Power Plant

JOJOBERA THERMAL POWER STATION
(TATA POWER COMPANY LIMITED)
ENERGY AUDIT OF
Auxiliary Power Consumption
Boiler Efficiency
Turbine Heat Rate and Efficiency
And
Condenser Performance
EXECUTIVE SUMMARY
An auxiliary power consumption and Heat rate energy audit was carried out for unit 2 and
associated off-site auxiliaries at Jojobera Thermal Power Station, Tatanagar by NTPC. At
the outset, the audit team compliment the plant management towards excellent house-keeping
in boiler area,
The major findings and brief summary of the recommendations in each area is given below.
For technical and saving details please refer respective equipment / area sheet.
(1) The recorded Auxiliary Power Consumption during the audit was 8.63 %.
(2) Major recommendations and their energy saving potential are given below
SAVING IN INVESTMENT
ENERGY
S No. RECOMMENDATION RUPEES IN RUPEES
SAVING (MUs)
(LAKH) (LAKH)
A Auxiliary Power Consumption study
1 Main Plant Auxiliaries
a Boiler Feed Pump
Checking of internals of
BFP 2A, 2B & 2C and
(i) their recirculation valve 2.44 57.4
and overhauling if
required
b Condensate Extraction Pump
Checking of internals of
condensate pump B and
(i) its recirculation valve .09 2.18
and overhauling if
required
c Induced Draft Fan
Arresting Air ingress
across heaters and in flue
gas ducts from APH
(i) 0.54 12.6
outlet to ID fan inlet and
optimizing fan
performance
d Forced Draft fan
Optimizing air flow and
inspection/maintenance
(i) 0.8 19
of Forced draft fan A &
B
e Primary Fans
Optimization of primary
(i) 1.0 23
air flow
2
f Coal Mills
overhauling of Mills &
(I) 2.8 66
three mill operation
g Circulating Water Pump
Providing polymer
(i) coating on CW pump 0.34 7.9 10
internals
Provision of Online
h energy monitoring 0.36 8.5 10
system
2 OFFSITE AUXILIARIES
a Coal Handling System
(i) Direct bunkering of coal 0.44 10.4
b AHP and other pumps
Polymer/ceramic on
i 0.16 3.77 3
pumps
c Lighting System
Voltage reduction in
(i) lighting circuit in AHP & 0.08 2
CHP areas
Replacing 763 numbers
(ii) 40W FTL by 28W T-5 0.18 4.24 5.7
Tube-light
Asbestos sheets to be
replaced with translucent
(iii) 0.17 4.02 16.6
sheets in CHO
Conveyors gallery
B Boiler Efficiency Test
Reduction sensible heat
a loss by trimming excess 85.5
air
Reduction of un-burnt
carbon in fly ash and
b 60.9
bottom ash by
combustion optimization
C Turbine Heat Rate and efficiency test
Improvement in heat rate
( including HR
a improvement by 7.9 186
improving vacuum as
given below )
D Condenser Performance test
Improvement in vacuum
a by overhauling of CW- 4.6 108
CT system
17.3 553
Total
3
Remark : (i) Saving in Rs includes saving against s.no. B.a & B.b also
(ii) Energy saving does not include saving against s.no. D.d
(3) Other recommendations ( in addition to above ) in each area is given below.
(1) Main Plant Area

(i) All drains and vents in feed water line should be checked for passing.
(ii) Merit order operation in BFPs can be done. Considering the audit period SEC
of BFPs, it is recommended to keep BFP A & C in service and BFP B can be
used as standby.
(iii) It is recommended to keep FRS DP as low as possible. It can be seen from the
comparison table above, that there was no operational problem at FRS DP of
4.4 Kg/cm2. FRS DP can be kept at 4 Kg/cm2and if no problem is faced in
maintaining drum level it can be reduced to 3 Kg/cm2. it will reduce BFPs
power consumption.
(iv) Provision of Flue gas flow measurement in all ID Fans should be made. This
will help in monitoring of air ingress.
(v) Provision for sample collection for O2 should be made in all the places e.g.
APH inlet, APH outlet and each ID Fan inlet. This will help in monitoring of
air ingress at various places in the flue gas duct.
(vi) Provision of Flue gas temperature measurement at all ID Fans’ inlets should
be made. This will also help in monitoring of air ingress and exit temperature
of flue gas.
(vii) Internal inspection of fan B needs to be done.
(viii) Complete flue gas duct from APH to Fan inlet should be checked by
pressurizing the furnace before unit overhaul.
(ix) Provision of pressure gauge at all ID Fans outlet should be made. This will
help in calculating air power and other auditing parameter.
(x) Provision of individual fan flow measurement in all FD Fans should be made.
This will help in monitoring of air flow and fan performance.
(xi) Internal inspection of both the fans.
(xii) Whenever opportunity comes, complete air duct from fan to wind box should
be checked by pressurizing the furnace.
(xiii) Efforts need to be made for three mill operation. Because of four mill
operation, primary air flow was high and secondary air flow was less. Due to
low secondary air flow, fans were running at low load i.e. in low efficiency
zone. Therefore three mill operation will lead to operate FD fans in high
efficiency zone.
(xiv) Provision of individual fan flow measurement in all PA Fans should be made.
(xv) Internal inspection of both the fans.
(xvi) Whenever opportunity comes, complete air duct from fan to mills including
air heater should be checked.
(xvii) Efforts need to be made for three mill operation. Because of four mill
operation, primary air flow was high and secondary air flow was less. Due to
high air flow, primary air fans were consuming more power. Therefore three
mill operation will help in optimizing primary air flow.
(xviii) Three mill operation should be tried
(xix) Mill maintenance philosophy should be reviewed. This should include review
of roller and other associated auxiliaries replacement practice.
(xx) Rollers spring tension should be lessened
(xxi) Roller and other auxiliaries running hour vise status should be maintained
( presently not available.)
4
(xxii) Coal fineness of 70% through 200 mesh should be maintained. This level of
fineness is sufficient for coal having volatile matter of more than 18 %.
Classifier opening should be increased.
(xxiii) CW ducting inspection should be done at suitable opportunity. If scaling
inside duct is observed, it could be one of the reason of low cooling water
flow .
( 2 ) Offsite Area
(a) Coal Handling Plant
(i) Conveyor running hours along with Crushers running hours may be logged
and analyzed on daily, monthly and yearly basis. For accurate monitoring,
time totalizers should be installed at major CHP auxiliaries switchgears. This
will help in monitoring and controlling idle running of equipments.
(ii) No-load power consumption in CHP may be reduced by optimizing no-load
run of the conveyors, which is very routine in nature.
(b) Ash Handling Plant & Other auxiliaries pump
(i) Ash water ratio needs to be checked on regular basis (once a day) and to be
maintained as per design.
(ii) In Ash slurry pump series, Ist pump to be checked for under loading,
(iii) HP water pumps to be checked for poor flow.
(d) Compressed Air System

(i) Provision to isolate compressor with receiver tank is to be made during annual
maintenance of compressed air system. This will help to evaluate Free air
delivery (FAD) test of Compressors and efficiency thereafter.
(e) Cooling Tower

1 Performance test of Cooling tower to be conducted during peak summer and
rainy season. During this period heat load on CT is maximum due to ambient
conditions and actual performance can be evaluated.
2 For energy savings and better air flow FRP fan blades are being used.
Which is a good practice and to be continued.
3 CW flow needs to be increased up to design level i.e 18000 m 3/hr. CW
pumps to be checked for less flow.
4 Increased air flow measured during the test, may be due to use of FRP
blades.
5 Cooling tower fills needs to be checked for fill chocking and poor water
distribution.. Equal and uniform water flow to each cell to be ensured for
proper distribution of water. This will improve effectiveness of CT. Improved
CT performance will allow to stop one CT fan during extreme cold conditions
(night time of winter)
6 Voltage level needs to be increased up to 415 Volt for CT fan 1,2 and 6 by
tap adjustment.
5
Audit
6
The Plant Load Factor and auxiliary power consumption ( provided by TPC energy audit
team ) during audit period is given below
Date PLF APC

08.01.07 99.93 8.14
09.01.07 100.03 8.97
10.01.07 99.91 8.68
11.01.07 100.14 8.67
12.01.07 99.06 8.70
The power consumption pattern of major auxiliaries are given below:
Specific energy Consumption of BFPs,

Kw/T of flow
8.40
8.20
8.00
8.29
7.95
7.80
7.60
7.61
7.40
7.20
BFP A BFP B BFP C
Specific Energy Consumption of CEPs,

Kw/T of flow
0.75
0.75
0.70
0.68
0.65
0.60
CEP A CEP B
7
Power consumption in ID Fans,
Kw
460
440
459
420
408
400
380
IDFAN A ID FAN B
Power Consumption in FD FANS, kW
320
300
319
280
273
260
240
FD FAN A FD FAN B
Power Consumption in PA FANs, kW
400
300
308
200
248
100
0
PA FAN A PA FAN B
8
Specific Energy Consumption of Mills,
Kw/T of flow
25.0
20.0
15.0
21.8
15.5
14.7
15.7
14.4
10.0
5.0
0.0
MILL A MILL B MILL C MILL D MILL E
Power Consumption of SA FANs, kW
19
19
18
19
18
17
17
17
16
16
SA FAN A SA FAN B
9
SPECIFIC ENERGY CONSUMPTION ANALYSIS
AND
RECOMMENDATIONS
FOR
REDUCTION
IN
AUXILIARY POWER CONSUMPTION
10
MAIN PLANT AUXILIARIES
11
BOILER FEED PUMP
There are three BFPs in the units. Two BFPs are kept in service and third act as standby.
The designed flow is 215.2 TPH and motor capacity is 2000 kW.
The comparative study of all BFPs is given below.
S.No Description Units BFP A BFP B BFP C

1 Unit Load MW 119.00 119.67 120.33
3 BFP Suction Flow TPH 190.10 180.70 175.90
4 Feed Water Flow TPH 371.90 372.27 371.30
5 Speed rpm 3562 3565 3486
6 DP Across FRV Kg/cm2 4.40 5.43 5.83
8 BFP suction Pressure Kg/cm2 6.27 6.30 6.33
9 BFP Discharge Pressure Kg/cm2 149.57 150.37 152.00
10 FW Pressure
a At Heater Inlet Kg/cm3 148.13 150.13 150.27
b At Heater Outlet Kg/cm4 147.23 149.00 149.07
iv Power Consumption kW 1447.5 1497.8 1399.2
12 Pump Hydraulic Power kW 742.33 709.40 698.22
Specific Energy
13 Consumption Kwh/T 7.61 8.29 7.95
14 Combined Efficiency % 51.28 47.36 49.90
15 Motor Loading % 72 75 70
16 Flow Loading % 88 84 82
RECOMMENDATIONS
Based on the observation recorded above in comparison sheet, following are the major
recommendations.
(i) The Specific energy consumption (SEC) for BFP 2A, 2B & 2C was 7.6, 8.3 & 8 kWh/T.
As per the pumps specification, design SEC can be calculated as 7.3 kW/T of feed water.
The specific energy consumption pattern indicates that all BFPs were consuming more
power than the designed power consumption. As performance guarantee test specific
energy consumption and efficiency is not available, the designed SEC is taken for
performance comparison.
Since unit loads were near to full load during audit of all BFPs, pump flow and other
conditions can be considered same .
Since all the BFPs configuration are same, the possible reason for high SEC can be
(a) Deterioration in performance of BFP

(b) Increase in system resistance.
Therefore
(a) Overhauling of pumps 2A, 2B & 2C may be done.
(b) All drains and vents in feed water line should be checked for passing.
The energy saving potential is calculated below.
12
BFP 2A
Designed SEC = 7.3 kW/T of feed water

SEC of BFP 2A = 7.6 kW/T of feed water
Difference in SEC = 0.3 kW/T
Hence energy saving potential = 0.3*190.1
= 57 kWh
Annual running hours is assumed as 8000 Hrs. As there are three BFPs in the unit and
only two are kept in service during normal running condition, therefore running hours for
one BFP can be taken as 5300 hrs.
Annual energy saving potential = 57*5300

= 302100 kWh
= 0.3 MUs
Considering energy cost as Rs 2.35 per kWh
Annual saving potential in Rs = 0.3*1000000*2.35
= 7.1 lakh
BFP 2B

SEC of BFP 2B = 8.3 kW/T of feed water
Hence energy saving potential = 1*180.7
= 180.7 kWh
Annual energy saving potential = 180.7*5300
= 1487710 kWh
= 1.49 MUs
Considering energy cost as Rs 2.35 per kWh
= 35 lakh
BFP 2C

SEC of BFP 2A = 8.0 kW/T of feed water
Hence energy saving potential = 0.7*175.9
= 123.1 kWh
Annual energy saving potential = 123.1*5300
= 652589 kWh
= 0.65 MUs
= 15.3 lakh
(ii) Merit order operation in BFPs can be done. Considering the audit period SEC of
BFPs, it is recommended to keep BFP A & C in service and BFP B can be used as
standby.
(iii) It is recommended to keep FRS DP as low as possible. It can be seen from the
comparison table above, that there was no operational problem at FRS DP of 4.4
13
Kg/cm2. FRS DP can be kept at 4 Kg/cm2and if no problem is faced in maintaining
drum level it can be reduced to 3 Kg/cm2. it will reduce BFPs power consumption.
CONDENSATE EXTRACTION PUMP
Two CEPs are available in the unit. One pump is kept in service and other act as standby.
The designed flow is 360 TPH and motor capacity is 250KW.
The comparative study of all CEPs is given below.
S. No Description Units CEP A CEP B

1 Unit Load MW 118 119
2 Grid Frequency Hz 48.77 48.91
3 Suction Temp. ºC 46.8 47.6
4 CEP Flow TPH 332 309
5 Condenser back Pressure(-) Kg/cm2 0.91 0.90
6 Hot-well Level mm 809.6 822.3
7 Discharge Pressure Kg/cm2 16.5 16.6
8 Power Consumption kW 225.1 230.9
9 Specific Energy Consumption kWh/T 0.68 0.75
10 Motor Loading % 90 92
11 Pump Loading % 92 86
12 Condensate Flow to Unit Load ratio TPH/MW 2.8 2.6
RECOMMENDATIONS
recommendations.
(i) The Specific energy consumption (SEC) for CEP A was 0.68 KWh/T which was
lower than the pump B SEC. During the audit of CEPs, it was observed that when pump
B was started , its discharge pressure was continuously dropping. CEP B could be run for
2 minutes only and CEP A was again taken in to service. It indicates that CEP A NRV was
passing. Due to passing of NRV , some portion of CEP B discharge was returning back to
condenser and discharge pressure was falling. Hence CEP A NRV should be attended at
the earliest.
As design specific energy consumption was not available, the lowest specific energy
consumption is taken for comparison.
The energy saving potential by attending CEP A NRV, is calculated below.
SEC of CEP A = 0.68 kW/T of water flow

SEC of CEP B = 0.75 kW/T of water flow
Difference in SEC = 0.07 kW/T of water flow
Energy saving potential = 0.07*332
= 23.24 kW
Hence annual energy saving potential = 23.24*4000
= 92960 kWh
= 0.09 MU
Annual energy saving potential in Rs = 2.35*92960
= 2.18 lakh
14
INDUCED DRAFT FAN
There are 2 induced draft fans in the unit. Both fans are kept in running condition. The fan
capacity is 126 m³/sec ( 453600 m³/hr ) and the motor rated output is 800 kW. Each fan was
tested separately. Rated flue gas exit temperature is 139 deg C.
The comparison study of ID Fan is given below.
S. N0. Description Units A B

1 Unit Load MW 120 119
2 Frequency Hz 48.93 48.62
3 Total Air Flow TPH 430 429
4 Coal Flow TPH 64 64
5 Suction Pressure (-) mmwcl 174 176
6 Flue gas temperature at ID inlet A/B deg C 133/131 133/131
7 Current ( Control room ) Amps 48.6 52.7
8 Power Analyser Readings
i Current Amps 48.4 52.6
ii Voltage Kv 6.5 6.5
iii Power Factor 0.75 0.78
iv Power kW 408 459
9 Motor Loading % 60 67
The possible reason for higher power consumption in B could be due to air ingress and
deterioration in fan & motor performance. As per the on line data and chemistry reports ,
calculated gas flow at ID Fan inlet was 533.6 TPH. The calculated air ingress across APH
and flue gas duct is 62.4 TPH which is about 12-13 % of total flue gas flow at APH inlet
( 489 TPH ).
Due to non availability of PG test or designed power consumption, expected power
consumption is tried to assess by using performance curve.
As per the performance curve of the fan ( provided by Tata Power ), the expected fan flow
with design coal is 489 TPH. As calculated gas flow in audit condition and design condition
are same, the power consumption can also be assumed to be same. Calculated Power
consumption at design condition is about 380-390 kW ( assuming motor efficiency as 90 %).
Hence total power consumption of both ID Fans in the unit would be about 760 kW, but
considering coupling and other losses, let us assume it to be 800 kW.
As observed cumulative ID Fan power consumption was about 867 kW, it can be said that
fans are consuming about 67 kW more power, which can be saved.
Expected saving in Power consumption = 67 kW

Running hour assumed = 8000
= 536000 kWh
= 0.54 MUs
Annual energy saving potential = 0.54*2.35*1000000
= 12,59,600
= 12.6 Lakh
It is recommended that
15
(i) Provision of Flue gas flow measurement in all ID Fans should be made. This will
help in monitoring of air ingress.
(ii) Provision for sample collection for O2 should be made in all the places e.g.
APH inlet, APH outlet and each ID Fan inlet. This will help in monitoring of air
ingress at various places in the flue gas duct.
(iii) Provision of Flue gas temperature measurement at all ID Fans inlets should be
made. This will also help in monitoring of air ingress and exit temperature of
flue gas.
(iv) Internal inspection of fan B should be done as it is consuming more power
compared to fan A.
(v) Whenever opportunity comes, complete flue gas duct from APH to Fan inlet
should be checked by pressurizing the furnace for detecting air ingress point.
(vi) Provision of pressure gauge at all ID Fans outlet should be made. This will help
in calculating air power and other auditing parameters.
16
FORCED DRAFT FAN
Two FD Fans (two running + no standby) are available in the unit. The design capacity of
each fan is 75.83 m3/sec and the output of the motor is 480 kW. Each fan was tested
separately.
The comparative study of all FD fans is given below
S. N0. Description Units FD FAN A FD FAN B

1 Unit load MW 121 121
3 Total Secondary air Flow TPH 257 258
4 Discharge Pressure mmwcl 232 245
5 Secondary Air Pressure
a After AH ( L ) mmwcl 102 101
b After AH ( R ) mmwcl 103 106
6 Secondary Air Flow
a After AH ( L ) TPH 136 136
b After AH ( R ) TPH 121 122
7 Wind Box Pressure
a Left 101 102
b Right 102 102
8 Power Consumption kW 319 273
9 Secondary Air Flow to Unit load Ratio TPH/MW 2.1 2.1
RECOMMENDATIONS
The possible reason for higher power consumption in A could be due high air flow or/and
deterioration in fan & motor performance. As per the on line data, total secondary air flow
was 257 TPH. As only total secondary air flow was available on-line, individual fan specific
energy consumption can not be calculated.
As per the performance curve of the fan ( provided by Tata Power ), power consumption at
observed air flow and pressure should be about 240 kW ( assuming motor efficiency as 90
%). Hence total power consumption of FD Fans in the unit should be about 480 kW.
As observed cumulative FID Fan power consumption was about 592 kW, it can be said that
fans are consuming about 100 kW more power, which can be saved.
Expected saving in Power consumption = 100 kW

= 800000 kWh
= 0.8 MUs
= 18,80,000
= 19 Lakh
(i) Provision of individual fan flow measurement in all FD Fans should be made.
(ii) Internal inspection of both the fans.
17
(iii) Whenever opportunity comes, complete air duct from fan to wind box should be
checked by pressurizing the furnace.
(iv) Efforts need to be made for three mill operation. Because of four mill operation,
primary air flow was high and secondary air flow was less. Due to low secondary
air flow, fans were running at low load i.e. in low efficiency zone. Therefore three
mill operation will lead to operate FD fans in high efficiency zone.
PRIMARY AIR FAN

18
Two PA Fans (two running + no standby) are available in the unit. The design capacity of
each fan is 44.26 m3/sec and the output of the motor is 675 kW. Each fan was tested
separately.
The comparative study of PA fans is given below:
S. N0. Description Units PA FAN A PA FAN B

