synchronous, 48 pole low RPM, direct driven, Gear less generators
  • Rotor speed is 16 - 48 RPM
  • Tip speed is 25 - 75 m/ sec


600KW : 3 nos.

  • Enercon make type E -40 Synchronous, 48 pole low RPM, direct driven, Gear less generators.
  • Rotor speed is 18- 38 RPM
  • Tip speed is 38 - 80/41-78 m/ sec


Plant performance :

The Plant performance for last eleven years is shown below

Sr No Year PLF(%) Availability(%)
1 2004-05 29.31 99.36
2 2005-06 27.59 98.62
3 2006-07 28.07 97.61
4 2007-08 26.02 94.93
5 2008-09 25.29 98.49
6 2009-10 24.11 96.93
7 2010-11 21.56 96.63
8 2011-12 25.65 97.38
9 2012-13 25.38 98.21
10 2013-14 25.86 98.30
11 2014-15 22.52 98.49
     Goa Power Station
Dahanu

 

Goa Power Station

The Goa Power Station is a 48MW combined cycle power plant, located at Zuarinagar, just 5 Kms away from the Dabolim Airport of Goa. The Power Station had commenced its commercial operations on 14th August 1999.

During last one and half decades, the Goa Power Station has evolved from a Generating Company to a complete Distribution and Utility Enterprise.

During its initial phase, the major part of the electricity generated from the Plant was supplied to the Grid of Government of Goa. However, later on, through its dedicated underground distribution network and systems, Power Station extended its reach to industries in the state, including Mormugao Port Trust and other renowned industries.

The power station has also developed robust underground cable distribution network system and sub stations in the areas like Verna, Kundaim and Madkaim Industrial Estate to ensure quality and reliable power supply to the industries.

 
 

Plant Performance

GPS Plant Performance
Parameters Units FY 10-11 FY 11-12 FY 12-13 FY 13-14
PLF % 69.46 65.72 58.37 57.42
Availability % 91.16 94.28 91.00 91.00



Environmental Performance

Goa Power Station

The 48 MW combined cycle Goa power station uses Natural Gas, one of the most environment friendly fuels, as the primary fuel and Naphtha as the secondary fuel. The average levels of emission recorded at the power station were much below the limits stipulated for the environmental parameters by the Goa State Pollution Control Board.

The plant has taken up several initiatives towards conservation of resources and improving environmental performance. Zero Discharges of Industrial Effluents since inception of the power station which is achieved by using "Reduce, Recycle and Reuse" concepts achieved through the recovery of Steam and Water Analysis System as well as higher Cycle of Concentration (COC) operation of Cooling Water System resulting reduction in water consumption. An area of about 5 hectares is covered under forestation in and around the plant premises.

Emission Parameters at Goa Power Station :

Sr. No Parameters UOM GSPCB Limit 11-12 12-13 13-14
1. Sulphur Dioxide (SO2) mg/Nm3 50 27.59 27.28 10.83
3. Nitrogen Dioxide (NO2) mg/Nm3 188 39.87 39.37 23.73
     Ambient Air Quality
1. PM 10 mg/M3 100 22.41 28.68 33.69
2. PM 2.5 mg/M3 60 6.52 7.47 10.48
3. Sulphur Dioxide (SO2) mg/M3 80 1.98 2.10 2.45
4. Oxides of Nitrogen(NO2) mg/M3 80 6.43 6.78 8.45

GSPCB :  Goa State Pollution Control Board
UOM :     Unit Of Measurement

Global Warming and Environment

The 48 MW Combined Cycle Power Plant is located in South Goa District of the State of Goa, situated in Sancoale village, along the Verna-Vasco main road. The latitude and longitude are 15o22'N and 73o52'E respectively. The plant area is bounded by Mormugao Bay, Cortalim village and NH17A to the north; Fr Joso Vaz and Consaulim to the east; Pale and M/s. Zuari Industries to the south and village Issorcim and the Arabian Sea to the west.

There is no National Park, Sanctuary, Elephant / Tiger Reserve (existing as well as proposed), or migratory route within 10 km radius of the plant.

The power station has demonstrated its commitment for mitigation of climate change through following major initiatives :

On consumption side, efficiency improvement, by installing variable frequency drives (VFDs) on Pumps & other electric motors etc. GPS has controlled its auxiliary power consumption well below the CEA (Central Electricity Authority) norms. Reduced auxiliary power consumption resulted in lower CO2 emission.


Carbon Emission Control

The Company has addressed the issue of carbon emission reduction by taking following measures :

The power station has achieved and consistently maintained its average Auxiliary Power Consumption (APC), Sp. Oil consumption and DM Water consumption much lower than the national standards.

Major efficiency measures :

  • Installation of Variable Frequency Drive
  • Corrocoating of CW Pumps.
  • Use of Energy Efficient Lighting systems.
  • Use of solar street lighting
  • CT Fan optimization


Technical Specifications :

The plant consists of one Frame 6B gas turbine (GT) generating an output of 32 MW with matching heat recovery steam generator (HRSG) and a steam turbine generator (STG) of 37 MW capacity giving a total output of 48 MW in combined cycle mode.


Energy Conservation & Efficiency Improvement :

The Goa Power Station has an Energy Management Cell consisting of highly qualified energy managers and auditors. Conservation of energy is their continuous agenda and they follow a defined energy policy. Regular internal and external energy audits are conducted to ensure the efficiency standards are adhered to.

The various energy conservation measures that have been implemented :

  • Installation of Energy Efficient CT Fan Blades
  • Installation of Vacuum Pump in place of Steam Ejectors for improving Condenser Vacuum and Power output for Steam Turbine.
  • Installation of Variable Frequency Drive (VFD) for 6.6kV High Pressure Boiler Feed Pump (HP BFP).
  • Replacement of the existing Condenser Cooling Water (CCW) pump with Energy Efficient Pump.
  • Installation of LED Based Outdoor lightning for plant area.
  • Installation of Solar System Based Street lightning for plant area.
  • Installation of Solar based LED office lightning (Solar Powered Power Pack).
  • Modification of existing Cooling Tower (CT) distribution system to Pressurized Header System.
  • Multi-stage pressure reduction drag valve.
  • Up gradation of HP Evaporator Module of HRSG
  • Gas Turbine Up-rate (From PG651B to equivalent PG6581B)
  • Gas Conversion of Plant from Naphtha to Natural Gas.
  • Station has Installed and commissioned CAAMS - Continuous Ambient Air Monitoring System.
  • Established Surveillance System in the Goa Power Station.