First Prize Thermal Power Stations (Coal Fired Plants > 100 MW Capacity) INDEPENDENT POWER PLANT (4X600MW) Vedanta Limited, Jharsuguda (Odisha) Unit Profile Vedanta Ltd. power operations include a 2,400 MW. It is an Independent Power Plant with 4X600MW unit configuration. Boiler is a subcritical reheat, single furnace, single reheat forced circulation, balance draft, dry bottom, suspension type coal fired boiler. The furnace is tangential firing type with one layer of light oil gun and three layers of heavy oil guns in every corners of boiler. The boiler is designed to produce 2028 tons/hour steam at 17.5 MPa pressure and 541deg.C at MCR capacity with coal having high heating value of 3300 kcal/kg. The turbine type is: sub-critical, primary reheat.single shaft.three cylinder and four-flow, and condensing type and its design rated power is 600MW,which characteristics include: Combination of the HP& IP cylinder, double-flow reverse arrangement of the LP cylinder. Plant is equipped with state of art Hybrid ESP(ESP with Bag filter) to reduce the emission level below 50mg/NM 3.High concentrated slurry discharge system(hcsd) installed to reduce water consumption as well as optimum use of resources for ash storage. 477
Salient Features of Independent Power Plant Sl. No. Features Details 1 Capacity 2400 MW 2 Configuration 4 x 600 MW 3 Type of boilers Pulverized coal fired boilers 4 Power evacuation Power transmission through 400 KV lines to National & State grid 5 Fuel Coal 6 Source of Coal Mahanadi Coal Fields (45-km from proposed site) 7 Coal Requirement 14 Million MT 8 Sulphur content 0.3 to 0.5 % (Max) 9 Ash Content in Coal 41.6 % (Max) 10 Ash generation 16700 TPD (Based on 100% PLF) 11 ESP efficiency 99.95% 12 Stack Two twin Flue stacks of 275-m height 13 Water Requirement 6146 m3/hr. from Hirakud & Source Plant Operating Parameters Sl Operating Parameter UOM F.Y F.Y F.Y F.Y 2011-2012- 2013-2014- 12 13 14 15 1 Plant Loading Factor % 44% 40% 40% 39% 2 Availability % 64% 60% 58% 56% 3 Utilisation % 69% 66% 69% 70% 4 Aux Power % 10.45% 9.89% 8.55% 8.08% 5 Station Heat Rate Kcal/kWh 2444 2431 2429 2338 6 Specific Coal @ 3000 GCV gms/kwh 815 810 810 779 7 Specific Oil Consumption ml/kwh 2.29 1.12 0.56 0.38 478
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Energy Efficiency Projects Achievement of Annual energy savings in 2014-15 Year of Project Description Electricity Fuels* Investment Commis- (Lacs Coal F.Oil Gas Total Total incurred sioning kwh) (ton (kl) (Lac fuel savings on the of the nes) Nm 3 ) (MTOE) (Rs. project projects Lacs) (Rs.Lacs) CW P/P modification- Speed 6 1 0 0 0 0.000005 123 0 reduction by increasing the no. of poles from 16 to 18 Loading reduce on ID Fan by 5 7 0 0 0 0.000005 114 0 replacing APH seal with soft seal Replacement of FF bags to 3 8 0 0 0 0.000003 76 100 reduce ID Fan loading CEP modification by De-staging 1 8 0 0 0 0.000002 35 0 Stopping of One CW pump 7 0 0 0 0 0.000006 140 0 Arresting of air leakage 1 1 0 0 0 0.000001 23 0 PA header. Power saving in Mills by 5 7 0 0 0 0.000005 114 0 decreasing the no of balls. FY 2014-15 Retrofitting of VFD in Bottom 8 0 0 0.000001 15 30 ash slurry pump Stopping of DP transfer pump 1 3 0 0 0 0.000001 26 0 (taking hot-well makeup through vacuum) Vacuum pump running 1 6 0 0 0 0.000001 32 0 hours optimization During unit Start-up use 6 0 0 0 0.000001 12 0 TDBFP instead of MDBFP installation of dozing line in 8 0 0 0 0.000001 16 0 DP pump to boiler filling line Mill Optimization on part loads 1 0 0 0 0 0.000001 21 0 Running Optimization of 2 2 0 0 0 0.000002 44 0 service water pump stopping of 2 compressor 3 1 0 0 0 0.000003 62 0 Geho pump running 2 0 0 0 0.000000 4 0 hour reduction Belt utilization for bunkering 1 1 0 0 0 0.000001 23 0 from 37% to 58% Isolation of standby cooler 2 0.000000 5 0 of OCCW Saturated steam washing 0 87600 0 0 0.030099 1822 0 of Unit#1 turbine deposits Optimization of Excess Oxygen 0 32938 0 0 0.011317 685 0 by defined oxygen control limits near to 3% Furnace Cleaning-Optimization 0 1226 0 0 0.000421 26 0 in Soot Blowing operation SH & RH spray auto loop tuning 0 2453 0 0 0.000843 51 0 480
SADC controlling for control 0 7 0 1 0 0 0.000241 15 0 the drift and RH steam temperature on higher side. Monitoring of losses impacting 0 23687 0 0 0.008139 493 0 on Heat rate and corrective action Boiler modification. 0 24528 0 0 0.008428 510 0 Re-heater temperature 0 15768 0 0 0.005418 328 0 improvement Condenser performance 0 2628 0 0 0.000903 55 0 improvement methods. Turbine offline washing 0 25200 0 0 0.008659 524 0 in Unit#2 Reduction in Un-burnt carbon% 0 5256 0 0 0.001806 109 0 DM make up reduction. 0 26280 0 0 0.009030 547 0 CBD flash tank optimal usage 0 5 2 6 0 0 0.000181 11 0 Charging of auxiliary header with ext-4 when unit load is 0 2102 0 0 0.000722 44 0 greater than 400MW Start-up time reduction 6 0 1 9 8 0 0.000183 127 0 Reduction in number of tripping 1 4 0 1340 0 0.001240 806 0 Energy Policy 481