1 Unit load MW 121 120
3 Total Primary air Flow TPH 173 173
4 Coal Flow TPH 65 65
5 Discharge Pressure mmwcl 864 864
6 DP across PAH air side TPH 32 32
7 Power kW 248 308
8 Primary Air Flow to Unit load Ratio TPH/MW 1.42 1.44
9 Primary Air to Coal Ratio 2.65 2.65
RECOMMENDATIONS
recommendations.
As recorded above, It can be seen from the above, that primary air to coal ratio is 2.65.
This is quiet high against the design primary air to coal ratio of 1.65. All effort should be
done to optimize the present ratio. The possible reason for high ratio could be four mill
operation against the design provision of three mill operation. Other reason could be air
leakage from the ducts or air heaters.
The possible reason for higher power consumption in B could be due to high air flow or /
and deterioration in fan & motor performance. As per the on line data, total primary air
flow was 173 TPH. As only total primary air flow was available on-line, individual fan
specific energy consumption can not be calculated.
As per the performance curve of the fan ( provided by Tata Power ), the expected power
at rated air flow and pressure is about 230 kW ( assuming motor efficiency as 90 %).
Hence total power consumption of PA Fans in the unit should be about 460 kW.
As observed cumulative PA Fans power consumption was about 556 kW, it can be said
that fans are consuming about 90-100 kW more power which can be saved.
(i) Provision of individual fan flow measurement in all PA Fans should be made. This
will help in monitoring of air flow and fan performance.
(ii) Internal inspection of both the fans.
(iii) Whenever opportunity comes, complete air duct from fan to mills including air
heater should be checked.
(iv) Efforts need to be made for three mill operation. Because of four mill operation,
primary air flow was high and secondary air flow was less. Due to high air flow,
fans were consuming more power. Therefore three mill operation will help in
optimizing primary air flow.
As already discussed above, actual primary air to coal ratio was high at the time of
testing, energy saving potential if primary air flow is reduced by having three mill
operation, is calculated below
Saving potential is given below
19
Designed primary air flow = 135 T
Actual primary air flow = 173 T
Additional primary air flow = 38 T
PA Fans Cumulative SEC = 3.21 kWh/T
Saving in Power consumption = 3.21*38
= 122 kW
= 975840 kWh
= 1 MUs
= 22,93,000
= 23 Lakh
COAL MILLING SYSTEM

20
Five coal mills are available in the unit. . The mills are XRP-683 bowl mills with capacity of
36.5 T/hr and motor capacity of 300 kW.
Comparative study of all mills is shown below
MILL MILL MILL

S. N0. Description Units MILL A MILL E
B C D
1 Unit load MW 119.0 118.3 119.3 119.3 119.3
2 Frequency Hz 49.1 48.9 49.0 48.9 48.9
3 Total air flow TPH 430.0 430.0 430.4 430.8 431.0
4 Hot PA header pressure mmwc 804.3 805.5 806.1 806.5 799.6
5 Mill inlet pressure mmwc 439.8 509.3 496.9 363.3 393.3
6 Mill Differential Pressure mmwc 381.4 368.7 192.4 170.9
7 Cold Air Damper position % 62.9 71.6 53.8 65.2 41.2
8 Hot Air Damper position % 27.0 30.9 33.4 31.3 27.8
Primary air temp after mill air 0
9 C 297.0 297.1 297.4 297.4 289.8
pre-heater
0
10 Air temp at mill inlet C 148.2 153.8 160.8 114.0 171.4
0
11 Mill Outlet temp C 88.5 87.4 88.5 85.9 91.8
12 Coal flow to mill TPH 17.6 18.0 17.6 10.1 13.3
13 PA flow TPH 45.9 46.5 42.9 43.5 47.1
14 Total PA flow TPH 177.2 176.9 177.0 176.5 187.6
15 Mill Fineness (-)75 Mesh % 85.2 85.6 88.1 91.7
16 Mill power analysis
a Current (control room) Amps 30.4 29.9 30.0 26.8 30.0
b Power Analyser Readings
i Current Amps 31.3 30.0 30.1 26.7 25.6
ii Voltage kV 6.5 6.5 6.5 6.5 6.5
iii Power Factor 0.8 0.8 0.8 0.7 0.7
iv Power kW 273 260 259 220 209
17 Specific power consumption kW/T 15.5 14.4 14.7 21.8 15.7
18 Motor Loading % 90.9 86.5 86.3 73.4 69.8
19 Mill Loading % 48.2 49.3 48.1 27.7 36.4
OBSERVATION
It can be seen from the table that all the mills are less than 50% loaded, though their motor
loading are much higher. One reason for high power consumption of mills is use of middling
coal having HGI of 45. But this factor alone can not be held responsible for high power
consumption.
As per mill performance curve, due to reduction in HGI from 55 to 45, mill capacity should
be reduced by 15-20 %. But low moisture ( about 4.5 % ) in the middling coal compared to
high moisture( 12 % ) in design coal should also help in getting better mill output. For
reduction in moisture content from 12 to 5 % , mill output should be increased by about 5 %.
Therefore due to change in coal properties like HGI and moisture, mill capacity can be
assumed to be reduced by about 15 %.
High fineness could be one of the major reason for high power consumption. As per design,
coal fineness of the order of 70 % through 200 mesh at mill outlet is sufficient for coal of 18
% or more volatile matter. As per fineness vs mill output curve, for coal fine-ness of 85 % or
more, mill output is reduced to 60 %.
Therefore based on the above observations, it can be said that three mill operation is possible
even with middling coal.
21
It was reported that un-burnt carbon in bottom and fly ash is high. As already written above,
because of four mill operation, coal air mixture is too lean to have sufficient temperature in
combustion zone.. Moreover due to high primary air, coal particle velocity at burner outlet
will be high. This may even lead to flame un-stability and secondary combustion.
RECOMMENDATIONS
Therefore considering all above it is recommended

(i) Three mill operation should be tried
(ii) Mill maintenance philosophy should be reviewed. This should include review of
roller and other associated auxiliaries replacement practice.
(iii) Rollers spring tension should be lessened
(iv) Classifier opening should be increased.
(v) Roller and other auxiliaries running hour vise status should be maintained
( presently not available.)
(vi) Coal fineness of 70% through 200 mesh should be maintained. This level of
fineness is sufficient for coal having volatile matter of more than 18 %.
The energy saving potential by three mill operation is given below:

Total power consumption of four mills = 1012 kW
Total power consumption for three mill = 759 kW
Energy saving potential = 1012-759
= 353 kW
Running Hours = 8000 Hrs
Annual energy saving = 353*8000
= 2824000 kWh
= 2.8 MUs
Cost of annual energy saving (Rs) = 2824000 *2.35
= 66 Lakh
CIRCULATING WATER PUMPS
22
There are two CW Pumps at JJPS, which are common to both units. Pump designed flow is
9500 M³/Hr and motor capacity is 610 kW.
Average power consumption of CW Pump A & B was 527 & 531 kW respectively during the
audit. Their discharge flow was 8216 & 8102 M³/Hr respectively. It can be said that both the
pumps performance are same. Both the pumps discharge flow was less than the design flow,
hence their internal inspection should be done for impeller and casing surface roughness,
gaps etc.
RECOMMENDATIONS
(i) Pump efficiency and can be improved by applying polymer coating on pump
internals. There are manufacturers, who claim that pump efficiency can be improved
by 5-6 % by coating. Energy consumption by such coating can be reduced by 4-5 %.
Total Power Drawn by both the pumps = 1058 kW
Expected Power after improvement in efficiency = (1-0.04)*
(Assuming 4 % improvement in power consumption) = 1016 kW
Expected Running Hours (assumed) = 8000 Hrs
Power saving = (1058-1016)
= 42
Annual energy saving (Units) = 42 * 8000
= 3,36,000 kWh
= 0.34 MUs
Cost of annual energy saving (Rs) = 3,36,000 *2.35
= 7,89,600
= 7.9 Lakh
Approximate cost of polymer coating on both pump internals (Rs)
= 10 Lakh
Pay Back Period = Two Years
Since it is a new initiative, coating should be tried on one pump and depending on the extent
of efficiency improvement achieved, it may be tried on other pumps.
(ii) On line flow measurements should be provided in the cooling water flow duct.
(iii) CW ducting inspection should be done at suitable opportunity. If scaling inside duct is
observed, it could be one of the reason of low cooling water flow .
23
ELECTROSTATIC PRECIPITATOR
ESP at jojobera was in good working condition. Energy efficient BAPCON system is already
commissioned at Jojobera power station. The chimney exhaust was also quiet clear.
As individual field power measurement was not possible, ESP transformer power
measurement was done. Power consumption of ESP transformer 2A & B was 566.88-577.98
kW & 76.13-97.96 kW respectively.
OTHER SAVING POTENTIAL
(i) On line energy monitoring/management system
It is claimed by the vendors that it is possible to conserve 0.5 – 2% of annual electricity

consumption by using on line energy monitoring system.
Taking minimum of 0.5 % savings in auxiliary power consumption
Auxiliary power consumption of unit 2 for 2005-06 : 72.33 MUs

Annual energy savings (For year 2005-06) : 72.33*0.005
: 0.36 MU
Annual Cost savings @ Rs. 2.35/kWh : Rs. 8.5 lakh
Investment cost : Rs. 10 lakh
Simple payback period : Two Year
24
OFFSITE AUXILIARIES
25
COAL HANDLING PLANT
Jojobera Thermal power plant is having a well designed and well maintained Coal handling
plant. In CHP coal is received through rail and fed to coal bunkers. Presently most of the coal
used is middling coal and fired through pre determined coal mills, and 100% coal is stacked
and reclaimed Following Coal feeding circuits are being used to feed the coal.
Direct bunkering
Wagon Tripler-1→ Conveyor-1A→ Conveyor-2→ Primary Crusher-A→ Conveyor-3→
Conveyor-4→ Secondary Crusher-A→ Conveyor-5→ Conveyor-6→ Conveyor-7A→
Conveyor-8A→ Conveyor-9A
Wagon tripler-2→ Conveyor-1B→ Conveyor-1A→ Conveyor-2→ Primary Crusher-B→

Conveyor-3→ Conveyor-4→ Secondary Crusher-B→ Conveyor-5 → Conveyor-6→
Conveyor-7B→ Conveyor-8B→ Conveyor-9B
Uncrushed Coal stacking
Wagon Tripler-1 → Apron feeder (AFD)-A → Conveyor-1A→ Conveyor-2→ Conveyor

12→ Conveyor 13→Uncrushed coal yard
Wagon tripler-2→Apron feeder (AFD)-B → Conveyor-1B → Conveyor-1A→ Conveyor-2→

Conveyor 12→ Conveyor 13→ Uncrushed coal yard
Uncrushed Coal Reclaiming
Uncrushed coal yard→ Apron feeder (AFD)-C→ Conveyor-2→ Primary Crusher-A/B →

Conveyor-3→ Conveyor-4→ Secondary Crusher-A/B → Conveyor-5→ Conveyor-6 →
Conveyor-7A/7B→ Conveyor-8A/8B→ Conveyor-9A/9B
Crushed Coal stacking
Wagon Tripler-1 → Apron feeder (AFD)-A → Conveyor-1A→ Conveyor 2→ Primary

Crusher-A→ Conveyor-3 → Conveyor-4→ Secondary Crusher-A→ Conveyor-5→
Conveyor-10→ Stockyard-1
Wagon tripler-2→Apron feeder (AFD) B → Conveyor-1B → Conveyor-1A→ Conveyor 2→

Primary Crusher-B→Conveyor-3→ Conveyor-4→Secondry Crusher-B→ Conveyor-5 →
Conveyor-6→ Conveyor-14→ Stockyard-2
Crushed Coal Reclaiming
Stockyard-1→ Conveyor11→ Conveyor-6→ Conveyor-7A/7B→ Conveyor-8A/8B→

Conveyor-9A/9B
Stockyard-2→ Conveyor15→ Conveyor-7A/7B→ Conveyor-8A/8B→ Conveyor-9A/9B

Specific Energy Consumption s of various drives in CHP are given below
EQUIPMENT UNITS SEC kW

CONVEYOR - 1A kW/MT 0.044 32.85
CONVEYOR - 2 kW/MT 0.230 173.10
26
CONVEYOR - 3 kW/MT 0.108 81.45
CONVEYOR - 4 kW/MT 0.135 101.75
CONVEYOR - 5 kW/MT 0.085 64.05
CONVEYOR - 6 kW/MT 0.194 117.75
CONVEYOR - 7B kW/MT 0.223 145.20
CONVEYOR - 10 kW/MT 0.098 95.40
CONVEYOR - 12 kW/MT 0.018 13.50
CONVEYOR - 13 kW/MT 0.062 46.50
PRIMARY CRUSHER-1 kW/MT 0.044 32.85
SECONDRY CRUSHER-1 kW/MT 0.196 147.60
Direct Bunkering UNITS SEC

CONVEYOR - 1A/1B kW/MT 0.043568
CONVEYOR - 2 kW/MT 0.229576
PRIMARY CRUSHER-A/B kW/MT 0.043568
SECONDRY CRUSHER-A/B kW/MT 0.195756
CONVEYOR - 7A/7B kW/MT 0.223385
CONVEYOR - 8A/B kW/MT 0.233525
1.609
Uncrushed coal Stacking UNITS SEC

0.353
Uncrushed coal reclaiming UNITS SEC

CONVEYOR - 1B kW/MT 0.043568
CONVEYOR - 1A kW/MT 0.043568
PRIMARY CRUSHER-B kW/MT 0.043568
SECONDRY CRUSHER-B kW/MT 0.195756
1.653
Crushed coal Stacking UNITS SEC

PRIMARY CRUSHER-A/B kW/MT 0.043568
SECONDRY CRUSHER-A/B kW/MT 0.195756
27
CONVEYOR - 10 / 6,14 kW/MT 0.098351
0.939
Crushed coal Reclaiming UNITS SEC

CONVEYOR* - 11/15 kW/MT 0.108370
0.877
*Conv-11 Power consumption calculated assuming 140 amps current,
0.7 pf and 415 volt supply
OBSERVATIONS
1 Coal Handling Plant found to be in Good healthy condition.
2 Conveyor 11 and 15 found to be designed for 750 TPH. Where as rest of the CHP
system is designed for 1176 TPH. These conveyors (11 & 15) are used for
reclaiming coal. Presently 100% coal is stacked and reclaimed. These conveyors
leads to capacity under utilization.
3 As per energy meter data, Specific power consumption for the coal handled,
varies from 1.21 to 1.43 Kwh /Tone during FY 05-06. and the average for the year
05-06 found to be 1.28 Kwh /Tone.
4 As per details provided, Total running hrs of Conv-1A and 1B are recorded as
5271 hrs and total coal unloaded during the FY 05-06 is 1777397 MT. Through
put rate is calculated 337.20 TPH, against the design of 1176 TPH Which indicate
poor plant utilization factor 28.67%
5 Power consumption of conveyors 1B, 7A, 8A, 9A, 11, 14, 15 and Primary
Crusher-B and Secondary Crusher-B could not done due to operational constrains.
(flash over in switchgear during audit period). Specific Power consumption of
these conveyors assumed equal to identical conveyors for further analysis.
6 Specific power consumption during direct bunkering found to be 1.609 kW/MT
7 Specific power consumption during Uncrushed coal stacking found to be 0.353
kW/MT
8 Specific power consumption during Uncrushed coal Reclaiming found to be
1.653 kW/MT
9 Specific power consumption during Crushed coal stacking found to be 0.939
kW/MT
10 Specific power consumption during Crushed coal Reclaiming found to be 0.877
kW/MT
RECOMMENDATIONS
1 It is recommended to improve through put rate from existing average 337.50 to

average 600-650 TPH by increasing the conveyor loading. Average system running is
calculated as 14.44 hrs/day. After increasing the through put rate to 600 TPH system
running will be reduced to 8.11 hrs/day This will reduce energy consumption by
reducing overall system running time.
2 It is recommended to start direct bunkering. This will lead to less power and better
capacity utilization. (operation of low capacity Conveyor 11 & 15 will be
28
reduced).(case-1) Energy savings potential is 297048 kWh / annum, or Rs 6.98 lakh
/annum and ).(case-2) Energy savings potential is 146544 kWh / annum, or Rs 3.44
lakh /annum assuming 50 % of coal is fed directly instead of (case-1) Uncrushed coal
stacking and reclaiming or (case-2) Crushed coal stacking and reclaiming
Case-1
Avg Specific power consumption during direct bunkering = 1.631 kW/Tone
Avg Specific power consumption during Uncrushed coal Stacking and reclaiming
= 0.353 +1.653
= 2.006 kW/MT
Savings potential in direct bunkering 2.006-1.631 = 0.375 kW/MT
Annual Coal consumption ( FY-05-06) = 1584258 Ton
Savings potential if 50% coal is directly fed to bunkers
= 1584258 x 0.5 x 0.375
=297048 kWh
Saving potential in RS (Lakh) =2.35 * 297048/100000
=6.98 Lakh
Case-2
Avg Specific power consumption during direct bunkering = 1.631 kW/Tone
Avg Specific power consumption during Crushed coal Stacking and reclaiming
= 0.939 +0.877
=1.816 kW/MT
Savings potential in direct bunkering 2.006-1.631 = 0.185 kW/MT

Annual Coal consumption ( FY-05-06) =1584258 Tone
Savings potential if 50% coal is directly fed to bunkers = 1584258 x 0.5 x 0.185
= 146544 kWh
Saving potential in RS (Lakh) =2.35 * 146544/100000
=3.44 Lakh
3 Time totaliser may be installed on all major drives for accurate monitoring over idle
running of equipments.
COOLING TOWER
29
Cooling tower provided for unit-2 at Jojobera thermal power station has following design
specifications
Make BDWT Chennai

Induced draft counter
Type flow
Water flow 18000 M3/hr
Nos of cell 6
Hot water Temp 43OC
Cold water Temp 33OC
Wet bulb temp 28.8OC
Approach 4.2
Evp Loss 289.8 TPH
Drift Loss 1.8 TPH
Range 10
REDUCTION GEAR BOX

Manufacturer Flender (Kharagpur)
Model Kemns 200
Type Bevel - helical
Qnty 6
Reduction Ratio 12 : 5.1
Nos of Stages 2
Nominal kW Rating 45
Transmission efficiency 97.5
FAN
Manufacturer Prag Fan, Indore
Nos of fans / Cell 1
Nos of fans / Tower 6
Nos of Blade / fan 4
Max discharge through fan 1789369.2 M3/hr
Static head at Max discharge 6.8 MWC
Speed 116 RPM
MOTOR
Make ABB
Capacity 45 kW
Current 37.128
RPM 1500
30
OBSERVATIONS
COOLING TOWER PERFORMANCE
Units Design Measured

