Dahanu Thermal power station

Dahanu Thermal Power Station (DTPS) 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.   Dahanu Thermal Power Station (DTPS) consists of two units of 250 MW and is located around 120 K.M. north of Mumbai on Mumbai-Ahmadabad rail line. The plant is located between two creeks very close to the Arabian Sea. The station is conveniently approachable by road and is about 20 Kms from the main Mumbai-Ahmadabad Highway NH-8.

The plants utilises 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) which is located about 1400 Kms from the plant site. Imported coal is received from various countries like Indonesia, South Africa etc.

Dahanu Thermal Power Station is certified for Integrated Management System covering 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: 2008 - Social Accountability Management System
• ISO 27001: 2005 - Information Security Management System
• ISO 50001:2011 - Energy Management System

Plant Performance:

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

DTPS Plant Performance Parameters Units FY 06-07 FY 07-08 FY 08-09 FY 09-10 FY 10-11 PLF % 101.79 101.53 100.99 102.33 101.00 Availability % 96.79 96.70 96.3 97.18 96.48

Major Milestones and Achievements:

• The land development commenced in the year 1990
• The main plan contract got finalised in the year 1991
• Unit no. 1 was synchronised on 6th January 1995 and 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 September 07.

Technical Specifications:

Many features distinguish the Dahanu plant as one of India’s 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.
• The Dahanu Thermal Power Station is known for possessing the chimney of 275.3 mtrs for proper emissions dispersion.It has an Advance Air Pollution Monitoring System and an Integrated Management System for Quality, Environment, Occupational Health & Safety and Information Security in position
• An Electronic Electrostatic Precipitator (ESP) of 99.9% efficiency is used to collect fly ash thereby assisting in prevention of air pollution.
• Four ambient air quality monitoring stations tomeasure SPM, RSPM, SO2 and No2.
• The highly advanced Supervisory Control and Data Acquisition (SCADA) system provides complete centralized control over transmission and distribution.
• The organization has adopted an advanced air pollution monitoring system to ensure minimization of the plant’s environmental impact.

Plant features

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)

Steam turbine

Make	:	BHEL, KRAFT WORK UNION DESIGN
Rated Load	:	250 MW
Max. Load under Valve Wide	:	262.5 MW
Open construction	:	THREE CYLINDER REHEAT CONDENSING TURBINE

BOILER

Manufacturer: BHEL (C.E. Design)

Type: Natural circulation, Balance draft, Double pass, Single drum, Single reheat, Direct Pulverised Coal Fired Water Impounded Bottom. (Gas firing & Gas regulating system, provision for future)

Boiler Design Pr & Temp.	:	182.5 Kg/cm2 & 540 O C
Boiler Designation	:	15240 199 63 .5 11506 142 63 .5
Type of Firing	:	Tilting Tangential

Energy Conservation:

Reliance Infrastructure DTPS has achieved remarkable results since it has consistently maintained its average heat rate of 2300 Kcal/Kwh for the last five years. This is a major milestone considering the Central Electricity Regulatory Commission (CERC) has set a norm of 2500 Kcal/Kwh for a unit of this size.

Reliance Infrastructure has proactively contributed by adopting a range of effective energy conservation measures such as:

• Installation of Variable Frequency Drive in Condensate Extraction Pumps, Coal Mill Seal Air Fans, PA Fan.
• Corrocoating of CW Pumps & ACW Pumps.
• Installation of Wind turbo-ventilator.
• Investing in Vapour Absorption Air Conditioning.
• Use of Energy Efficient Lighting systems.
• Use of solar street lighting
• Variable Frequency Drive

The Energy Management Cell at DTPS consists of qualified Energy Managers and Auditors who continue to drive the 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 SOx, NOx, and TPM in Flue gas.
• Four Ambient air quality monitoring Stations to measure SPM, RSPM, SOx, NOx,
• Along with one meteorological station for weather monitoring.
• Mobile Van to monitor Ambient Air quality in remote areas.