Unit Load MW 120 120
Inlet Cooling Water Temperature oC o
C 43 43.25
Outlet Cooling Water Temperature oC O
C 33 32.15
o O
Air Wet Bulb Temperature near Cell C C 28.8 15.8
Air Dry Bulb Temperature near Cell oC O
C 24.3
Number of CT Cells Nos 6 6
Cooling Water Flow M3/hr 18000 16318
CT Fan Flow M3/hr 1789369.2 1939045
Excess air flow / cell M3/hr 149676
Excess air flow / cell % 8.36
CT Flow/Cell, m3/hr = 3000 2720
CT Fan Flow, m3/hr (Avg.) = 1789369 1939045
CT Fan Flow kg/hr (Avg.)@ Density of 1.08 =
kg/m3 1932519 2094168
L/G Ratio of C.T. kg/kg = 1.55 1.30
CT Range = 10 11.1
CT Approach = 4.2 16.35
% CT Effectiveness = 70.42 40.44
Cooling Duty Handled/Cell in kCal = 180000000 181129800
(i.e., Flow * Temperature Difference in kCal/hr) =
3
Evaporation Losses in m /hr = 266.67 268.34
m3/hr per cell = 44.44 44.72
Percentage Evaporation Loss = 0.25 0.27
Blow down requirement for site COC of 4 = 14.81 14.91
Make up water requirement/cell in m3/hr = 59.26 59.63
1 Energy audit performance test was conducted during peak winter Jan 2007.
2 In cooling tower fans, FRP blades are being used.
3 Comparison of CT actual performance vis a vis design are shown in table.
4 Power measurement of CT fans during performance testing is enclosed
5 Air flow measured during the test found to be 8.36 % more than design.
6 Water flow measured 16318 m3/hr (design 18000 m3/hr) which is 9.34 % less than
design.
7 CT range found to be 11.1 against design 10
8 CT approach found to be 16.35 against design 4.2 indicates, low ambient temp
and poor heat transfer.
9 CT effectiveness found to be 40.44 % against design 70.42%. which indicates
poor heat transfer in CT
10 Evaporation Losses found to be 268.34 m3/hr against design 266.67 m3/hr.
31
11 Blow down requirement for (COC of 4) found to be 14.91 m3/hr against design
14.81 m3/hr.
12 Make up water requirement/cell found to be 59.63 m3/hr against design 59.26
m3/hr.
13 Power measurement indicate normal loading on CT fan motors and power factor
is around 0.85 . Which is normal.
14 Voltage level found to be 399-400. which is on lower side in CT fans 1,2 and 6
RECOMMENDATIONS
1. Performance test of Cooling tower to be conducted during peak summer and rainy
season. During this period heat load on CT is maximum due to ambient conditions
and actual performance can be evaluated.
2. For energy savings and better air flow FRP fan blades are being used. Which is a
good practice and to be continued.
3. CW flow needs to be increased up to design level i.e 18000 m3/hr. CW pumps to
be checked for less flow.
4. Increased air flow measured during the test, may be due to use of FRP blades.
5. Cooling tower fills needs to be checked for fill chocking and poor water
distribution.. Equal and uniform water flow to each cell to be ensured for proper
distribution of water. This will improve effectiveness of CT. Improved CT
performance will allow to stop one CT fan during extreme cold conditions (night
time of winter)
6. Voltage level needs to be increased up to 415 Volt for CT fan 1,2 and 6 by tap
adjustment.
32
ASH HANDLING SYSTEM AND OTHER PUMPS
OBSERVATIONS
1 Presently Ash water ratio is not being monitored regularly.
2 In Ash slurry pump series, Ist pump found to be under loaded, as shown in above
table.
3 HP water pumps are consuming more than design Specific Energy Consumption,
Which is due to less flow.
4 Ash slurry pump series -2 was not available for testing. And flow of Ash slurry
series -1 could not be measured.
RECOMMENDATIONS
1 It is recommended to check & monitor Ash water ratio on regular basis. This will
control ash water pumping power, Ash slurry pumping power, Ash water
recirculation pumping power and Raw water savings
2 In Ash slurry pump series, Ist pump to be checked for under loading,
3 HP water pumps to be checked for poor flow.
4 It is recommended to provide Polymer / Ceramic coating on ACW Pumps, ACW
Booster Pumps and HP water pumps internals. Savings potential in ACW
pumps, ACW Booster Pumps & HP Water pumps per annum = 160706 kWh or
Rs 3.77 lakh / year (considering 2 ACW pumps, 2 ACW Booster pumps and 1 HP
Water Pump running for 8000 hrs/year)
Savings and pay back calculations are as under
SAVINGS SAVINGS
POWER SAVINGS
Annual POTENTIAL POTENTIAL
S.No. DESCRIPTION CONS POTENTIAL@
R/H /ANNUM /ANNUM
kW 4% kW
(kWh) (Rs)
1 ACW-2A 117.95 4.72

2 ACW-2B 118.14 4.73 16000 74515 175111
3 ACW-2C 113.2 4.53
ACW Booster Pump
4 -2A 56.36 2.25
ACW Booster Pump –
16000 37604 88370
5 2B 62.28 2.49
ACW Booster Pump
6 -2C 57.63 2.31
7 HP Water Pump-2A 150.4 6.02
8 HP Water Pump-2B 150.4 6.02 8000 48587 114179
9 HP Water Pump-2C 154.7 6.19
Total 160706 377659
33
Presently all the water pumps i.e. ACW Pumps, ACW Booster Pumps, HP Water Pumps etc
which are working with raw water, consume considerable amount of electrical energy & their
internals gets eroded with time necessitating their replacement.
A new technology has emerged, in which Polymer coating is provided on the pump internals
to improve the efficiency of the pump this hard layer of polymer also provide increase in
pump life. The supplier is providing polymer coating with guaranteed 4% energy savings.( As
per our experience 6-7 % energy savings can be achieved)
Since it is a new technology, it is recommended to provide polymer coating on one of the
water pump and depending on the results , this may be provided on the other pumps also.
Energy Saving Potential
ACW Pumps
Annual energy savings (two pumps in service) : 74515 kWh
Annual Cost savings @ Rs. 2.35 /kWh : Rs. 1.75 lakh
Investment cost : Rs. 1.2 lakh
Simple payback period : under 1 Year
ACW Booster Pumps

Annual energy savings (two pumps in service) : 37604 kWh
Simple payback period : 1 Year
HP Water Pumps
Annual energy savings (one pump in service) : 48587 kWh
Simple payback period : under 2 Year
34
COMPRESSED AIR SYSTEM
OBSERVATIONS
1 Individual compressor with its receiver tank could not be isolated, hence it is not
feasible to conduct free air delivery test.
2 Pressure survey conducted in unit 2 areas, and no major pressure drop was observed.
3 Compressed air Leakages points observed during pressure survey are listed below.
a) IAC # 2C drain line leakage from Separator tank sampling line
b) Ext AS-4 valve at 5-M TG.
4 No Loading / Unloading of compressors observed.
5 Compressors power measured and table listed below.
6 Running Hrs of different compressors are as under
Comp No Power (On) Running Hrs Load Hrs Nos of Stops

2A 41211 38038 30188 305
2B No data
2C 43654 38383 33018 281
Compressed Air Pressure Survey
Project : Jojobera Thermal Power Station

Date : 12/1/07
Time : 12:15 to 13:00 Hrs
System : Instrument Air & Service Air
S.No. Location Actual Pressure Remarks
(Kg/cm2)
1 Control Room 7.26

2 Comp. – 2A 7.38 Combined
3 Comp. – 2C 7.37 Combined
3 Local Gauge 6.75 Service Air
4 Local Gauge 7.15 Instrument Air
5 Boiler # 1I (15-M) AB Elevation 6.80 Service Air
35
Voltage Current PF Freq kW
R Y B R B
AHP Air
Comp-A 443.4 444.3 443.9 139.7 86.31 141.1 0.8 48.9 86.31
443.6 442.8 443.2 140.9 86.28 140.4 0.8 49.16 86.28
AHP Air
Comp-B 441.2 442.3 443.1 160.2 102.1 161.4 0.83 49.1 102.10
440.2 441.2 441.2 165.3 104.9 167.2 0.83 49.2 104.90
Air Comp-
2A 6.5 6.4 6.4 58.488 608.58 58.568 0.94 49.2 608.58
6.5 6.4 6.4 58.712 609.36 58.496 0.94 49.3 609.36
Air Comp-
2B 6.9 6.8 6.9 63.272 711.76 64.016 0.94 49.12 711.76
6.9 6.9 6.9 56.104 626.87 56.552 0.93 49.22 626.87
6.9 6.9 6.9 63.272 713.78 63.872 0.94 49.26 713.78
Air Comp-
2C 6.7 6.6 6.6 59.792 661.77 61.08 0.95 48.8 661.77
6.7 6.6 6.7 56.704 631.63 57.936 0.95 48.9 631.63
6.7 6.6 6.7 56.344 626.63 57.504 0.95 49.0 626.63
RECOMMENDATIONS
1 Heat of compression may be used in air dryer in place of electric heater, which may
be a good energy conservation option.
2 Loading hrs of Comp -2A may be increased by proper loading / unloading pressure
settings, which will save unload power otherwise wasted.
3 Provision to isolate compressor with receiver tank is to be made during annual
maintenance of compressed air system. This will help to evaluate Free air delivery
(FAD) test of Compressors and efficiency thereafter.
4 Leakages identified during audit needs to be plugged at the earliest for energy
savings.
36
LIGHTING SYSTEM
OBSERVATIONS
General
1. Plant lighting at most of the locations was good and well maintained.
Based upon power measurement
1. Power consumption measured at different feeders is enclosed.

2. Voltage level at most of the feeders was in the range of 230-240 Volts. But in
AHP feeder voltage level found to be in the range of 262-264 Volts and CHP
feeder voltage level found to be in the range of 251-259 Volts
3. Power Factor was normal
Based upon lux measurement
1 Around 763 FLTs have been provided at different location in unit # 2 MCC
room, Control room, DM plant MCC room & Control room, CHP MCC room
& Control room and Ash Plant MCC room & Control room. These 763 FLts
are consuming (40+15 watt each) glowing 24 hrs/day.
2 In CHP area conveyors galleries of Conveyors 2,3,4,5,6,7,8,10,11,12,13,14
&15 are Covered with conventional asbestos sheets. Lights are kept on
day/night for normal working.
3 Lighting lux level at Switch yard Control room, Ash pump house found to be
on higher side.
4 At cooling tower top lighting fixtures found dirty
RECOMMENDATIONS
1 Voltage level to be reduced to 215-220 Volt in AHP lighting circuit by tap

adjustment. Saving potential in load after voltage reduction is estimated
as 5.18 kW average on a day. Annual savings potential after voltage
reduction to 220 V in AHP lighting circuit is 45376 Kwh /annual or Rs
1.06 Lakh.
2 Voltage level to be reduced to 215-220 Volt in CHP lighting circuit by tap
adjustment. Saving potential in load after voltage reduction is estimated
as 3.92 kW during day load & 5.19 kW during night load. Annual savings
potential after voltage reduction to 220-230 V in CHP lighting circuit is
39911 Kwh /annual or Rs 0.93 Lakh.
3 763 FLTs may be replaced with 28 watt Energy efficient T-5 technology
tube lights with electronic chock in phased manner. Annual savings
potential is calculated below :
Saving in wattage : 763 * (55-28)

: 20600 Watt:
Saving potential : 20600*24*365/1000
: 180464 Kwh
Saving potential in RS : 2.35 * 23652
37
: 424092
Approximate 28 watt T-5 tube lights is Rs 750
Total cost of replacement : 750*763

: Rs 572250
Simple payback period : One to Two year (1.35 year)
4 In CHP area conveyors galleries of 2,3,4,5,6,7,8,10,11,12,13,14 &15

Conveyors 1/3 rd of existing asbestos sheets may be replaced with fire
resistant translucent sheets (Polycarbonate sheets) for controlling day light
power consumption. Energy savings potential Rs 4.02 Lakh and simple
pay back period is 4.13 years.
Total nos. of sheets (approx.) at Conveyors 2,3,4,5,6,7,8,10,11,12,13,14 &15

= 4742 nos.
Nos. of sheets to be replaced (1/3 of total sheets) = 4742 / 3
= 1581 nos.
Cost of one sheet (Rs) = 1050/ Sheet
(@525/-M2)
Total cost of sheets (Rs) = 1581 x 1050
= 16,59,700
Nos. of light fittings can be switched off during day time = 558 nos. x 70 watt
= 39.06 kW
Total energy savings potential / annum = 39.06 x 365 x 12
(assuming sun light availability 12 hrs/ day) = 171082 KWh
Total energy savings / annum (Rs)(@ 2.35 /-KWh) = 176076 x 2.35
= 402044
Simple Pay back period = Four to Five year
38
EFFICIENCY AND HEAT RATE TESTS
39
BOILER EFFICIENCY
40
METHODOLOGY
The method of performance assessment chosen is the indirect method of heat loss and
boiler efficiency as per BIS standard 8753 and the employed relationships are presented in
annexure-I.
Prior to the trial, the list of boiler operating parameters to be monitored and the
corresponding transducer reference in the data acquisition system were identified and the
same was monitored every fifteen minutes interval. The list of access points for various
parameters are presented as annexure-II.
The boiler efficiency trials were conducted during January 2007 for unit no. 2, 120 MW in
as run operating condition. During the trial, values of as-run parameters observed, are
indicated in annexure- III.
During the trial period, the following conditions and procedures were adopted:
• The test was carried out for a 4 hour duration each, during which both CBD and IBD
was stopped. No soot blowing was carried out during this period.
• During the period of as run testing, the unit no. 2 remained isolated and at steady full
load condition
• The steam flow was maintained steady during the as run trial.
• Coal samples were collected at regular intervals during period of testing, were mixed
and a composite sample was prepared.
• Ash samples were collected during de-ashing and from ESP hoppers during the testing.
• Exit gas analysis for O2, CO2, CO and temperature was measured using portable gas
analyzer IMR I400.
For comparison of operating data, design data for the unit was referred to, the same was
also compared with he PG test results of unit no. 3, in the absence of PG test data of unit
no. 2, Since both the units are identical.
41
BOILER HEAT LOSS PROFILE
The heat loss profile covering losses through unburnt in ash, sensible heat loss in flue
gases, moisture in combustion air, loss due to presence of hydrogen and moisture in coal,
radiation and unaccounted loss, are as follows:
SL.
Operating Parameters Unit AVG AVG
No
DATE 10/01/2007 10/01/2007
10.30 hrs to 15.00 15.00 hrs to 19.00
DURATION HR
hrs hrs
A. HEAT INPUT TO BOILER KCAL/HR 299776213.125 299765713.569
B. HEAT LOSSES IN THE SYSTEM :

B1 UNBURNTS IN ASH :
BOTTOM ASH % 0.65866 0.65845
FLY ASH % 1.06508 1.06687
B2 SENSIBLE HEAT IN FLUE GAS % 4.28299 4.27665
B3 MOISTURE IN FLUE GAS % 8.78621 8.78560
B4 MOISTURE IN COMB. AIR % 0.07059 0.07072
B5 RADIATION & UNACCOUNT & 1.21000 1.21000

C. TOTAL LOSSES % 16.074 16.068
BOILER EFFICIENCY
D. % 83.926 83.932
(100 - TOTAL LOSSES)
E. EXCESS AIR % 23 23
F OVERALL HEAT RATE KCAL/KWH 2549.76791 2524.22476
Above trial data is average value during 15 min. interval.

It may be observed that as against 87% design efficiency, there is a margin of about 3-4%
improvement by various measures, which are largely O&E related and R&M related. About
2% improvement is possible by various O&E related aspects mentioned above. For further
improvement in efficiency, R&M activities are required specially in the area of mills.
42
OBSERVATIONS
(i) The thermal efficiency of boiler of unit no. 2 estimated based on heat loss method
during the trial period is found to be around 83% with the firing of middlings as
against 87% as per design at 100% TGMCR.
(ii) The average boiler heat losses ranges from around 16.1% against design value of
12.97%.
(iii) The average controllable losses like combustible loss in ash, sensible heat loss to dry
flue gas range from 6%.
(iv) The excess air percentage maintained at air pre-heater outlet is found to be 23% with
an oxygen percentage of 3.9% as against design value of 20% equivalent to 3.5%
oxygen level. Though the excess air level is reasonably satisfactory, scope exists
towards fine tuning the same to bring down excess air level to 17% to 18% using
washery middlings. It was observed that at present the oxygen analyzer installed at
APH inlet and outlet respectively indicate oxygen percentage as 7.7% and 5.5%
respectively and was reported out of commission during the observation period by the
plant management. It is strongly recommended to repair, calibrate or replace the
same for trimming of oxygen level apart from controlling relevant operating
parameter. This will restrict the sensible heat loss through the dry flue gases to a
large extent thereby reducing boiler losses and improve operating efficiency. The
details of flue gas measurement for oxygen, excess air, temperature as against desired
design values are given in Table – I
Table – I : Flue Gas Analysis Results :
SL. Parameter Unit Location of Sampling

No. ECO Outlet / APH APH Outlet / ESP ID Fan Inlet
Inlet Inlet
Design Actual Design Actual Design Actual
1 O2 % 3.00 3.9 5.5 5.9
2 Co2 % 15.0 16.8 15.2 14.8
3 Co ppm 65 10 12 13
o
4 Temperature C 345 343* 142 148 137 135
5 Excess Air % 20%
o
* Measured 31.7 C at UCB
(v) The exit flue gas temperature after air pre-heater outlet was found to be 147 to 148oC
as against design value of 139oC in spite of dilution and air ingress. This has also
lead to higher dry flue gas losses.
(vi) The in-leak air in the air pre-heater area as well as between APH inlet to ID fan inlet
ranges from 10% to 15% equivalent to 6% oxygen level, as against design value of
maximum 2% increase in oxygen content. The in leak air specially in APH flue path
as well as flue duct between APH and ID fan causes detrimental effect towards
effectiveness of heat transfer of APH area. It may also shift the draft level in the flue
gas path apart from increase in ID fan motor load. It is recommended to regularly
monitor oxygen percentage of flue gas through portable oxygen analyzers at ESP inlet
as well as ID fan inlet, analyze the data with respect to on line monitoring system at
APH inlet and outlet towards control of in leak points in the ducting area. Any effort
43
to minimize the in leak air would directly help in ID fan capacity release apart from
power saving in ID fan.
(vii) Pertinent to boiler operations, the recognized concern area are with regard to coal
quality are GCV of coal, ash content in coal, VM and HGI towards mill performance.
GCV of coal fired during the observation as compared to design value was found to
be much higher than design, apart from Ash & FC content which are favourable
compared to design. The middling coal fired during trial was little harder since HGI is
45 as compared to design coal of HGI 55. With this the mill output is expected to be
reduced by 15%. However, since moisture content in coal used during the trial period
is much lower compared to design coal moisture, the effect should be favourable
towards output. The design vis-à-vis actual coal utilized during observation period is
given Table-2:
TABLE – 2: DESIGN VIS-À-VIS ACTUAL COAL UTILIZED

Coal used during Coal used
Sl. Design Coal
Parameter Unit trail and December’06
No. (MCL)
observation **
1. Moisture * % 0.53 - 12
TM ** 4.44 to 4.56 4.5
2 Ash % 35.61 to 36.11 34.13 45
3. VM % 20.33 to 20.78 19.12 21.8
4. Carbon 43.53 to 42.58 41.62 21.2
5. Hydrogen 3 to 4 - -
6. Nitrogen 0.2 to 0.6 - -
7. Sulpher 0.4. to 0.8 - -
Kcal per
8. GCV * 5006.2 to 48.36.3 3350
Kg
4646.19 to
GCV ** 4850
4803.38
9. HGI 45 55
*Air dry basis
** As received basis
(viii) The losses due to moisture and Hydrogen in coal are comparable to design value.
(ix) Coal mill fineness observed during the trial period is found about 85 to 91% passing
through 200 mesh size compared to design coal fineness of 70% passing through 200
mesh (i.e., 75 micron level) and is found to be over grinded. This will also lead to
reduced mill output apart from increasing the mill electrical power loading and
reduced residence time within the furnace area. These are separately discussed in the
auxiliary power consumption study of the mill. The mill fineness observed during the
study period is given below in Table –3. It may further be pointed out that over
grinding may also lead to higher wear and tear of mill parts. The present preventive
maintenance schedule of the mills are after every 750 to 1000 running hours.
Table – 3: Mill Fineness Analysis : 10/1/2007

44
Mill No. and
range of fineness + 300 - 300 + 250 - 250 + 125 - 125 +75 - 75 + 0
(micron)
A 0 0.06 1.36 13.43 85.15
B 0 0.25 3.83 10.31 85.61
C 0. 0.08 2.31 9.53 88.08
D 0 0.02 2.71 5.59 91.73
(x) Total coal flow to maintain full load at design is 81% of rated mill TPH using a
combination of 3 mills: ie., @ 27 TPH using design MCL coal, where as during trial
observation period 4 mills are being utilized to maintain full load using Middlings,
total coal flow is found to be 63-64 TPH, @ 17-18 TPH per mill, the load of 4th mill is
only 10-11 TPH, leading to lean air coal mixture. However there is no mill gap and
adjacent mills were being utilized during trial and observation period. The mill motor
load was approaching almost full load at this condition leaving no margin. Details
are given in Table – 4 & 5.
Table – 4 : Mill Loading Analysis
Mill No. / Parameter A B C D Total

Actual Coal Flow, T/hr
11.2 18 18.3 17.4 64.9
(using Middlings)
Design coal flow /
PG test value of unit # 3, T/hr - 27.19 28.63 27.85 83.67
(using ROM coal)
% Loading 66% 64% 62.5%
Table – 5: Mill Power Consumption using washery coal
Mill No. A B C D
kW 274 261.1 261 221.8
Loading % 98 93 93 79
Rating /
280 / - 280 / 240.71 280 / 224.28 280 / 206.65
PG test value*
* During PG test of mill unit no. 3, MCL coal was used and mill was operated at
higher than 80% output to meet 100% TG MCR capacity.
Improvement in mill operations towards achieving rated coal flow with 3 mill
operation is identified as key result area of concern. The results would manifest as
reduced excess air loss as well as reduced loss due to unburnt in bottom ash and fly
ash apart from reduced auxiliary consumption.
(xi) During the observation, mill reject quantity for mill no. 2C was found to be
much higher 0.14% of coal flow) compared to other operating mills (mill
combination 2A, 2B, 2C & 2D). The GCV of mill reject is about 2300-2400
KCAL/KG requiring thorough maintenance of the mill apart from classifier vane
adjustment. The details are given in the table –6 below :
45
Table – 6 : Mill rejects analysis result : 10.1.07
Mill No. A B C D
Quantity (Kg/hr) 13.25 9 25.5 18.5
*GCV (Kcal/Kg) 2325.9
Moisture (%) 0.5
Total moisture
2.19
(%)
Ash (%) 61.13
*Air dry basis
(xii) Combustible matter in bottom ash and fly ash is found to be in the range of 5.7% and
2.7% respectively, which is much higher than the design value of 4% and 0.5%
respectively using design coal. The same for unit # 3, PG test value is 1.37% and
0.11% respectively. This loss is directly related to fuel combustion efficiency and also
upon operational factors. The loss due to unburnts in ash is about 2.31% as compared
to design value of 1.1%. The details of unburnt analysis results using middling coal
is given in the table –7. It may be mentioned that combustible in ash is also a
function of the ratio of fixed carbon and volatile matter in the coal fired and with the
increase in the ratio there is a tendency towards increase in the combustible matter
both in the fly ash and bottom ash, the ratio being almost double for middlings
compared to ROM coal.
Table –7: Combustible matter in fly ash and bottom ash :

date of sample 10.1.07.
Combustible matter in Fly Ash Combustible matter in Bottom Ash
Location Analysis of Analysis of

Design Dec’06 10.01.2007 Design Dec’06 10.01.2007
(avg) (avg)
46
Field 23 V1 2.6
23 V2 2.25
23 V3 2.29
23 V4 2.32
0.5 1.62 4 5.52 5.72
Vessel 21 1.79
(1 to 6)
Vessel 22 1.78
(1 to 6)
(xiii) The heat required/heat released at full load is 280-290 MKCAL/Hr as per design. The
same during operation at full load (100% TG MCR) using Washery Middlings is
found 7.5% higher (Coal GCV being 3600 KCAL/KG at design as compared to
Middling at 4725 KCAL/KG fired during trial observation). This clearly indicates
that gain in terms of higher heat value of middlings is lost towards very lean air : coal
mixture, loss of combustion efficiency, very low capacity output of the mills, coal
being harder resulting use of more no. of mills leading to lean air coal mixture.
(xiv) The primary air through the mills was found 30% to 31% above design/test value
indicating lean air coal mixture. This is also corroborated by higher unburnt
percentage of combustible in fly ash and bottom ash. However, secondary air flow is
controlled for restricting total air quantity, the secondary air flow is kept only 59% of
total air quantity. The details of FD air flow, primarily air coal ratio, primary air flow,
primary : secondary air ratio at 100% TG MCR both at design as well as during
observation on 10.1.07 using middlings is given in Table-8.
Table-8: FD Air Flow, Primary Air Coal Ratio, Primary air flow, Primary
air/secondary air ratio ( at 100% TG MCR).
Design Coal Observation on

Parameter Unit with 3 mill 10/1/07 using
operation Middlings.
1. No. of Mills in
Nos. 03 04
operation
2. Total air flow T/hr. 438 430
3. Primary air flow

T/hr 135 176.4
* Primary air flow as %
% 31 41
of total air flow
4. Secondary air flow T/hr 303 253.6
* Secondary air flow as
% of total air flow % 69 59
5. Coal flow T/hr 81.5 63.5
6. Primary air : coal ratio 1.65 2.78
7. Primary Air:
0.45 0.69
secondary air ratio
After the trial, an attempt was made by plant operating personnel to reduce primary
air flow and also restricting to 3 mill operation, however, it was reported by the
operating personnel that there is deposition of coal particles at the mill outlet and at
the first level of coal pipelines and load could not be maintained with 3 mill
47
operation. The PA fan header pressure was found to be well within limit during
observation period.
(xv) The wind box pressure, FD fan discharge pressure, furnace draft, wind box to furnace
DP was found well within design limits during the operation on 10/1/07. The details
are given in Table-9.
Table – 9 : Wind box pressure, FD Fan discharge pressure, furnace draft,windbox to

furnace.
Sl.
Parameter Unit Design Actual
No.
1. Wind box pressure mmwc (+) 100 (+) 95-96
2. FD fan discharge pressure mmwc 240 234 to 238
3. Furnace draft mmwc (-) 4 (-) 6.4 to 8.8
4. Windbox to furnace DP mmwc - (+) 100 – 105
(xvi) Combustion efficiency is closely linked with temperature of secondary air as also mill
performance with respect to moisture removal and coal fineness and unburnts in ash
and any drop may affect combustion. During trial, the secondary air temperature was
found 280-290 OC as against design value of 273- 282 OC and is well within the
design limit.
(xvii) Though housekeeping in boiler area is commendable and, improvements are
possible in the following areas :
• Leakage from bottom ash de-ashing hopper.
• Hot Air leakage from secondary air heaters.
• Improvement of insulation in economizer and APH area.
• Though the inspection doors/peep-holes are tightly fitted and kept closed properly, high
radiation loss from them was noted.
RECOMMENDATIONS
Two energy conservation opportunities are identified in the area of boiler operations namely
• Excess air control
• Control of combustible in fly ash and bottom ash
(i) SAVINGS POTENTIAL BY O2 TRIMMING (EXCESS AIR CONTROL)
Present Condition :
O2% at APH out let = 5.5%

Corresponding excess air level at APH out let = 35.48%
Sensible heat loss in flue gas = 4.28%
Boiler Efficiency = 83% (Avg.)
48
The improvement in operating efficiency of boiler, by reduction excess air level (and there by
reduction in sensible heat loss percentage) is identified as a key result area.
Proposed Condition :
O2% at APH out let = 3.5%

Corresponding excess air level at APH out let =20%
Sensible heat loss in flue gas = 3.35%
Boiler Efficiency = 83.95% (Avg.)
Fuel savings by operation of Boiler at 83.95% = 63 TPH x 8000 x {1- (83/83.95)}
= 5703 MT per year
Landed cost of coal = 1500 MT
Annual saving potential (Rs.) = 85.5 Lakh
(ii) SAVINGS BY CONTROL OF COMBUSTIBLES IN FLY ASH AND BOTTOM ASH
Control of combustible in fly ash and bottom ash, through mill performance improvements,
is identified as a key result area for attention.
During field study period, lab. Analysis of un-burnt in bottom & fly ash, w.r.t. design values
are given below :
Un-burnt Carbon % in Fly Ash & Bottom Ash

Date Un-burnt Fly Ash (%) Un-burnt in bottom Ash (%)
Design Actual Design Actual
10th January, 2007 0.5% 2.7% 4% 5.7%
PG test value of Unit # 3 0.11 1.37
Energy Savings estimate

Existing heat loss due to un-burnt in fly ash & bottom ash =1.724%
Existing boiler efficiency =83% (avg.)
Envisaged heat loss with improved mill performance. = 1.05%
Increased Boiler Efficiency after reduction in un-burnt loss =83.674 %(avg.)
Improvement in Boiler Efficiency =0.674%
Annual reduction in coal consumption (MT) by boiler efficiency improvement

=63 x 8000 x {1 - (83/83.674)}
= 4059 MT
Landed cost of coal = 1500 MT
Annual saving potential (Rs.) =Rs.60.9 lacs.
49
50
TURBINE HEATRATE AND EFFICIENCY TEST
Background
Performance assessment of turbine system, based on ‘As- run trials’ was
conducted during January, 2007 with the objective of validation against design
value. The as run trials , findings are envisaged to help in assessing the
performance, vis-à-vis design/ rated values, factors and parameters affecting
performance, key result areas for improvement and attention.
This ‘ As - Run Performance Test ’ determines the turbine performance with regard
to performance indices as follows:
• HP & IP Cylinder efficiencies
• Turbine Heat Rate
51
METHODOLOGY
The ‘ As - Run Performance Test’ is conducted by the enthalpy drop efficiency

method. Enthalpy drop test are used as a method of trending the performance of
high pressure (HP) and intermediate pressure (IP) sections of the steam turbine.
This method determines the ratio of actual enthalpy drop across turbine section to
the isentropic enthalpy drop. This efficiency method provides a good measure for
monitoring purposes, provided certain qualifications are met in obtaining results.
While it is very difficult to make immediate corrections to turbine performance

degradation, the information can be used as part of cost benefit analysis to
determine the optimum point at which the losses due to decreased performance are
greater than the costs associated with turbine maintenance. The enthalpy drop test
is performed at the valve wide-open condition. The test at valve wide open
provides a base line and the test at similar Pre and post condition is used to
evaluate the improvements made during turbine overhaul.
As run trial results with respect to HP and LP cylinder efficiency, Heat rate , Heat
load are presented in Annexure –I & II.
HP & IP Cylinder Efficiency:

In connection with the requirements of ‘ As - Run Performance Test ‘, two numbers
of turbine trials of one hour duration each was conducted on the same date. The
requisite numbers of readings taken for the relevant operating parameters during the
trial period were averaged out for computing HP & LP cylinder efficiencies.. The
trial values are provided in Annexure II&III.
The values of average operating parameters were obtained from trial I&II and
corresponding design data, as required for computation of Turbine Cylinder Efficiency
by Enthalpy drop method was complied. Based on the respective Inlet and outlet steam
condition at HP, IP & LP Cylinders, the Turbine Cylinders Efficiency have been
computed. The details of cylinder efficiency computation are provided below
52
Table-1: Computation of HP, IP and LP Cylinder Efficiency
Design values As- run Values
Parameters Pr. Temp Flow Enthalp Entropy Pr. Temp. Flow Enthalp Entropy
y y
Unit Kg/cm2 O
C Tph Kcal/ kg Kcal/kgOK Kg/cm2 O
C Tph Kcal/ kg Kcal/kgOK
H1 Steam Inlet condition (H P Cylinder)
126 535 355.5 822.2 1.559 122.3 531 359 820.81 1.577
H2 Steam outlet condition
h1 CRS Steam 32 342 301 740.4 1.604 31.99 345.7 302.67 742.30 1.603
h2 HPH-6 33.06 342 36.6 739.4 1.595 31.0 348.0 37.16 734.20 1.592
h1+h2 CRS+HP-6 32 342 337. 738.9 1.595 31.99 346.88 339.83 738.75 1.597
(at actual)
h1+h2 CRS+HP-6 32 327 337.6 735.64 1.559 31.99 318.2 337.1 726.00 1.577
(at iso –
entropic)
Actual enthalpy drop [H1- ( h1 + h2)] 83.30 [H1- ( h1 + h2)] 82.06
Iso entropic enthalpy drop) [H1- ( h1 + h2’ )] 86.56 [H1- ( h1 + h2’ )] 94.81
HP cylinder Efficiency [Actual drop/ Iso-entropic 96.23 86.6
drop] x 100 %
IP Cylinder
H3 Steam Inlet condition
53
Hot Reheat. 29.8 535 301.7 845.9 1.757 29.4 533 304.5 844.9 1.757
Steam
H4 Steam Outlet condition
H3 HPH-5 Ext. 10.6 398.0 19.2 779.6 1.779 12.6 419.3 19.53 772.5 1.754
Steam
h4 Back Pr. Ext. 5.33 288 285 727.00 1.777 5.49 301 15.94 734.2 1.744
steam to LPT
h5 Back Pr. Ext. 5.1 294 15.9 730.14 1.779 5.44 264.4 292.1 715.0 1.746
steam to DA
h4+h 5 Iso entropic 5.1 269.5 15.9 717.9 1.757 5.44 279.2 267 722.5 1.757
enthalpy
54
Actual
H5 [(H3-h3)+(h3-h4)] 118.9 [(H3-h3)+(h3-h4)] 110.7
enthalpy drop
Iso entropic [H1 – ( h4 + h5)]
H6 [H1 – ( h4 + h5)] 128.00 122.5
enthalpy drop
IP cylinder efficiency [ H5 / H6 ]x100 % 92.9 [ H5 / H6 ]x100 % 90.4
Overall HP+IP Cylinder
efficiency
Actual 202.2
H7 192.76
enthalpy drop
Iso entropic 214.56
H8 drop in 217.23
HP&LP
Overall HP stage efficiency 94.24 88.74
LP cylinder efficiency
H9 Steam inlet condition
LPT inlet steam(IPT 5.33 288 285 727 1.76 5.44 264.4 289.78 1.746
715.30
EXT)
H10 Steam outlet condition
h7 LPH-3 Ext. 1.87 195 14.7 685.4 1.226 1.852 224.51 14.77 1.913
682.3
Steam
h8 LPH-2Ext. 0.91 105 12.5 645.2 2.039 0.65 187.43 11.82 1.945
681.59
Steam
h9 LPH-1Ext. 0.35 86.5 10.58 635.88 1.866 0.32 70.1 10.87 1.855
618.90
Steam
h10 LPT outlet 0.07 41.6 249.3 616.5 1.985 0.1 45.5 260.51 1.947
618.18
steam
LPT outlet steam(iso 0.07 38.63 249.3 546.2 at 1.769 0.1 45.42 260.51 1.745
552.39 at
entropic) 0.87 DF
0.87 DF
Actual enthalpy drop 110.5 97.12
Iso entropic enthalpy drop(H9-h10) 180.8 162.91
LP cylinder efficiency 61.1 59.6
55
In the absence of steam metering at various operating points, the same has been
computed by making mass & energy balance wrt each of the operating parameters
and the corresponding design values.
Dryness fraction at LPT outlet considered same i.e. 0.87 as design value.
Turbine Cycle Heat Rate
Along with turbine cylinder efficiency assessment the’ Turbine Cycle Heat Rate’
value which is a key performance indicator and defined as the ratio of energy input to
the turbine cycle to the net electrical generation arrived at . The relevant trial
parameters as follows:
Sl.
Parameters Unit Design Value Trial Value
No.
1 MS Flow Tph 355.5 359.00
2 RH steam flow Tph 301.7 304.52
3 Main Steam Enthalpy Kcal/Kg 822.2 820.81
4 FW Enthalpy Kcal/Kg 239.57 238.34
5 R. H. Steam Enthalpy Kcal/Kg 845.9 844.90
6 Cold Reheated Steam Enthalpy Kcal/ Kg 740.4 742.30
7 Generator Net power MW 120 117.760
8 Heat Rate = (MS Flow x (MS Kcal/ Kwh 240350482
Enthalpy - FW Enthalpy) + 117760
( RH steam Flowx(RH 1991 = 2036
Enthalpy- CRS Enthalpy))
/Generation net power
9 Heat Rate After parameter Kcal/ Kwh
2041
Correction
56
Correction Factors for variation in Parameters
The following parameters, which have considerable deviation from the design condition,
is corrected as per the specified figures in Heat Rate Calculation.
Table- 3 : Correction Factors in Turbine Heat Rate
Parameter Deviation Effect on Heat Rate
Main steam temp. -3.8 0C +1.74 Kcal/ Kwh

2
Sl. Main steam Pressure -2.68 Kg/ cm
Design+2.68
valuekcal/ Kwh
Parameters Unit Trial-Value
No. Re-heater circuit pressure drop 2
+0.39 Kg/ cm - 0.39 Kcal/ Kwh
1 Inletwater
Feed Enthalpy
Temp. Kcal/Kg
- 1.2 0C 822.2
+ 0.552 Kcal/ Kwh 820.81
2 Inlet
CW Flow
inlet Temp. T/Hr-3.06 C 0 355.5
+1.40 kcal/ Kwh 359.00
3 CRS Enthalpy
Total Correction Kcal/Kg 740.4
+ 5.98 kcal/ Kwh 742.30
4 HRS Enthalpy Kcal/Kg 845.90 844.90
5 HRS Flow T/Hr 301.7 304.52
6 FW Enthalpy Kcal/ Kg 239.88 238.34
7 Mechanical Losses kW 412.0 422.00
8 Generator Output kW 120000 117760
9 Generator Efficiency % 99% 99 %
at 98% load
0
10 CW Inlet(L) Temp. C 34.0 30.15
0
11 CW Inlet(R) Temp. C 34.0 31.74
0
12 CW output(L) Temp. C 43.0 41.67
0
13 CW output(R) Temp. C 43.0 42.72
2
14 CW DP (CCP-01) Pr. Kg/ cm 0.383
2
15 CW DP (CCP-02) Pr. Kg/ cm 0.400
16 Heat Load Kcal/ Hr 139726698
Heat Load = (Inlet Enthalpy - FW Enthalpy) x =134247366 =139726698 Kcal
3
Inlet Flow x 10 + (HRS Enthalpy - CRS Kcal / hr / hr
3
Enthalpy ) x HRS Flow x 10 - (Generator
Output / Generator Efficiency + Mechanical
Losses ) X 860
Correction in heatrate wrt deviation of different parameters were made after

considering the permissible fluctuations
Heat load of the turbine was calculated based on the as run trial values, as follows
Table -4 : Heat Load Calculation
57
• The Heat load of turbine is at as run condition = 139.72 million Kcal/hr.
• In comparison the design Heat Load is = 134.24 million Kcal/hr.
RECOMMENDATIONS
Based on the As-Run turbine performance test, the performance parameters of
turbine systems are summarized as below:
Table-5: Summarized Turbine Performance Parameters

Sl. No. Performance Parameters Design values Test values
1 HP Cylinder Efficiency 96.23 86.6

2 IP Cylinder Efficiency 92.90 90.40
3 HP & IP Cylinder Efficiency 94.24 88.74
4 LP Cylinder Efficiency 61.10 59.60
5 Turbine Efficiency 54.63 46.66
6 Turbo Generator Efficiency 35.31 34.37
(Taking 98% & 99% as
mechanical transmission and
alternator Efficiency)
58
7 Turbine Heat Rat 1991 2036*
8 Unit Heat rate 2288** 2483***
*Value is taken without correction.