ASH DISPOSAL

• Four ash ponds for disposal of ash slurry.
• Pond management designed to minimize pollutants in discharge effluent.

Dry Fly Ash collection System for maximising ash utilization as per MOEF notifications.

ENVIRONMENTAL REPORTS

Environmental Monitoring Reports Jul-Dec 2011

GOA Power Station

Located about five kilometres from the Dabolim Airport, at Zuarinagar, Goa, the Power Station commenced its commercial operations on 14th August 1999. A total production of 48 MW of electricity, the plant is equipped with state of the art Gas Turbine (32 MW) and Steam Turbine (16 MW), both with Mark V control system and Heat Recovery Steam Generators.   In a decade of successful operation, 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 Government of Goa grid. With its dedicated network of underground distribution system, the Power Station had extended reach to private industries based in Goa, including Mormugao Port Trust.

It has also set up reliable underground cable distribution network system and sub stations in Verna, Kundaim and Madkaim Industrial Estate to supply quality and steady electricity to industries. The consumer base includes reputed major Indian and multinational companies, such as Finolex, Watson Pharma, Abbot Laboratories, Colorcon, Universal Cables, Dr. Reddy's Laboratories, Lupin Pharma, Pentair, Syngenta (Novartis), etc. With its operational efficiency it has been acknowledged as the preferred electricity supplier and technological solution provider in Goa. 

An insight into the power allocation of the Goa Power Station, reveals about 33% of the generated power is distributed to Government of Goa grid in Sancoale sub-station, while the remaining 67% is supplied directly through dedicated underground cable distribution network to approximately 84 industrial customers. 

The Power Station has been certified for Integrated Management System consisting of the following systems:-

• ISO 9001:2008 - Quality Management System
• ISO 14001: 2004 - Environment Management System
• OHSAS 18001: 2007 - Occupational Health and Safety Management System
• ISO 27001: 2005 - Information Security Management System

Plant Performance:

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

GPS Plant Performance Parameters Units FY 04-05 FY 05-06 FY 06-07 FY 07-08 FY 08-09 PLF % 79.95 83.36 84.32 77.73 79.58 Availability % 97.33 96.93 94.93 91.66 95.19

Major Milestones and Achievements:

• The commercial operation commenced on 14th August1999.

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

Awards

Sr. No Description Category Award Year Issuing Agency/Authority 1. Recognition of Lowest Frequency Rate of Accidents Safety State Safety Award 2004 Green Triangle Society 2. 7th Annual Greentech Environment Excellence Award 2006 Environment Gold 2006 Greentech Foundation, New Delhi 3. 8th Annual Greentech Environment Excellence Award 2007 Environment Silver 2007 Greentech Foundation, New Delhi 4. 6th Annual Greentech Safety Award 2007 Safety Gold 2007 Greentech Foundation, New Delhi 5. 9th Annual Greentech Environment Excellence Award 2008 Environment Gold 2008 Greentech Foundation, New Delhi 6. 7th Annual Greentech Safety Award 2008 Safety Gold 2008 Greentech Foundation, New Delhi 7. 8th Annual Greentech Safety Award 2009 Safety Gold 2009 Greentech Foundation, New Delhi 8. 10th Annual Greentech Environment Excellance Award Environment Gold 2009 Greentech Foundation, New Delhi

 

The BSES Kerala Power Limited

The BSES Kerala Power Limited (BKPL) is a 165 MW aggregated cycle power plant situated in Kochi which initiated its commercial operation on 23rd November 2001.

Known for its highly focused energy conservation techniques, the power station uses Naptha as its source of fuel. BKPL is certified for an Integrated Management System comprising of the following systems:-

• ISO 14001: 2004 Environment Management System
• OHSAS 18001: 2007 Occupational Health and Safety Management System
• ISO 9001:2000 Quality Management System

Plant Performance:

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

BKPL Plant Performance
Parameters	Units	FY 04-05	FY 05-06	FY 06-07	FY 07-08	FY 08-09
PLF	%	8.23	2.71	13.24	25.8	60.47
Availability	%	95.3	99.9	94.7	82.8	87.7

Low PLF is on account of low demand and high cost of Naphtha fuel.