** Based on design boiler efficiency = 87 %
*** Based on operating boiler efficiency = 83%
It can be noted that
• Performance gap between design and test values for
HP turbine (HP + IP) efficiency = 5.8 %
 Similarly, the gap with respect to design and test value of turbine heat rate
= 2.2 % (45 Kcal/Kwh )
• The annual loss wrt. above gap in heat rate of the turbine = 17.8 MU
( @ of 75 % plant PLF and average generation 90 MW – basis 2006-07 generation figure)
• On a conservative estimate, a reduction in HR deviation of 20 Kcal/ Kwh will result in
benefit. In terms of cost the annual savings is = 7.9 MU
= Rs. 186 lacs@ Rs. 2.35 / Unit)
The following actions are recommended for sustainability of Heat Rate / Efficiency
Improvement Programme,
• Introduction of Formal Efficiency Management System.
• Establishing Base Line Performance Data.
• HR Deviation System on Real Time basis instead of Design.
• Analysis of HR deviation in terms of Cost.
• Routine Performance Testing on Sub-System basis.
Specific improvement option may be established by inspection especially during overhaul, and
diagnosis of pre and post overhaul conditions/trials.
59
CONDENSER PERFORMANCE TEST
BACKGROUND
The assessment of condenser performance is important to determine equipment performance
degradation. Plant performance assessment was done through the use of automated data
collection and processing devices. The “As run performance tests” can be used as the base line
for evaluating the performance improvement activities, as well as maintenance efficiency.
The design data (key technical specifications) of condenser is presented as Annexure 4.
METHODOLOGY
Prior to trials conducted on 11th January 2007, the list of condenser operating parameters to be
monitored and corresponding transducer reference in the data acquisition system were identified
and the same was monitored every 15 minutes interval.
During trial period the following conditions were adopted :
o The test was carried out for 45min.
60
o The Unit-II remain isolated and at steady full load condition.
o The steam flow rate was maintained steady.
o The steady back pressure was observed during trial.
o The pressure drop (DP) across condenser was kept steady.
o Cooling water flow was measured by Ultrasonic Flow Meter.
o Condensate temperature was found steady.
o For comparison of operating data, design data of condenser was referred to.
OBSERVATIONS
The ‘As- run’ trial was carried out with an objective to arrive at performance in
indicators and scope areas for improvement.
The ‘As- run’ performance indicators observed during trial, are summarized as
follows.:
As-run Condenser Performance data

Trial Date : 11-01-2007
Sl. Nomenclatu (TIME)

DESCRIPTION UNITS DESIGN
No. re 12:00 12:10 12:28 12:45 Avg
1 Unit Load MW 120 116.6 115.9 120.5 115.9 117.2
2 Frequency Hz 50 49.3 49.0 49.1 49.2 49.1
Condenser Back 0.106
3 Kg/cm2 0.10 0.10 0.10 0.10 0.10
Pressure (Vacuum) at 34 OC
CW Inlet Temp.
4 °C t1L 29.8 29.8 30.0 29.5 29.7
(Left)
CW Inlet Temp.
5 °C t1R 31.3 31.4 31.6 31.1 31.3
(Right)
CW Inlet Temp. °C
6 ( t1 ) 34 30.5 30.6 30.8 30.3 30.5
(L/R-Avg)
61
CW Outlet Temp.
7 °C ( t2L ) 43 41.3 41.3 41.6 40.9 41.3
(Left)
CW Outlet temp.
8 °C ( t2R ) 43 42.3 42.3 42.7 41.9 41.8
(Right)
CW Outlet Temp. °C
9 ( t2 ) 43 41.8 42.8 42.15 41.4 41.5
(L/R-Avg)
CW Temp. rise
10 °C ( t2 – t1 ) 9.0 11.3 12.2 11.35 11.1 11
(Avg)
12 Saturation Temp °C (T) 46.5 45.3 45.3 45.3 45.3 45.3
Terminal
13 Temperature °C (T – t2) 3.5 3.5 2.5 3.15 3.9 3.8
Difference (TTD)
Condenser  t 2 − t1 
14 Factor   0.72 0.764 0.830 0.783 0.740 0.743
Effectiveness  T − t1 
DP Across
15 mmWC 3894 3812 3823 3823 3838
Condenser (L)
DP Across
16 mmWC 4006 3941 4089 4080 4029
Condenser (R)
DP Across
17 Condenser mmwc 3950 3876.5 3956 3951 3934
(L/R-Avg)
18 Condenser CW flow m3/hr 16000 14640
Condensate Temp.
19 °C 46.3 46.7 46.4 46.4 46.5
(L)
Condensate Temp.
20 °C 46.5 46.9 46.6 46.6 46.6
(R)
Condensate Temp.
21 °C 46.4 46.8 46.5 46.5 46.5
(L/R-Avg)
22 LMTD °C 7.07 7.837 6.887 7.434 8.240 8.090
Condenser Thermal MKcal/h

23 H* 145.23 161.04
Load r
Heat transfer Kcal/hr-
24 U** 2652.64 2570.41
coefficient m2
* H = CW flow X ∆T
** U = Thermal load x 106
7743.88 SQM x LMTD
CW FLOW ADEQUACY:
Based on As run Trial, the measured CW flow across condenser, of 14640 CMH amounts
to 91.5% of rated 16000 CMH flow, indicating CW inadequacy.
CONDENSER THERMAL LOAD:
The Condenser Thermal Load being served (As measured) works out to 161.04 MKCal/hr
for measured flow and temperature difference, as against rated 145.23 MKCal/hr, i.e.
10.88% higher w.r.t. design.
CW VELOCITY:
62
With reference to the design CW velocity of 1.96 m/sec, the actual velocity works out to
1.79 m/sec, on account of reduced CW flow, affecting the heat transfer.
CW DIFFERENTIAL PRESSURE & FLOW ESTIMATE:
The measured average differential pressure across condenser, of 3.934 mwc, against rated 5
mwc value, translates to 89% of rated CW flow, taking place across condenser, w.r.t. rated
(by Corelation).
It is felt that CW inadequacy is a key result area for attention. The lower flow (14640
CMH) could be due to any / combination of reasons which include, low frequency (pump
rpm), increased drawal by other auxiliary loads tapped before condenser, or, drop in CW
pump efficiency.
CONDENSER EFFECTIVENESS:
As run value of condenser effectiveness, of 0.743, w.r.t. rated value of 0.72 is felt to be
comparable on account of lower CW inlet temperature.
TTD:
As run TTD of 3.8 OC, w.r.t. rated value of 3.5 OC indicates scope for improvement.
LMTD:
As run value of LMTD of 8.09 OC w.r.t. rated 7.07 OC indicates effects of inadequate CW
flow, fouling etc. and scope for improvement.
HEAT TRANSFER COEFFICIENT:
Condenser heat transfer Coefficient, (U factor) in as run condition, is assessed to be
2570.41 Kcal/hr-m2 w.r.t. rated value of 2652.64 Kcal/hr-m2, mainly on account of
increased thermal load, despite increase in LMTD. The Surface heat transfer area
considered is 7743.88 SQM.
The as-run condenser cleanliness factor, being a ratio of as run heat transfer Coefficient and
design heat transfer Coefficient, works out to 96.90% of design, i.e. 0.823 (design
cleanliness factor being 0.85). The drop in cleanliness factor also indicates scope for
improvement.
In the absence of condenser curves and accurate back pressure measurement, PG test data
of condenser, the scope for improvement is assessed, based on relevant co-relations and
accepted norms.
The reference parameters are as under:
Item Reference Unit Design As-Run

CW temperature O
C 34 30.5
(Inlet)
CW temperature O
C 43 41.5
(Outlet)
O
CW temp. Diff. C 9 11.0
63
103.95
mbar at 34 OC CWin. 98.06
Condenser Vacuum
(w.r.t. 0.106 (w.r.t. 0.10 kg/cm2)
kg/cm2)
O
Saturation temp. C 46.5 45.3
O
TTD C 3.5 3.8
Analysis
(i) Back pressure with clean tubes at design 34 = 103.95 mbar
O
C CW Inlet temp.
(ii) Saturation temp. Predicted due to CW Inlet = 30.5 OC + Design CW temp.
temp. being lower, at ideal conditions drop + Design approach
= 30.5 + 9 + 3.5
= 43 OC
(iii) Corresponding predicted back pressure in = 86.39 mbar
ideal conditions with lower CW in tem.
(iv) Saturation temp. predicted due to actual CW = 41.5 OC + Design approach of
Outlet temp. and design approach. 3.5 OC
= 45 OC
64
(v) Corresponding predicted back pressure with = 95.8 mbar
lower CW Inlet temperature, actual CW ∆T
due to lower flow and design approach.
(vi) Saturation temperature w.r.t. actual CW = 41.5 OC + actual approach of
Outlet conditions and actual approach (As- 3.8 OC
Run condition)
= 45.3 OC
(vii) As-Run back pressure, at above condition = 98.06 mbar
(viii) Loss in vacuum on account of lower CW = (98.06 – 86.39) mbar

flow, and fouled condenser tubes, at 31.5 OC
CW Inlet temp. in as run conditions.
{Item (vii) – Item (iii)}
= 11.67 mbar
(ix) Loss in vacuum on account of lower CW = (98.06 – 95.80) mbar

flow, and fouled condenser tubes above, at
31.5 OC CW Inlet temperature.
{Item (vii) – Item (v)}
= 2.26 mbar
A profile of desirable vacuum conditions at varying inlet CW temperature from 28 OC
to 36 OC, with 9 OC as CW ∆T and 3.5 OC as approach, are as follows:
CW Inlet Temperature Predicted Saturation Predicted Vacuum in

(OC) temperature in OC (Ideal) mbar (Ideal)
28 40.5 75.76
30 42.5 84.15
32 44.5 93.41
34 46.5 103.41
36 48.5 114.49
RECOMMENDATIONS
1. It is recommended to install an accurate vacuum gauge for regular monitoring of
performance. (with mbar reading).
2. The CW flow to condenser needs to be enhanced to 16000 CMH (rated condition) by
reducing other drawals in the CW path before condenser, CW pump performance
improvements etc. Once indicator of performance and flow adequacy being that
pressure drop across condenser should always be greater than rated 5 MWC. If
necessary, separate CW pump may be installed for aux. Cooling, so that condenser CW
flow is increased.
65
3. State of the art measures for performance upkeep like chlorination (for bio fouling),
online cleaning of condenser tubes, opportunity based back wash of condenser, may be
taken up.
4. The vacuum improvement margin of 11.67 mbar, if achieved through above
improvements, would translate as equivalent heat rate improvement, i.e. 11.67
kcal/kWh, and accordingly, would easily justify any investments towards improvements
in condenser performance. The detailed CW-CT system overhauling action plan is
attached in the annexure
Taking average generation 90 MW ( on the basis of 2006-07 generation figure) for 8000
hours
Saving potential = 11.67*90*1000*365*24
= 9200628000 Kcal
Designed Turbine Heat Rate = 1991Kcal/kW
Annual energy saving = 9200628000/1991
= 4.6 MUs
Enrgy cost (Rs./kWh) = 2.35
Annual saving potential = 108 Lakh
66
ANNEXURE
Annexure 1
O B S E R VA T I O N S H E E T S
(EQUIPMENT/AREA WISE)
BFP A
S.No Description Units Test 1 Test 2 Test 3 Average

1 Unit Load MW 119 118 120 119.00
2 Grid Frequency Hz 48.85 48.85 48.96 48.89
3 BFP Suction Flow TPH 190.7 190.1 189.5 190.10
4 Feed Water Flow TPH 375.2 364.8 375.7 371.90
5 Speed rpm 3552 3537 3596 3561.67
67
6 DP Across FRV Kg/cm2 3.5 5.9 3.8 4.40
7 Deaerator Pressure Kg/cm2 5 5 5.1 5.03
8 BFP suction Pressure Kg/cm2 6.2 6.3 6.3 6.27
9 BFP Discharge Pressure Kg/cm2 149.3 149.1 150.3 149.57
10 FW Pressure
a At Heater Inlet Kg/cm3 148 147 149.4 148.13
b At Heater Outlet Kg/cm4 147.6 145.8 148.3 147.23
11 BFP Power Analysis
i Current A 139.85 139.48 135.44 138.26
ii Voltage kV 6.5 6.5 6.5 6.5
iii Power Factor 0.93 0.93 0.93 0.93
iv Electrical Power kW 1464 1460 1418 1448
12 Pump Hydraulic Power kW 742.33
Specific Energy
13 Consumption Kwh/T 7.61
14 Combined Efficiency % 51.28
15 Motor Loading % 72
16 Flow Loading % 88
BFP Suction flow to unit
17 TPH/Mw 1.60
load ratio
NO LOAD OBSERVATION
S.No Description Units Test 1 Test 2 Average

2 Speed rpm 2250 2245 2247.50
5 Power kW 591 581 591
BFP B

1 Unit Load MW 120 120 119 119.67
4 Feed Water Flow TPH 366.2 367 383.6 372.27
5 Speed rpm 3572 3572 3550 3564.67
6 DP Across FRV Kg/cm2 5.3 5.2 5.8 5.43
7 Deaerator Pressure Kg/cm2 5.1 5.1 5 5.07
9 BFP Discharge Pressure Kg/cm2 150.7 151 149.4 150.37
10 FW Pressure
a At Heater Inlet Kg/cm3 150 151 149.4 150.13
i Current A 141.70 141.76 142.60 142.02
68
ii Voltage kV 6.5 6.4 6.5 6.5
iii Power Factor 0.94 0.94 0.94 0.94
Specific Energy
17 TPH/Mw 1.51
load ratio
NO LOAD OBSERVATION

2 Speed rpm 2217 2220 2218.50
5 Power kW 614 615
BFP C

1 Unit Load MW 120 121 120 120.33
4 Feed Water Flow TPH 369.6 377.3 367 371.30
5 Speed rpm 3462 3541 3455 3486.00
6 DP Across FRV Kg/cm2 6 4.7 6.8 5.83
7 Deaerator Pressure Kg/cm2 5.1 5.2 5.1 5.13
10 FW Pressure
a At Heater Inlet Kg/cm3 150.2 152.4 148.2 150.27
i Current A 129.98 137.20 129.48 132.22
ii Voltage kV 6.5 6.5 6.5 6.5
69
iii Power Factor 0.94 0.94 0.94 0.94
Specific Energy
15 Motor Loading % 70.0
17 TPH/Mw 1.46
load ratio
NO LOAD OBSERVATION

2 Speed rpm 2188 1618 2197 2001
5 Power kW 570 622
CONDENSATE EXTRACTION PUMP

Pump A
1 Unit Load MW 116 119.00 119.00 118.00
3 Suction Temp. ºC 46.5 46.9 46.9 46.8
4 CEP Flow TPH 334 329 332 332
Condenser back
5 Kg/cm2 0.91 0.91 0.91 0.91
Pressure(-)
6 Hotwell Level M 808 811.5 809.3 809.60
7 Disch. Pressure Kg/cm2 16 17 17 16.5
8 CEP Amps ( Control room ) A 22.6 22.8 22.9 22.8
i Current A 22.9 23.0 23.0 23.0
ii Voltage kV 6.5 6.5 6.5 6.5
iii Power Factor 0.87 0.87 0.87 0.87
iv CEP Power kW 225 225 225 225
10 Specific Energy kWh/T 0.68
70
Consumption
12 Pump Loading % 92
Condensate Flow to Unit TPH/MW
13 Load ratio 2.81
Pump B

1 Unit Load MW 119 119 119
2 Grid Frequency Hz 48.96 48.85 48.91
3 Suction Temp. ºC 47.5 47.7 47.6
4 CEP Flow TPH 298 320 309
5 Condenser back Pressure(-) Kg/cm2 0.90 0.90 0.90
6 Hotwell Level M 818.1 826.5 822.30
7 Discharge Pressure Kg/cm2 17 16 16.55
8 CEP Amps ( Control room ) A 22.4 23.1 22.7
i Current A 23.1 23.5 23.3
ii Voltage kV 6.5 6.5 6.5
iii Power Factor 0.88 0.88 0.88
iv CEP Power kW 229 233 231
10 Specific Energy Consumption kWh/T 0.75
12 Pump Loading % 86
Condensate Flow to Unit TPH/MW
13 Load ratio 2.60
INDUCED DRAFT FANS
ID FAN A
S. N0. Description Units Test 1 Test 2 Test 3 Average

1 Unit Load MW 120 120 120 120.00
2 Frequency Hz 48.85 48.97 48.97 48.93
3 Total Air Flow TPH 430.1 430.2 429.5 429.9
4 Coal Flow TPH 63.8 63.9 63.8 63.8
5 Suction Pressure (-) #DIV/0!
a ID Fan A mmwcl 173.9 174.1 173.9 174
b ID Fan B mmwcl 177.8 177.9 177.7 178
0
6 Flue gas temperature at ID inlet A/B C 133/131 133/131 133/131 133/131
7 Fan power analysis
8 Current ( Control room ) Amps 48.5 48.9 48.5 48.6
9 ID Fan A
i Current Amps 48.3 48.5 48.4 48.42
ii Voltage kV 6.5 6.5 6.5 6.49
71
iii Power Factor 0.75 0.75 0.75 0.75
iv Power kW 408
ID FAN B

1 Unit Load MW 119 120 119 119.33
2 Frequency Hz 48.9 48.73 48.23 48.62
3 Total Air Flow TPH 429.1 429 430.2 429.4
4 Coal Flow TPH 63.9 63.9 63.9 63.9
5 Suction Pressure (-)
a ID Fan A mmwcl 173.4 171.5 172.4 172
b ID Fan B mmwcl 1 77.6 176.2 176.7 176
Flue gas temperature at ID inlet 0
C
6 A/B 133/131 133/131 133/131 133/131
7 Fan power analysis
8 Current ( Control room ) Amps 53.1 52.6 52.5 52.73
i Current Amps 52.9 52.5 52.4 52.59
ii Voltage kV 6.4 6.5 6.5 6.5
iii Power Factor 0.78 0.78 0.78 0.78
iv Power kW 458.62
AIR INGRESS CALCULATION
S.No Parameter Description Units Test

1 Unit Load MW 120.00
3 Total Air Flow TPH 430.00
4 Flue gas temperature at ID inlet deg C 132.00
5 Flue gas density Kg/m3 0.87
6 Total Coal flow TPH 64.00
7 % Ash in Coal % 35.61
8 Total Bottom ash (20% of total ash) TPH 4.56
9 Total Fly ash ( 80% of total ash) TPH 18.23
10 Flue Gas at APH inlet TPH 489.44
11 ESP Efficiency % 99.90
12 Flue Gas without fly ash TPH 471.23
13 Avg. O2 at APH inlet % 3.90
14 Flue Gas at APH inlet (In % of Stoichiometric Air ) % 122.81
15 Avg. O2 at APH outlet % 5.50
16 Flue Gas at APH Outlet (In % of Stoichiometric Air ) % 135.48
72
17 Avg. O2 at ID fan inlet % 5.90
Flue Gas at ID Fan inlet (In % of Stoichiometric
18 Air ) % 139.07
19 Flue gas Flow at APH inlet TPH 489.44
20 Flue gas Flow at APH outlet TPH 538.10
21 Flue gas Flow at ID inlet TPH 533.66
22 Air ingress across APH TPH 48.66
23 Air Ingress between APH & ID fan TPH 13.77
24 Total Air Ingress TPH 62.43
FORCED DRAFT FAN

FAN A
1 Unit load MW 120 121 122 121.00
2 Frequency Hz 48.85 49.32 49.08 49.08
3 Total Secondary air Flow TPH 257.6 258.1 255.1 257
4 Discharge Pressure
Fan A mmwcl 233.5 231.1 230.7 231.8
Fan B mmwcl 242.1 243.1 241.4 242.2
After AH ( L ) mmwcl 105.3 96.6 102.8 101.6
After AH ( R ) mmwcl 100.9 101.1 106.9 103.0
After AH ( L ) TPH 136.4 136.8 134.9 136.0
After AH ( R ) TPH 121.2 121.3 120.2 120.9
7 Wind Box Pressure
Left 100.1 99.1 103 100.7
Right 100.4 102.3 104 102.2
8 FD Fan power Analysis
a Current( Control room ) A 33.1 33 32.5 32.9
i Current A 33.3 33.5 32.9 33.2
ii Voltage kV 6.47 6.47 6.43 6.5
73
iii Power Factor 0.86 0.86 0.86 0.86
iv Power kW 319.3
FAN B
1 Unit load MW 121 121 121 121.00
2 Frequency Hz 48.85 48.85 48.73 48.81
3 Total Secondary air Flow TPH 258.1 257.2 257.5 258
Fan A mmwcl 234.8 231.5 232.8 233.0
Fan B mmwcl 244.5 245.1 244.3 244.6
After AH (L) mmwcl 101.5 101.3 100.1 101.0
After AH R mmwcl 109 107 103.2 106.4
After AH R TPH 136.2 135.7 136.1 136.0
After AH (L) TPH 121.9 121.5 121.4 121.6
7 Wind Box Pressure
Left 103 101 103 102.3
Right 102 100 103 101.7
8 FD Fan power Analysis
a Current A 32.8 32.7 32.6 32.7
i Current A 28.8 28.7 28.6 28.7
ii Voltage kV 6.5 6.5 6.5 6.47
iii Power Factor 0.85 0.85 0.85 0.85
iv Power kW 273.3
PRIMARY AIR FAN

FAN A
1 Unit load MW 121 122 121 121.33
2 Frequency Hz 48.96 48.85 48.78 48.86
3 Total Primary air Flow TPH 173 172.4 172.5 173
4 Coal Flow TPH 65 65 65 65
i Fan A mmwcl 864 863 865 864.0
ii Fan B mmwcl 863 861 863 862.3
6 Primary Air Temperature
0
i AH inlet C 34 34 34 34
0
ii After AH C 296 297 297 296
7 Hot PA header mmwcl 803 801 803 803
8 DP across PAH air side TPH 31.5 31.7 31.5 31.6
9 PA Fan power Analysis
a Current ( Control room ) A 28 28.1 28.5 28.2
i Current A 28.5 28.4 28.5 28.5
ii Voltage kV 6.4 6.4 6.4 6.4
iii Power Factor 0.78 0.78 0.78 0.78
iv Power kW 247.5
Primary Air Flow to Unit load
10 TPH/MW 1.42
Ratio
74
11 Primary Air to Coal Ratio 2.65
FAN B
1 Unit load MW 121 119 120 120.00
2 Frequency Hz 48.98 48.92 48.97 48.96
3 Total Primary air Flow TPH 172 173 173 173
4 Coal Flow TPH 65 65 65 65
i Fan A mmwcl 870 862 863 865
ii Fan B mmwcl 868 862 862 864
6 Primary Air Temperature
0
i AH inlet C 34.4 34.3 34.4 34.4
0
ii After AH C 296.5 296.8 296.8 296.7
7 Hot PA header 811.5 807 804 807.5
8 DP across PAH air side TPH 31.8 32 32.2 32.00
9 PA Fan power Analysis
a Current ( Control room ) A 28 27.8 28.2 28.00
i Current A 32.65 32.76 32.91 32.77
ii Voltage kV 6.47 6.47 6.47 6.47
iii Power Factor 0.84 0.84 0.84 0.84
iv Power kW 308.33
10 Primary Air Flow to Unit load Ratio TPH/MW 1.44
11 Primary Air to Coal Ratio 2.65
MILLS
MILL A

1 Unit load MW 119 119 119 119.0
2 Frequency Hz 49.2 49.11 48.96 49.1
3 Total air flow TPH 430 430 430 430.0
4 Hot PA header pressure mmwc 807.6 802 803.4 804.3
5 Mill inlet pressure mmwc 438.3 442 439.2 439.8
6 Mill Differential Pressure mmwc 382 382 380.1 381.4
7 Cold Air Damper postion % 63 62.9 62.9 62.9
8 Hot Air Damper position % 27 27 27 27.0
9 C 297 297 297 297.0
preheater
0
10 Air temp at mill inlet C 148 148 148.7 148.2
0
11 Mill Outlet temp C 88.3 88.6 88.6 88.5
12 Coal flow to mill TPH 17.6 17.6 17.6 17.6
13 PA flow TPH 46 45.7 45.9 45.9
14 Total PA flow TPH 177.4 177.3 176.9 177.2
15 Mill Fineness (-)75 Mesh % 85.15
a Current (control room) Amps 30.4 30.4
75
i Current Amps 31.2 31.0 31.6 31.3
ii Voltage kV 6.5 6.4 6.5 6.5
iii Power Factor 0.78 0.78 0.78 0.8
iv Power kW 273 269 276 273
17 Specific power consumption kW/T 15.5
19 Mill Loading % 48.2
MILL B

1 Unit load MW 118 118 119 118.3
2 Frequency Hz 48.85 48.85 48.85 48.9
3 Total air flow TPH 430 430 430 430.0
4 Hot PA header pressure mmwc 804.1 806.9 805.4 805.5
5 Mill inlet pressure mmwc 511 507.5 509.4 509.3
NOT
6 Mill Differential Pressure mmwc
AVAIALABLE
7 Cold Air Damper postion % 71.25 72.4 71.22 71.6
8 Hot Air Damper position % 30.84 30.84 30.89 30.9
Primary air temp after mill 0
9 C 297.2 297.2 297 297.1
air preheater
0
10 Air temp at mill inlet C 153.8 153.7 154 153.8
0
12 Coal flow to mill TPH 18 18 18 18.0
13 PA flow TPH 44.7 49.8 45 46.5
14 Total PA flow TPH 176.9 176.8 176.9 176.9
a Current (control room) Amps 29.9 29.9
76
i Current Amps 30.1 29.8 29.9 30.0
ii Voltage kV 6.5 6.5 6.5 6.5
iv Power kW 263 257 258 260
Specific power
17 kW/T 14.4
consumption
MILL C

1 Unit load MW 120 119 119 119.3
2 Frequency Hz 48.97 48.96 49.08 49.0
3 Total air flow TPH 430 430.6 430.5 430.4
4 Hot PA header pressure mmwc 805.9 806.5 806 806.1
5 Mill inlet pressure mmwc 494.1 498.8 497.7 496.9
9 C 297.4 297.4 297.4 297.4
preheater
0
10 Air temp at mill inlet C 160.8 160.9 160.7 160.8
0
13 PA flow TPH 42.6 43.2 43 42.9
14 Total PA flow TPH 176.6 177.3 177 177.0
a Current (control room) Amps 30.12 29.84 30.15 30.0
i Current Amps 30.0 30.1 30.2 30.1
ii Voltage kV 6.5 6.5 6.5 6.5
iv Power kW 260 256 261 259
Specific power consumption of
17 kW/T 14.7
Mill
77
MILL D

1 Unit load MW 119 120 119 119.3
2 Frequency Hz 48.85 48.97 48.97 48.9
3 Total air flow TPH 431.1 431.2 430.2 430.8
4 Hot PA header pressure mmwc 808.7 805.6 805.2 806.5
5 Mill inlet pressure mmwc 364.4 362.2 363.3 363.3
9 C 297.4 297.4 297.4 297.4
preheater
0
10 Air temp at mill inlet C 113.8 114 114.2 114.0
0
13 PA flow TPH 43.4 43.7 43.3 43.5
14 Total PA flow TPH 176.6 176.6 176.3 176.5
i Current Amps 26.1 27.0 26.8 26.7
ii Voltage kV 6.5 6.5 6.5 6.5
iv Power kW 214 224 222 220
17 kW/T 21.8
Mill
78
MILL E

1 Unit load MW 120 120 118 119.3
2 Frequency Hz 49.05 48.88 48.85 48.9
3 Total air flow TPH 430.5 429.2 433.3 431.0
4 Hot PA header pressure mmwc 800 799.6 799.2 799.6
5 Mill inlet pressure mmwc 393 393 393.9 393.3
6 Mill Differential Pressure mmwc 172.2 170 170.4 170.9
9 C 289.8 289.8 289.9 289.8
preheater
0
10 Air temp at mill inlet C 171.6 171.3 171.2 171.4
0
13 PA flow TPH 47.3 46.6 47.3 47.1
14 Total PA flow TPH 186.9 187.5 188.3 187.6
15 Mill Fineness (-)75 Mesh %
i Current Amps 25.6 25.5 25.6 25.6
ii Voltage kV 6.5 6.5 6.5 6.5
iv Power kW 210 207 210 209
17 kW/T 15.7
Mill
79
COAL HANDLING PLANT

CONVEYOR - 1A
Motor Rating 132 kW
Length 26257 mm
Width 1600 mm
Capacity 1176 T/Hr
Speed 1.6 M/Sec
S.NO. DESCRIPTION UNITS TEST 1 TEST 2 Average

1 Coal Flow TPH 754 754 754
2 Power Analyser Reading
3 On Load
a Current Amp 97.10 99.40 98.25
b Voltage Volt 444.00 445.70 444.85
c Power Factor 0.6 0.60 0.60
d Power kW 44.80 46.10 45.45
4 SEC kW/MT 0.060
CONVEYOR - 2
Motor Rating 277 kW
Length 348235 mm
Width 1600 mm
Capacity 1176 T/Hr
Speed 1.6 M/Sec

3 On Load
a Current Amp 17.00 17.10 17.05
80
b Voltage Volt 6.70 6.70 6.70
d Power kW 172.60 173.60 173.10
4 SEC kW/MT 0.230
CONVEYOR - 3
Motor Rating 132 kW
Length 103241 mm
Width 1200 mm
Capacity 1176 T/Hr
Speed 2.66 M/Sec

3 On Load
a Current Amp 112.80 111.60 112.20
b Voltage Volt 442.20 440.40 441.30
d Power kW 82.10 80.80 81.45
4 SEC kW/MT 0.108
CONVEYOR - 4
Motor Rating 150 kW
Length 168069 mm
Width 1200 mm
Capacity 1176 T/Hr
Speed 2.66 M/Sec

3 On Load
a Current Amp 12.00 11.90 11.95
d Power kW 101.30 102.20 101.75
4 SEC kW/MT 0.135
CONVEYOR - 5
Motor Rating 132 kW
Length 136330 mm
Width 1200 mm
Capacity 1176 T/Hr
Speed 2.66 M/Sec

3 On Load
a Current Amp 121.50 120.60 121.05
b Voltage Volt 440.30 439.20 439.75
d Power kW 63.90 64.20 64.05
4 SEC kW/MT 0.085
81
CONVEYOR - 6
Motor Rating 225 kW
Length 322526 mm
Width 1200 mm
Capacity 1176 T/Hr
Speed 2.66 M/Sec

3 On Load
a Current Amp 349.00 355.70 352.35
d Power kW 116.60 118.90 117.75
4 SEC kW/MT 0.194
CONVEYOR - 7B
Motor Rating 225 kW
Length 275300 mm
Width 1200 mm
Capacity 1176 T/Hr
Speed 2.66 M/Sec

3 On Load
a Current Amp 6.70 6.70 6.70
d Power kW 145.60 144.80 145.20
4 SEC kW/MT 0.223
CONVEYOR - 8B
Motor Rating 225 kW
Length 178093 mm
Width 1200 mm
Capacity 1176 T/Hr
Speed 2.66 M/Sec

3 On Load
a Current Amp 399.00 399.90 399.45
d Power kW 147.80 148.50 148.15
4 SEC kW/MT 0.235
CONVEYOR - 9B
Motor Rating 225 kW
Length 219750 mm
Width 1200 mm
82
Capacity 1176 T/Hr
Speed 2.66 M/Sec

3 On Load
a Current Amp 264.20 265.80 265.0
d Power kW 75.20 78.10 76.65
4 SEC kW/MT 0.118
CONVEYOR - 10
Motor Rating 150 kW
Length 159937 mm
Width 1200 mm
Capacity 1176 T/Hr
Speed 2.66 M/Sec

1 Coal Flow TPH 940.00 1000.00 970.00
3 On Load
a Current Amp 11.70 11.60 11.65
d Power kW 94.90 95.90 95.40
4 SEC kW/MT 0.098
CONVEYOR - 12
Motor Rating kW
Length 103241 mm
Width 1600 mm
Capacity 1176 T/Hr
Speed 2.66 M/Sec
S.NO. DESCRIPTION UNITS TEST 1 Average
1 Coal Flow TPH 754.00 754.00
3 On Load
a Current Amp 34.30 34.30
b Voltage Volt 456.00 456.00
c Power Factor 0.5 0.50
d Power kW 13.50 13.50
4 SEC kW/MT 0.018
CONVEYOR - 13
Motor Rating kW
Length 103241 mm
Width 1600 mm
Capacity 1176 T/Hr
Speed 2.66 M/Sec
83
1 Coal Flow TPH 754.00 754.00 754.00
3 On Load
a Current Amp 108.00 107.70 107.85
b Voltage Volt 457.20 455.60 456.40
d Power kW 46.20 46.80 46.50
4 SEC kW/MT 0.062
PRIMARY CRUSHER-1
Motor Rating kW
Length mm
Width mm
Capacity T/Hr
Speed M/Sec

1 Coal Flow TPH 754.00 754.00 754.00
3 On Load
a Current Amp 8.40 8.30 8.35
d Power kW 33.70 32.00 32.85
4 SEC kW/MT 0.044
SECONDRY CRUSHER-1
Motor Rating kW
Length mm
Width mm
Capacity T/Hr
Speed M/Sec

1 Coal Flow TPH 754.00 754.00 754.00
3 On Load
a Current Amp 51.60 52.80 52.20
d Power kW 145.20 150.00 147.60
4 SEC kW/MT 0.196
COAL CONSUMPTION DATA (FY05-06)
Coal receipt Coal Coal Coal Aux. Power

(MT) Stacked Reclaimed Consumed Kwh / Ton
(MT) (MT) (MT) Coal
Handled
Month
April, 05 161366 161366 125461 125461 1.43
May, 05 129649 129649 116772 116772 1.29
June, 05 92918 92918 114490 114490 1.26
July, 05 125167 125167 106734 106734 1.33
August, 05 123133 123133 116346 116346 1.30
September, 05 123489 123489 123489 123489 1.33
October, 05 176911 176911 136512 136512 1.26
November, 05 153579 153579 125452 125452 1.22
84
December, 05 141463 141463 142428 142428 1.21
January, 06 174314 174314 178442 178442 1.25
February, 06 142796 142796 154707 154707 1.29
March, 06 232612 232612 143425 143425 1.22
TOTAL 1777397 1777397 1584258 1584258 1.28
Conv Yearly
Conveyor Motor Motor Conv Conv
S.No. Name / Volt Current Running Hrs
Length Rating Speed Capacity Speed
No (FY 05-06)
No On
Meters kW Volt Amps RPM TPH M/sec
Load Load
1 Conv # 1A 62 132 415 227.00 1485 1176 1.60 127 2535
2 Conv # 1B 42 132 415 227.00 1485 1176 1.60 124 2485
3 Conv # 2 690 277 6600 30.00 1486 1176 1.60 127 2535
4 Conv # 3 224 132 415 227.00 1486 1176 2.66 127 2535
5 Conv # 4 338 150 6600 17.80 1480 1176 2.66 127 2535
6 Conv # 5 232 132 415 227.00 1486 1176 2.66 127 2535
7 Conv # 6 670 225 6600 24.00 1484 1176 2.66 1105 4420
Conv # 7A
559 225 6600 24.00 1484 1176 2.66 876 4380
8 & 7B
Conv # 8A
378 225 6600 24.00 1484 1176 2.66 876 4380
9 & 8B
Conv # 9A
600 225 6600 24.00 1484 1176 2.66 876 4380
10 & 9B
11 Conv # 11 307 132 415 227.00 1486 750 2.66 584 2920
12 Conv # 14 387 55 415 94.00 1475 1176 2.66 207 1035
85
COOLING TOWER AREA
POWER MEASUREMENT SHEET OF CT FANS
EQUIPME DATE TIME Voltage Current PF Freq kW

NT
R Y B R Y B
CT FAN-1 13.01.07 12.33 398.50 398.20 398.20 58.73 59.83 58.72 0.86 49.26 34.70
13.01.07 12.35 399.20 398.80 399.00 58.76 59.44 58.45 0.86 49.20 34.60
CT FAN-2 13.01.07 12.38 399.20 398.60 398.90 56.86 57.74 59.57 0.87 49.14 34.54
13.01.07 12.40 399.60 399.40 399.50 56.74 57.53 59.60 0.86 49.19 34.45
CT FAN-3 13.01.07 12.26 411.70 410.90 411.30 55.50 55.77 55.44 0.85 49.45 32.60
13.01.07 12.28 411.70 411.30 411.50 55.85 56.21 55.86 0.85 49.44 32.90
CT FAN-4 13.01.07 12.20 411.00 410.00 410.00 57.92 57.60 57.48 0.85 49.25 34.49
13.01.07 12.22 411.80 410.20 411.30 58.16 57.66 57.67 0.85 49.30 34.65
CT FAN-5 13.01.07 12.11 407.80 407.40 407.60 56.24 57.37 56.40 0.85 48.93 32.94
13.01.07 12.13 407.60 406.50 407.10 56.21 56.99 56.18 0.85 48.97 32.78
CT FAN-6 13.01.07 12.45 399.80 398.80 399.30 56.86 58.01 58.30 0.86 49.20 34.13
13.01.07 12.47 399.80 399.20 399.50 56.84 57.77 58.28 0.86 49.20 34.07
AIR FLOW MEASUREMENT SHEET
Wate
Air In Water
r In
Wind velocity Measurement AVG Area Flow let Out let
let
Temp Temp
Temp
M/Sec M/sec (M2) m3/hr Db deg C deg C
Cell No-1 2.2 2.8 2.6 3.3 3.3 3.5 2.95 168.03 1784459
Cell No-2 2.5 2.3 2.0 5.0 4.3 3.5 3.27 168.03 1976011
Cell No-3 2.4 3.1 2.7 3.8 3.3 2.9 3.03 168.03 1834867
24.4 43.25 32.15
Cell No-4 3.1 2.7 2.8 3.7 2.5 3.6 3.07 168.03 1855031
Cell No-5 2.8 3.1 3.0 4.0 3.8 3.7 3.40 168.03 2056665
Cell No-6 2.5 2.4 2.8 4.3 4.5 4.6 3.52 168.03 2127236
AVG FLOW 1939045
ASH SLURRY AND WATER PUMPS

86
ASH SLURRY PUMP-1A
Motor Rating 125 kW
Capacity 460 TPH
Disch. Head 35 Mts
Pump efficiency 67 %
S.No. DESCRIPTION UNITS DESIGN TEST 1 TEST 2 Average

1 Flow TPH 460 NA
Current Amp 219 73.30 72.90
Voltage Volt 443.40 441.60
Power Factor 0.45 0.46
3 Power kW 125.0 25.30 25.60 25.45
ASH SLURRY PUMP-3A

Motor Rating 125 kW
Capacity 460 TPH
Disch. Head 35 Mts

1 Flow TPH 460 425.00
Current Amp 219 74.10 74.50
Voltage Volt 415 444.10 443.20
Power kW 125.0 27.40 28.00 27.70
3 Suction Pr Mts 2.50
4 Discharge Pr Kg/Cm2 3.40
5 Net Head Mts 35 36.50

7 SEC kW/Ton 0.27 0.07
9 Head Loading % 104.29
10 Flow Loading % 92.39
87
ACW PUMP-2A
Motor Rating 125 kW
Capacity 770 TPH
Disch. Head 35 Mts
1 Flow TPH 770 932.50
Current Amp 219 194.60 194.90
Voltage Volt 415 406.60 406.30
Power kW 125 117.90 118.00 117.95
3 Suction Pr Kg/Cm2 2.00
Combined Efficiency % 64.63
6
7 SEC kW/Ton 0.16 0.13
ACW BOOSTER PUMP-2A

Motor Rating 75 kW
Capacity 945 TPH
Disch. Head 15 Mts
S.No. DESCRIPTION UNITS DESIGN TEST 1 Average

1 Flow * TPH 945 895.50*
Current Amp 131 100.75
Voltage Volt 408.87
Power Factor 0.79
Power kW 75 56.36 56.36

7 SEC kW/Ton 0.08 0.06
* Combined flow of two pumps measured and divided equally, as it was not
possible to measure flow individually.
88
H P WATER PUMP-1
Motor Rating 175 kW
Capacity 430 TPH
Disch. Head 105 Mts
Motor efficiency 95.5 %

1 Flow TPH 430 285.00
Current Amp 240.40 236.50
Voltage Volt 415 444.20 444.00
Power kW 175 151.7 149.10 150.40
6 Combined Efficiency % 75.45 52.67
7 SEC kW/Ton 0.41 0.53
ASH SLURRY PUMP-1B

Motor Rating 125 kW
Capacity 460 TPH
Disch. Head 25 Mts

1 Flow TPH 460 NA
Current Amp 219 105.80 106.20
Voltage Volt 415 442.70 446.50
Power kW 125 57.60 57.50 57.55
89
ASH SLURRY PUMP-3B
Motor Rating 125 kW
Capacity 460 TPH
Disch. Head 25 Mts

1 Flow TPH 460 425.00
Power Analyser
2 Reading
Current Amp 219 106.70 107.30
Voltage Volt 415 439.80 441.60
Power kW 125.0 57.70 58.30 58.00
7 SEC kW/Ton 0.27 0.14
ACW PUMP-2B
Motor Rating 125 kW
Capacity 770 TPH
Disch. Head 35 Mts
1 Flow TPH 770 960.00
Power Analyser
2 Reading
Current Amp 219 193.00 194.40
Voltage Volt 415 410.30 408.80
Power kW 125 117.90 118.37 118.14
Combined Efficiency % 53.15
6
7 SEC kW/Ton 0.16 0.12
90
ACW BOOSTER PUMP-2B
Motor Rating 75 kW
Capacity 945 TPH
Disch. Head 15 Mts
1 Flow* TPH 945 895.50*
Voltage Volt 404.07
Power Factor 0.87
Power kW 75 62.28 62.28
2
3 Suction Pr Kg/Cm 1.10

7 SEC kW/Ton 0.08 0.07
* Combined flow of two pumps measured and divided equally, as it was not
possible to measure flow individually.
H P WATER PUMP-2
Motor Rating 175 kW
Capacity 430 TPH
Disch. Head 105 Mts

1 Flow TPH 430 280.00
Power Analyser
2 Reading
Voltage Volt 415 439.50 440.80
Power kW 175 151.7 149.10 150.40
7 SEC kW/Ton 0.41 0.54
91
ASH SLURRY PUMP-1C
Motor Rating 125 kW
Capacity 460 TPH
Disch. Head 25 Mts

1 Flow TPH 460 NA
Current Amp 219 106.70 107.00
Voltage Volt 415 435.70 436.70
Power kW 125.0 57.10 57.50 57.30
ASH SLURRY PUMP-3C