Major Milestones and Achievements:

The combined cycle power station commenced its commercial operation on 23rd November 2001.

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

• The Power Station consists of three GE make LM 6000 PC series, state-of- the-art aero-derivative Gas Turbines Generators (GTGs), apt for dual-fuel operation.
• The GTGs and auxiliaries have been packaged, supplied and set up by Stewart & Stevenson, USA.
• Three dual pressure-45 tons per hour Heat Recovery Steam Generators (HRSGs) were supplied and set up by Thermax Babcok & Wilcox Limited.
• 39MW Steam Turbine Generators (STG) and auxiliaries have been supplied, set up 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. Further more 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:

Heat Rate Improvements:

• Additional Make Water Heater Modules in HRSGs
• Implementation of Vacuum for improvement in STG Vacuum
• Reduction in the LP steam injection pressure to avoid the throttling losses control valve
• MCW pump uprating
• De staging of CEP & LPBFP
• Installation of more efficient impeller by corrocoating in MCW Pump
• Replacement of CT fans by more efficient hollow FRP Fans
• Installation of Lighting transformer
• Energy Efficient Lighting system
• Installation of 6 nos. of Solar lamps

 

Samalkot Power Plant

Samalkot Power Plant (SPS) is located at Samalkot in the state of Andhra Pradesh, three kms away from Samalkot railway station, near Kakinada. The Plant Capacity is 220 MW.

With an output capacity of 220 MW, this project is 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 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. 

Located strategically near the railway station, here’s a proximity snapshot of the site:

• Location   Vetlapalem Village, Samalkot, Andhra Pradesh, India
• Roads & Highway 200 ft wide ADB Road connecting  Kakinada and Rajahmundry.
• Railway Station   Samalkot, 3 km
• Airport   Visakhapattanam, 155 km
• Sea Port   Kakinada, 20 km

The Samalkot Power Plant is certified for 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 04-05	FY 05-06	FY 06-07	FY 07-08	FY 08-09
PLF	%	61	45.28	50.55	60.61	52.5
Availability	%	98.3	89.39	97.4	97.4	97.08

Major Milestones and Achievements:

The power plant started its commercial operation on 24th December 2002.

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 combustion chamber, 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.

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	Condensation, Extraction
No. of Cylinders	2 (HP & LP)
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
• 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.
• Installation of High Efficiency Illumination system.

Awards:

The Samalkot Power Plant has been awarded with the 5’Th annual GREENTECH Environment Excellence silver award in year 2003-2004.

The Samalkot Power Plant has been awarded with the 10’Th annual GREENTECH Environment Excellence gold award in year 2009.

 

Wind Farm Project

The Wind Farm Project heralds the next generation of power generation in India. With the early move into the field of non-conventional and environment friendly energy resource, the organization commissioned its 7.59 MW (33 X 230 KW) Wind Farm Project at Jogimatti, Taluka Hiriyur, District Chitradurga in Karnataka state in Sept.1999. 

In June 2003, the company further commissioned a 1.8 MW (3 X 600 KW) Wind Farm Project.  

A total output capacity of 8.37 MW, the Farm now generates commercial power using all its 36 windmills.  

Plant performance:

The Plant performance for last five 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

Landmarks and Achievements:

• The 7.59 MW Wind Farm was commissioned in September 1999.
• Another 1.8 MW commissioned in June 2003.

Technical Features:

The Farm uses a total of 36 windmills to generate total power of 8.37 MW. Here’s an insight into the technical specifications:-

Generators:

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

System configuration:

Power generated at 440 Volts, 3 Phase from each generator stepped up to 33 KV level and transmitted through overhead transmission line to power evacuation station located about 9 KM away from Wind Farm. In the evacuation station, power is further stepped up to 66 KV level and pumped to KPTCL power grid with suitable metering arrangement.