Motor Rating 125 kW
Capacity 460 TPH
Disch. Head 25 Mts

1 Flow TPH 460 425.00
Power Analyser
2 Reading
Current Amp 219 106.20 106.50
Voltage Volt 415 443.50 445.50
Power kW 125.0 55.50 55.00 55.25
7 SEC kW/Ton 0.27 0.13
92
ACW PUMP-2C
Motor Rating 125 kW
Capacity 770 TPH
Disch. Head 35 Mts
1 Flow TPH 770 931.00
Power Analyser
2 Reading
Current Amp 219 191.90 190.00
Voltage Volt 415 404.80 405.60
Power kW 125 114.40 112.00 113.20
7 SEC kW/Ton 0.16 0.12
ACW BOOSTER PUMP-2C

Motor Rating 75 kW
Capacity 945 TPH
Disch. Head 15 Mts
1 Flow* TPH 945 NA
Voltage Volt 407.3
Power Factor 0.77
Power kW 75 57.63 57.63
* Flow could not be measured individually
93
H P WATER PUMP-3
Motor Rating 175 kW
Capacity 430 TPH
Disch. Head 105 Mts

1 Flow TPH 430 282.00
Power Analyser
2 Reading
Voltage Volt 415 441.00 440.80
Power kW 175 154.9 154.50 154.70
6 SEC kW/Ton 0.41 0.55
Design Actual Design Actual

S.No Pump details
kW kW SEC SEC
1 H P WATER PUMP-1 175 150.40 0.41 0.53
2 H P WATER PUMP-2 175 150.40 0.41 0.54
3 H P WATER PUMP-3 175 154.70 0.41 0.55
4 ACW BOOSTER PUMP-2A 75 56.36 0.08 0.06

5 ACW BOOSTER PUMP-2B 75 62.28 0.08 0.07
6 ACW BOOSTER PUMP-2C 75 57.63 0.08 NA
7 ACW PUMP-2A 125 117.95 0.16 0.13

8 ACW PUMP-2B 125 118.14 0.16 0.16
9 ACW PUMP-2C 125 113.20 0.16 0.12
10 ASH SLURRY PUMP-1A 125 25.45 0.27 NA

11 ASH SLURRY PUMP-1B 125 57.55 0.27 NA
12 ASH SLURRY PUMP-1C 125 57.30 0.27 NA
13 ASH SLURRY PUMP-3A 125 27.70 0.27 0.07

14 ASH SLURRY PUMP-3B 125 58.00 0.27 0.14
15 ASH SLURRY PUMP-3C 125 55.25 0.27 0.13
COMPRESSED AIR SYSTEM

94
Design data
1.0 Compressed Air required for Normal Operation

Service : 7315.5
Nm3/Hr
Instrumentation : 2058.74 Nm3/Hr
2.0 COMPRESSOR DETAIL
2.1 Number of Pump 2+1

2.2 Manufacturer Inger-soll Rand Ltd.
2.3 Type Centrifugal
2.4 Model No. CENTAC (C45MX3)
2.5 Stage 3
2.6 Normal capacity Capacity Discharge
Pressure kW
(M3.Hr.) (Kg/Cm2(a)
50 Hz (2975 rpm) 7213.52 9.818
693.24
48.5 Hz (2885 rpm) 6535.45 9.812
622.32
47.5 Hz (2826 rpm) 5982.5 9.81
574.30
2.7 Inlet Pressure 0.991 Kg/Cm2(a)
2.8 Design Ambient Temperature 47.2 deg. C
2.9 Relative Humidity 63 %
2.10 Inlet/Outlet Air Temperature for
Inter Cooler - I 143.5/37.3 deg.C
Inter Cooler - II 133.1/40 deg.C
After Cooler 125.8/41 deg.C
2.11 Inlet/Outlet Air Pressure for
Inter Cooler - I 2.228 / 2.188 Kg/Cm2 (a)
Inter Cooler - II 4.960 / 4.909 Kg/Cm2 (a)
After Cooler 9.917 / 9.812 Kg/Cm2 (a)
2.12 Min. Air Pressure for Instrument & 7.0 Kg/Cm2 (g)
Service at consumption point.
2.13 Direction of Rotation of Motor Counter Clock Wise (from
coupling end)
2.14 Main Motor Rating / Current / 76 A / 6.6 kV / 754 kW
3.0 SUCTION AIR FILTER
3.1 Total No. 3

3.2 Supplier Kirloskar Knecht, Pune
3.3 Type Dry / Washable
3.4 Filter Element Pre Filter (4 nos / filter) Washable, Fibre Glass
Paper
Fine Filter (4 nos./filter) Non Washable, Non woven
Filter Fibric
3.5 Rated Capacity 11043 M3/hr.
3.6 Pressure Drop 0.2 PSI
95
3.7 Efficiency Final filtering 99.97%
down to 2 micron as
per F209 D and 97% to
98% down to 3 micron
4.0 AIR RECEIVER
4.1 Total No. 4

4.2 Manufacturer Everest fabricators,
Ahmedabad
4.3 Installation Indoor, Vertical (in
compressor room)
4.4 Design Capacity 8 M3
5.0 AIR DRIER
5.1 Total No. 1+1

5.2 Manufacturer Trident Corporation,
Coimbtore
5.3 Type Blower Reactivated
Dryer
5.4 Duty Continuous
5.5 Max. Capacity at operating condition (FAD) 4800 m3/hr.
5.6 Type of Desiccant Activated Alumina
5.7 Quantity of Desiccant per chamber 1190 Kg
5.8 Expected Life of Desiccant 2 years
5.9 Air Pressure drop across drying plant at 0.3 Kg/Cm2
maximum flow
5.10 Due point of air at atmospheric pressure - 49 deg. C
5.11 Due point of air at operating pressure - 20 deg. C
5.12 Rate of water removed per cycle 95 Kg
5.13 Regeneration air temperature 180 deg. C
5.14 Adsorption Cycle Time 3 Hrs.
5.15 Reactivation Cycle Time
Heating 1 Hrs. and 52 min. / Adsorber
Cooling 1 Hrs.
Purging 8 Min.
5.16 Heater Rating 123 kW
6.0 COOLING WATER REQUIREMENT
6.1 Cooling Water Inlet Temperature 39 deg. C

6.2 Cooling Water Outlet Temp. from each Cooler 49 deg. C
6.3 Cooling Water Outlet Temp. from Oil cooler 44 deg. C
6.4 Cooling Water Inlet/Outlet Pressure 3.5 Kg/Cm2(g) / 2.5
Kg/Cm2(g)
ASH HANDLING COMPRESSORS

1 Total Nos for unit # 2 2
2 Model XF 125 W/C SP
96
3 Capacity 621 CFM
4 Rated operating Pr. 72 PSIG
5 Max discharge Pr 75 PSIG
6 Max module Pr. 75 PSIG
7 Drive Motor 125 HP
8 Fan Motor 1 HP
9 Power Supply 415 Volt / 3 Ph / 50 Hz
97
LIGHTING SYSTEMS
POWER MEASUREMENT OF DIFFERENT FEEDERS
Lighting Feeders Voltage Current PF Freq Power REMARKS

(Off site area)
Hz kW
CHP Lighting R Y B R Y B
LBD Incomes - 1 252.8 251.3 252.9 7.09 14.82 31.94 0.84 49.1 7.337 Day load
LBD Incomes - 1 255.5 254.6 251.5 23.86 16.00 32.93 0.59 49.1 10.68 Night load
LBD Incomes - 2 256.4 258.2 259.9 10.05 10.25 0 0.69 49.2 9.237 Night load
LBD Incomes - 2 251.4 255.4 256.6 9.69 9.94 0 0.70 49.2 8.567 Day load
Day load &
Ash Handling Plant
262.0 264.2 264.1 27.65 13.5 29.64 0.98 48.9 17.12 Night Load
LDB
Same
Lighting Feeders Voltage Current PF Freq Power REMARKS

(Main Plant area)
Hz kW
R Y B R Y B
LDB # 1 233.4 233.1 202.9 22.33 23.48 25.69 0.98 48.8 17.19 Day load
LDB # 1 233.4 233.2 232.5 22.67 25.38 26.19 0.99 48.9 17.80 Night load
LDB # 3 229.5 230.1 228.2 29.78 34.3 37.11 0.98 48.9 21.18 Day load
LDB # 3 229.5 230.1 228.2 29.78 34.3 37.11 0.98 48.9 21.18 Night load
LDB # 5 233.4 232.4 231.5 21.84 25.33 23.64 0.92 48.8 15.48 Night load
LDB # 1 233.2 232.9 232.2 5.79 5.25 6.76 0.98 48.8 1.07 Day load
LDB # 1 233.2 232.9 232.2 6.44 7.37 6.8 0.98 49.2 4.80 Night load
LDB # 3 230.1 229.9 227.8 6.83 8.44 8.02 0.98 49.1 5.16 Day load
LDB # 3 228.0 229.2 227.6 7.27 8.7 8.9 0.73 49.1 5.7 Night load
LDB # 5 233.9 233.3 232.5 No Day load
Load
LDB # 5 232.0 230.0 231.5 5.07 6.33 5.96 0.93 48.8 3.7 Night load
LDB # 3 NIE No Load Day load
Load is 3.7 Amp. Night load
LDB # 7 230.9 239.1 237.8 0.61 48.9 3.16 Day load
LDB # 7 230.9 239.1 237.8 0.83 48.9 3.50 Night load
LDB # 7 240.3 241.5 239.0 21.98 24.2 25.18 0.84 48.9 14.71 Night load
LDB # 7 240.3 241.5 239.0 18.34 21.15 24.22 0.86 48.9 12.89 Day load
98
LUX MEASUREMENT OF DIFFERENT LOCATIONS
Measured & Recommended Lux Level
Date: 9.01.07 Time: 10:00 - 12:00 hrs
Area Measured Lux Recommende Remarks

d Lux (BIS
Standard)
Front 73.0, 53, 62.3, 62.7, 72.6, 139.7,
126.7, 85.4, 94.4, 124.2, 93.6, 92.7, 100-150-200
73.1
Switch Gear 3M,
Vertical 56.7, 51, 40.8, 81.7, 71.2, 51, 58.2,
MCC 100-150-200
94.2, 35.3, 44.5
Rear Side 89.5, 107.4, 69, 104, 92.2, 82.7, 114,
100-150-200
102
Rear Side 200+, 32.2, 72.8, 183.4, 103.9(V), 27.7
ESP # 2 Switch 100-150-200
(V), 59.6(V)
Gear Room O-M
Front 79.3, 187, 200+ 100-150-200
Front 144.7, 142, 135, 215, 212, 287, 200-300-500
ESP Control Room 164(V), 77(V), 104(V)
Rear Side 200+, 235, 217 200-300-501
Front 166, 171, 242, 113, 142, 85(V), 95(V),
100-150-200
Ash Plant MCC # 196(V)
2&3 Rear Side 153, 79, 68, 104, 452, 203(V), 166(V), 100-150-200
114(V), 183(V)
Vertical 164, 101(V), 210, 111(V), 216(Table),
200-300-500
Ash Plant Control Penal 163(Table)
Room Front 337, 327, 215 200-300-500
Rear Side 144, 42, 129 200-300-500
Table 169, 187, 170 200-300-500
CHP C/R Front 167, 148, 92, 138(V), 56, 115(V) 200-300-500
Rear Side 258, 345, 357 200-300-500
120, 234, 157(V), 194, 143(V), 261,
116(V), 145, 127(V), 248, 126(V), 178,
121(V), 165, 106(V), 215, 118(V), 189, 100-150-200
CHP MCC Room
155(V), 238, 120(V), 115, 115(V), 196,
OM
145, 232
Rear Side 77, 64(V), 244, 167(V), 36, 170,
100-150-201
137(V), 46, 98(V)
CHP Office 354, 363, 287 150-200-300
Battery Room CHP 263, 187, 136, 142 50-100-150
PLC Room CHP 201, 196, 137(V), 159, 123(V) 150-200-302
Rear Side 329, 456, 421, 158(Table) 150-200-303
Cony-6 79, 203, 152, 49, 48, 57, 86, 201, 50, 50-100-150
138, 238, 29(mu)
Front 192, 92.0(V), 169.4, 88.1(V), 265,
173(V), 250, 153(V), 261, 251(V), 238, 200-300-500
213(V), 206, 140(V)
UCB # 2 Main Penal 191, 141(V), 116, 98(V), 111, 91(V), 200-300-500
143, 86(V), 264, 105(V)
114, 128, 128, 150(computer table),
200-300-500
Table 221(CT)
Rear Side 112, 269, 259, 243, 159 200-300-500
105, 225, 205, 126, 157, 126, 203,
141(V), 218, 140(V), 107, 310, 252,
Relay Room 200-300-500
147, 226, 143, 53, 97, 288, 153, 244,
281, 229, 183, 36, 192
99
Service Building AGM Office 132, 236 150-200-300
Conference Room 113, 251, 118 150-200-300
GM Office 180, 149 150-200-300
Table 197, 201 150-200-300
Library 199, 201, 160 150-200-300
Conference Room 259, 204, 194, 226, 180 150-200-300
C & I Office 235, 241 150-200-300
Service Room 204
150-200-300
No 200
Service Room 201
150-200-300
No 295
BE Group Room 382, 494, 362 150-200-300
EMD 178, 320, 381, 183, 107, 154, 160, 311 150-200-300
C&F Lab 209, 305, 235, 241, 175, 154, 114, 196 150-200-300
Mechanical Maint. 132, 234, 215, 183, 182, 169, 269,
150-200-300
off. 129, 189
Electrical Store 178, 200 150-200-300
CWP MCC Room- 253, 134(V), 224, 124(V), 156, 105(V),
Front 100-150-200
OM 160
92, 88(V), 58, 51, (V), 48, 76(V), 66,
Rear 100-150-200
49(V)
Front 220, 159(V), 204, 224(V), 183, 137(V) 100-150-200
DM Plant MCC
Rear 126, 103(V), 94(V), 129 100-150-200
116, 84(Penal), 68, 135(V), 82, 113(V), 200-300-500
DM Plant C/R 180(Table), 123, 98(V), 174
Rear 141, 154 200-300-500
DM Plant Equipment
100-150-200
area 37, 63, 103, 126, 144
AC Plant service
100-150-200
building 166, 43.9, 37.9, 46.7(Table), 137.5
TG OM # 2 57.5(BFP Area), 41.5, 8.9, 17.9, 24.1, 150-200-300
50.9, 37.1, 33.0, 42.5
Near HP Dozing Tank 104.1, 46.3 30-50-100
Walk Way 12.3, 6.4, 59.5 50-100-150
Centrifugal area 79.2, 21.9 100-150-200
Near Condenser 50.4, 48.3, 60.1, 25.5 100-150-200
Near ACW Pumps 6.9 100-150-200
100
Date: 10.01.07 Time: Night 18:00 - 19:30 hrs
Area Measured Lux Recommended Remarks

Lux (BIS
Standard)
165, 274, 194(V), 279, 130(V), 260,
# 2 Control Room 120(V), 213, 188, 95(V), 144, 92(V), 200-300-500
177, 85(V)
# 2 Control Room Rear 234, 310, 211, 107 200-300-500
30, 141, 160, 26, 257, 146, 95, 140,
Relay
# 2 Control Room 98, 110, 180, 240, 134(V), 130, 336, 200-300-500
Room
110(V), 205, 121, 127(V), 130
36, 38, 12 (Near Turbine), 39, 64(T6
TG-Hall # 2,
Front), 26, 32, 15, 37, 32(Gen Rear), 100-150-200
HP Heater area
40, 49, 57, 34(LPH), 41 (Stair)
84, 45, 22, 66 (CRH NRV), 65, 29, 34
5.5 M, TG 100-150-200
(Rear), 18, 43
# 2 Switch Gear Front 140, 120, 92, 91, 65(V), 34(V), 60, 84,
Room 3-M, MCC 61, 60(V), 80(V), 157, 89, 48, 105, 112, 100-150-200
Room 60, 48(V), 57, 518(operater table)
Street Light 28.6, 5.3, 27, 4, 11.6, 7.2, 20 5-20
Front 229, 197, 162, 150, 94, 135, 200, 135, 100-150-200
CHP MCC Room 144, 97(V), 95(V), 110(V)
CHP MCC Room Front 209, 176, 189, 135, 96(V), 196 100-150-200
Rear 127, 200, 187(V), 32, 27(V), 140, 116, 100-150-200
CHP MCC Room 163, 38(V), 201, 164(V)
364, 181, 201, 208, 86, 155(V), 94,
CHP - CR 200-300-500
Front 138(V)
CHP - CR Rear 216, 271, 277, 210 200-300-500
Front 138, 228, 146, 202, 164, 205(Table) 150-200-300
CHP Relay Room
Rear 209, 190, 105, 40 150-200-300
Walk Way C/R
200-300-500
outside 245, 68, 125, 50, 400, 300
Outside C/R open 4, 7
Conv - 6 14.5, 46, 28, 21, 3.5, 22 50-100-150
Coal yard near light
38.3, 8.0 5-20
tower
4.3(Entrance), 5.3, 15.4(seal Pump),
Ash Plant 100-150-200
145, 463, 324,
Excess
100-150-200
HP Water Pumps 330, 229, 143, 211 light
Slurry Pump 290, 270, 360, 167, 359 100-150-200
65, 259, 314, 325, 200 (Penal), 105(V),
200-300-500
C/R Entrance 150(Table)
215, 61, 280, 236, 131(V), 60, 87,
100-150-200
AHP MCC room Front 61(V)
105, 81(V), 48, 8, 7(V), 16, 52(V), 9,
100-150-200
AHP MCC room Rear 10(V)
Near ESP Pathway 7.1, 4.9, 16.7 50-100-150
27, 32, 25, 28, 25, 52, 30, 33, 20 (Near
50-100-150
ESP Area Air Tank)
Boiler O-M, MILL
50-100-150
Area 11, 8, 31, 17, 22(ID fan), 10(FD fan)
4, 2, 4, Near Ash Hoppers, 10, 29,
50-100-150
OM 7(IBD Tank), 14
ESP C/R 13(Entrance) 200-300-500
ESP MCC room Rear 154, 148, 157, 126(V), 58, 214 100-150-200
Relay
ESP MCC room 100-150-200
Room 196, 145(V), 71, 108, 79(V), 149
101
Cable Gallery 10, 29, 21, 35, 8, 50, 15 50-100-150
110, 6(condenser), 6, 34, 5, 34 (LP
100-150-200
O-M,TG Area dozing Tank), 16
BFP area 31, 30, 86, 91, 14, 5, 21, 85 100-150-200
O-M, Operator 131(Table) 100-150-200
15, 39(MOT), 7, 93, 16, 10,
100-150-200
Lub oil cooler 3(condenser rear), 19
Air Compressor 13(Entrance), 25, 65, 88, 71, 73(Tank
100-150-200
Room receiver), 73
GT Area 41 100-150-200
20, 37, 45, 37, 15, 17, 6, 21, 17, 51,
Switch Yard 100-150-200
20, 24
Excess
Switch Yard C/R 133, 368, 440, 410, 291, 366, 236 200-300-500
light
Stairs 167 50-100-150
Savings Potential calculations after Voltage reduction to 220 Volts in Lighting Circuits.
Lighting Feeders (Off Existing Recommen Existing Expected Expected Expected Expected
site area) Voltage ded Voltage Power New Power Annual Annual
(Average) (Average) Cons. Power Savings Energy Energy
Cons. (kW) Savings Savings
CHP Lighting (Kwh) (Rs)
LBD Incomes – 1 (Day
252.33 220 7.337 5.58 1.76 7708 18114
Load)
LBD Incomes – 1 (Night
253.87 220 10.68 8.02 2.66 11648 27374
Load)
LBD Incomes – 2 (Night
258.17 220 9.237 6.71 2.53 11078 26034
Load)
LBD Incomes – 2 (Day
254.47 220 8.567 6.40 2.16 9476 22270
Load)
AHP LDB (Night Load
263.43 220 17.12 11.94 5.18 45376 106634
and Day Load Same)
Total Savings in CHP Lighting Day Load = 1.76+2.16 = 3.92 kW

Total Savings in CHP Lighting Night Load = 2.66+2.53 = 5.19 kW
Total Savings in AHP Lighting load, (Day & Night)= 5.18 kW
Existing Expected Power

No.of No. of Watts/Tube+
Location Power Consumption
fittings FLTs Bllast extra
Consumption (with T-5 FLTs)
U#1,2,3, 3.0 mtr swgr. 142 254 40 13970 7112

UPS 6 12 40 660 336
Engineer's Room 10 20 40 1100 560
control room# 2&3 34 68 40 3740 1904
THL #2 48 95 40 5225 2660
UPS#2 6 12 40 660 336
N/E #2 11 22 40 1210 616
DM PLANT MCC 14 28 40 1540 784
DM PLANT C/R 10 20 40 1100 560
ESP#2 CR+MCC 15 30 40 1650 840
CW#2&3 MCC 12 24 40 1320 672
ASH PL2&3 C/R MCC 28 56 40 3080 1568
FLY ASH AIR COMP
ROOM 10 20 40 1100 560
CHP MCC+CR+PLC
Room 51 102 40 5610 2856
102
TOTAL 763 41965 21364
Conveyor No. of No of light fittings on Watt/Fixture

Number corrugated each side
sheets on each
side
Conveyor#2 222 26 70
Conveyor#10 194 23 70
Conveyor#11 39 6 70
Conveyor#12 21 3 70
Conveyor#13 220 26 70
Conveyor#14 123 15 70
Conveyor#15 118 14 70
103
ANNEXURE – 2A
BOILER EFFICIENCY TEST
The method of performance assessment chosen is the Indirect method of heat loss and Boiler
Efficiency calculation, drawn from Indian Standard ( IS – 8753 / 1977 ) and the deployed
relations are presented as follows.:
BASIS FOR HEAT LOSS CALCULATIONS:
A. HEAT LOSS CALCULATION (IN PERCENTAGES)
1. PERCENTAGE HEAT LOSS DUE TO UNBURNTS IN ASH:
i) IN BOTTOM ASH
= C. V. of Carbon (KJ/Kg) X Comb. in B. Ash (%) X B. Ash in Coal (Kg/Kg)

G.C.V. of Coal (KJ/Kg)
ii) IN FLY ASH
= C. V. of Carbon (KJ/Kg) X Comb. in Fly. Ash (%) X Fly. Ash in Coal (Kg/Kg)
G.C.V. of Coal (KJ/Kg)
2. PERCENTAGE HEAT LOSS DUE SENSIBLE HEAT IN DRY FLUE GAS:
%C %S
100 + 267
100 Comb. in B. Ash X B. Ash in Coal (Kg/Kg)
= X _
12 (%CO2 + %CO) 100
Comb. in F. Ash X F. Ash in Coal (Kg/Kg)
_
100
O
X 30.6 X Gas Temp at APH Out ( C) ___-Air Intake Temp (OC)
100
X G.C.V. of Coal (KJ/Kg)
3. PERCENTAGE HEAT LOSS DUE TO MOISTURE IN FLUE GAS:
104
= %M – 9X%H X 1.88
100
X Gas Temp at APH Out (OC) _ Air Intake Temp (OC) + 2442
100
4. PERCENTAGE HEAT LOSS DUE TO MOISTURE IN AIR:
= Air supplied (kg/kg of coal) X Moisture load (kg/kg of air) X 1.88
X Gas Temp at APH Out (OC) _ Air Intake Temp (OC)
100
5 5. PERCENTAGE HEAT LOSS DUE TO RADIATION & UNACCOUNTANTED

= 1.21%
B. HEAT INPUT TO BOILER (KCAL/HR)
= Coal cons (kg/hr) X G.C.V. of coal (Kcal/kg) - Mill Rejects (kg/hr) X G.C.V. of Reject
(Kcal/kg)
Heat Input
C. OVERALL HEAT RATE (KCAL/KWH) = Generation
ANNEXURE – 2B
Parameter used for efficiency computation
Sl. No Operating Parameters Unit Source
105
1 Avg. Unit Load MW DAS
2 Main Steam Flow TPH DAS
2
3 Main Steam Pressure KG/CM DAS
Main Steam Temperature O
4 C DAS
O
5 Feed Water Temperature C DAS
6 GCV of Coal (as received basis) KCAL/KG Plant laboratory
7 Avg. Coal Flow TPH DAS

8 Hot Reheat Steam Pressure KG/CM2 DAS
O
9 Hot Reheat Steam Temperature C DAS
10 Cold Reheat Steam Pressure KG/CM2 DAS

O
12 Cold Reheat Steam Temperature C DAS
1 POWER GENERATION (avg.) MW DAS

3 COAL CONSUMPTION TPH DAS
4 G C V OF COAL (as received basis) KCAL/KG Plant laboratory
5 TOTAL AIR FLOW TPH DAS

6 MILL REJECTS KG/HR Plant laboratory
7 G C V OF MILL REJECTS KCAL/KG Plant laboratory
8 C V OF CARBON KCAL/KG Plant laboratory
9 BOTTOM ASH QTY. (Dry basis) KG/KG Plant laboratory
10 COMB. IN BOTTOM ASH % Plant laboratory
11 COMB. IN FLY ASH % Plant laboratory
12 FLY ASH QTY. (Dry basis) KG/KG Plant laboratory
106
13 Flue Gas Analysis (APH Outlet)
13.1 CARBON DIOX!DE (CO2) % Plant laboratory
13.2 CO % Plant laboratory

Plant laboratory
13.3 OXYGEN (O2) %
13.4 TEMPERATURE DEGC Plant laboratory
14 Ambient conditions
14.1 DRY BULB TEMP DEGC Measured
14.2 WET BULB TEMP DEGC Measured
15 Proximate Analysis of Coal
15.1 FIXED. CARBON % Plant laboratory
15.2 VOLATILE MATTER % Plant laboratory

15.3 TOTAL MOISTURE % Plant laboratory
15.4 ASH % Plant laboratory
15.5 G C V OF COAL (as received basis) KCAL/KG Plant laboratory
16 Ultimate Analysis of Coal

16.1 CARBON (C) % Plant laboratory
16.2 HYDROGEN (H) % Plant laboratory
16.3 NITROGEN (N) % Plant laboratory
16.4 SULPHUR (S) % Plant laboratory
16.5 MOISTURE (H2O) % Plant laboratory
ANNEXURE – 2C
107
BOILER PERFORMANCE EVALUATION:
AS RUN KEY PARAMETERS DURING BOILER TRIALS (UNIT # 2)
Sl. No Operating Parameters Unit AVG. AVG.
DATE 10/01/2007 10/01/2007

10.30 hrs to 15.00 15.00 hrs to
DURATION HR
hrs 19.00 hrs
1 POWER GENERATION (avg.) MW 117.57 118.756
2 % OF NCR % 97.98 98.96
3 COAL CONSUMPTION TPH 63.48 63.478
4 G C V OF COAL (as received basis) KCAL/KG 4724.8 4724.8
5 TOTAL AIR FLOW TPH 429.98 429.994

6 MILL REJECTS KG/HR 66.25 66.25
7 G C V OF MILL REJECTS KCAL/KG 2325.9 2325.9
8 C V OF CARBON KCAL/KG 8077 8077
9 BOTTOM ASH QTY. (Dry basis) KG/KG 0.0698 0.06978
10 COMB. IN BOTTOM ASH % 5.52 5.52
11 COMB. IN FLY ASH % 2.36 2.36
12 FLY ASH QTY. (Dry basis) KG/KG 0.264 0.26

13 Flue gas analysis (APH Out)
13.1 CARBON DIOX!DE (CO2) % 16.8 16.8
13.2 CO % 0 0.0
13.3 OXYGEN (O2) % 5.5 5.5
13.4 TEMPERATURE DEGC 147.5 148
14 Ambient conditions
14.1 DRY BULB TEMP DEGC 25.6 26
14.2 WET BULB TEMP DEGC 15.95 16
14.3 RELATIVE HUMIDITY % 36.003 35.64
14.4 MOISTURE LOAD KG/KG 0.0073405 0.007365
108
15 Proximate analysis of Coal
15.1 FIXED. CARBON % 41.62 41.62
15.2 VOLATILE MATTER % 19.72 19.72
15.3 TOTAL MOISTURE % 4.5 4.5
15.4 ASH % 34.13 34.13
15.5 G C V OF COAL (as received basis) KCAL/KG 4724.8 4724.8
16 Ultimate analysis of Coal
16.1 CARBON (C) % 46.5 46.5
16.2 HYDROGEN (H) % 3.5 3.5
16.3 NITROGEN (N) % 0.4 0.4
16.4 SULPHUR (S) % 0.6 0.6
16.5 MOISTURE (H2O) % 5.5 5.5
NOTE: Above trial data is average value during 15 min. interval.
109
ANNEXURE – 3
CONDENSER DESIGN DATA
Sl.
DESCRIPTION UNITS VALUE
No.
1 Load MW 120.0
2 Frequency HZ 50
3 Number of Passes No 2
14000
4 Total Number of Tubes No
1200
5 Tube Length between Tube Plates Meters 7.400
6 OD of Condenser Tubes mm 22
18BWG for condenser & 22BWG
7 Thickness of tubes mm
for air cooler
C+Ni 90/10 for condensing and
8 Tube Material -
SA249CP304 for air cooler
9 Velocity through Tubes m/sec 1.96
O
10 TTD at design CW flow & temp. C 3.5
11 Condenser Vacuum kg/cm2 0.106 at 34 OC

O
12 CW temperature Rise C 9
13 Surface area SQM 7743.88

14 Condenser CW flow CMH 16000
15 Cleanliness Factor % 85
16 Water Box Diff. pressure mwc 5.0
17 CW Flow (capacity on line) CMH 9500*2
18 CW Pump speed rpm 495
19 CW pump discharge pressure Kg/cm2 1.3
20 Main Steam flow TPH 352.2
21 Main steam press Kg/ cm2 126
22 .Hot Re-heat Steam press Kg/ cm2 28.8
23 Cold Re-heat steam press Kg/ cm2 32.0
24 Main steam Temp. 0C 535.0
0
25 .Hot Re-heat Steam Temp. C 535.0
0
26 Cold Re-heat steam Temp. C 335.0
0
27 FW entering Econ. Temp. C 233.0
110
Annexure 4
CHEMISTRY REPORT
COAL SAMPLE ANALYSIS
TIME 7:00 AM 3:00 PM
S.NO. INGREDIENTS SAMPLE 1 SAMPLE 2
1 FC% 43.53 42.58
2 VM% 20.33 20.78
3 TOTAL MOISTURE 4.56 4.44
4 ASH% 35.61 36.11
5 GCV Kcal/Kg 4803.38 4646.19
SIEVE ANALYSIS
COAL FINENESS
DATE/TIME
S.NO. MILL -300+250* -250+125* -125+75* -75+0*
1 A 0.06 1.36 13.43 85.15
2 B 0.25 3.83 10.31 85.61
3 C 0.08 2.31 9.53 88.08
4 D 0.02 2.71 5.54 91.73
UNBURNT CARBON ANALYSIS

S.NO. BOTTOM ASH % FLY ASH
%
1 5.72 2.6
FLUE GAS ANAYSIS
O2 %
S.NO. APH inlet APH outlet ID Fan inlet
R/L R/L R/L
1 3.9 5.5 5.9
CO2 %
S.NO. APH inlet APH outlet ID Fan inlet
1 16 15 14
REJECT ANALYSIS
AIR DRY BASIS
GCV(kcal/kg
MOISTURE ASH % ) TM(%)
0.5 61.13 2325.9 2.19
111
Annexure 5
On – Line Energy Monitoring/Management System
The On – Line Energy Monitoring System involves recording and display of
pre-defined electrical parameters of the auxiliaries attached to this. It helps in
monitoring of electrical power consumption of the auxiliaries. With on-line energy
monitoring system, deviations in power consumption pattern or in other electrical
parameters can be detected early and suitable action can be taken accordingly.
Management may consider the long-term benefits of the system which includes:
(i) Accurate energy accounting and control.

(ii) Cumbersome process of manual readings is avoided and data is available on
PC.
(iii) Data of several months can be stored in PC. Hence comparison
with past consumption can be done using trends periodically.
(iv) Energy efficiency reports of attached auxiliaries can be generated.
(v) Early detection of variation in energy consumption pattern of auxiliaries as
hourly, daily reports can be prepared and analysed.
(vi) Merit order operation of equipments / drives can be introduced.
The use of data recording and analysis enables the plant to explore hidden energy
saving potential.
It is possible to conserve 0.5 – 2% of annual electricity consumption by the efficient

use of on line energy monitoring system.
It is proposed to have on line energy monitoring for all motors above 50 kW. A
comprehensive on line energy monitoring system may include all HT auxiliaries ,
compressed air system, Ash handling plant, Coal handling plant, DM Water plant and
integrated lighting feeder. After commissioning of monitoring system, monitoring
schedule and system can be devised for effective use.
For motors below 50 kW rating, monitoring of energy and other parameters can be
done with the help of energy analyzer. With this palm top analyzer having its own
memory, it is possible to collect data of each motor at various locations for few hours.
The Data from this analyzer can be downloaded in a PC as per convenience. This
analyzer can measure all electrical parameters . Harmonic analysis can also be done.
112
Annexure 6
Variable Speed Drives For Fans

Although, variable speed drives are expensive, they provide complete variability in
speed control. Variable speed operation involves reducing the speed of the fan to meet
reduced flow requirements. Since power input to the fan is directly proportional to the
cube of the flow, this is the most efficient form of flow control. However, variable
speed control may not be economical where flow variations are less. Before
considering variable speed drive, comparative techno-economics of various control
system i.e. fluid coupling, eddy-current, VFD, etc. should be analysed,
COMPARISION OF VARIOUS FAN VOLUME CONTROL METHOD
PERCENT OF FAN VOLUME

COMPARISION OF VARIOUS FAN OUTPUT CONTROL METHODS.
113
VARIABLE FREQUENCY DRIVE
The speed of an induction motor is proportional to the frequency of the AC voltage, as

well as the number of poles in the motor stator. This is expressed as given below:
RPM = (f x 120) / p
Where f is the frequency in Hz, and p is the number of poles in any multiple of 2.
Therefore, if the frequency applied to the motor is changed, the motor speed changes
in direct proportion to the frequency change. The frequency control is done by VSD.
The VSD's basic principle of operation is to convert the electrical system frequency
and voltage to the frequency and voltage required to drive a motor at a speed other
than its rated speed. The two most basic functions of a VSD are to provide power
conversion from one frequency to another, and to enable control of the output
frequency
The variable frequency drive have an efficiency of 95% or better at full load.
114
Annexure 7
Polymer coating on water pump internals
A new technology has emerged, in which Polymer coating is provided on the pump
internals to improve the efficiency of the pump this hard layer of polymer also
provide increase in pump life. The supplier is providing polymer coating with
guaranteed 4% energy savings. Since it is a new technology and yet to be fully
proven, it is recommended to provide polymer coating on one of the water pump and
if proven successful, this can be extended to other pumps also.
115
Annexure 8
General guideline for overhauling of Circulating water
system and cooling tower system
Cooling Tower
Depending on the availability of type of cooling tower system/equipment following

job can be taken up for overhauling:
1. CT fan gearbox, backlash checking

2. CT gear box internal inspection
3. Oil seals replacement
4. Gear Box oil replacement
5. Foundation bolds, beam healthiness to be checked
6. Fan blades cleaning with soap etc.
CT internals as given below should be checked and attended.
1. Nozzle cleaning and replacement of damaged nozzles

2. PVC fills cleaning (for film type by water jet cleaning)
3. Damage fills replacement
4. Damage drift eliminators to be replaced
5. Cold water basin cleaning
6. Structure algae removal.
7. Anti-corrosive paint (EPCO 2020 TX, Tar extended amine adduct quick curing)
during capital O/H in cement structure (At least once in 10 years).
8. Any vegetation growth near CT which obstructs air flow to be cleared (to avoid
this permanently, ash brick paving can be done all around CT 10-15 meter Wide).
9. Painting of corroded pipes to be done.
10. Riser V/V's servicing to be done, if required (once in two years).
In addition to above following work should be taken up to improve CW-CT system

performance.
• CW Pumps internals should be checked and any damage to pump impeller or

other surface should be attended.
• On Line Tube cleaning System if not available, their availability is to be ensured.
• Chlorine dosing should be done regularly.
• De silting of intake canal & CT basin should be done.
• HP/LP bypass checking should be done.
• All the steam and water drain valves passing should be checked and attended.
• Ejector & vacuum pump performance should be checked. Nozzle diffuser air gap
to be checked.
• Helium test for air ingress in the condenser.
• Cleaning of hot well and stand pipe and inspection of butterfly valves
116
• Condenser flood test.
• CEP suction strainer cleaning and inspection of CEP suction valve gland sealing
& servicing.
Following are the recommendations made during a workshop on cooling towers and
can be used as check points
1. Permanent approach platform to gearbox from stock door to be provided in all
fans for ease in inspection and maint. It may be in the form of collapsible type so
that air path restriction can be avoided.
2. For inspection and maintenance of nozzles, fills, hot water distribution pipes in
counter flow tower the sufficient space may be provided between Drift Eliminator
and hot water distribution pipe. It must be minimum man height. Because of
smaller space drift eliminators (DE) have to removed every time and then only
inspection/maintenance of nozzles, water distribution pipes, fills can be done. In
this process the DE also get damaged and also it takes more time.
This is the main season which causes maintenance problems in counterflow
tower.
3. Proper working walkway above fills and below HWD pipes, to be provided
around covers and in central position for maint. of nozzles & pipes.
4. Based on the experience of various sites, double helical gearbox has been found to
be a better option for CT fan, whereas worm & worm wheel gearbox are
maintenance prone.
5. For replacement, G/B should be double helical gear type and service factor to be
not less than 3.
6. For the measurement of CT cold water temperature in the basin at least 2 RTD are
to be provided (in 1/3rd and 2/3rd depth of water flowing in CT cold water basin
outlet channel as per ATC-105) for averaging the temperature.
7. At CT cold water outlet, trash rack / sieve to be provided for removal of debris
etc. to prevent these going to condenser water box through CW pumps.
8. Vibration pick up to be provided in CT fan gearbox only and not on the motor. It
has been experienced in stations where motor did not trip and CT fan gear box
failure problem occurred though the vibration sensor mounted on motor was
working all right.
9. From design point of view Poppe method is assumed to be best in industry.
117
10. Delinking of CW system from other systems like Ash Water, Fire system for
technical reason due to chemical treatments etc. is proposed.
11. On-line measurement of key parameters of CW system such as pH, conductivity,
ORP, are proposed to be provided at proper locations.
12. Routine microbiological test kits to be made available.
13. In place of Cl2 the possibility of ClO2 system for CW water may be considered
for ease in maintenance.
14. Flow measurement provision of CW water in CW pipe inlet to CT and for air flow
in fan stack to be made.
15. On line monitoring equipment for scaling, fouling, corrosion and bio fouling to be
installed.
16. The cleaning of CT fills (film type) must be taken up about 50% every year
(mech. Cleaning) where clogging problem is there and CT effectiveness is poor.
17. The circulating water pH to be maintained between 7.5 to 8.0.
18. During long shut down proper preservation is to be carried out for film fills
cooling towers by dozing Chlorine at a level of 2 ppm before shutting down.
19. Chlorine dozing is to be done continuously in CW system with residual Chlorine
0.5ppm followed by shock dozing 1ppm once a day for one hour.
20. Cold water basin cleaning is to be done every year which is followed by most of
the stations.
21. CT fan gearbox oil to be checked for its quality by chemistry quarterly.
22. Periodic cleaning of film fills from controlled pressure water jet from bottom is to
be done once in 3 months.
23. Efforts are to be made to optimize the performance of clarifiers so as to achieve
minimum possible turbidity in the outlet water.
24. All around cooling tower area it should be cleared from trees, bushes for clean air
inlet to CT. About 30 mtrs. From CT paving with ash brick or lawn to be made.
Annexure 9
118
General guideline for overhauling of Flue Gas system
Following jobs may be taken up for flue gas system overhauling
Air pre heater area
Depending on the type of air pre heater availability following job can be done
1. Checking general health of air pre heater and associated ducting and reparing
if required.
2. checking of tube choking/fouling
3. checking of leakage, thinning of tubes etc.
If 10 % or more heater tubes are blocked than those tubes or sets should be replaced.
Electro Static Precipitator area
Depending on the type of ESP, following jobs can be done
1. Water washing of ESP internals

2. Cleaning of ESP hoppers
3. Inspection and replacement of Emitting Electrodes
4. Inspection and replacement of Collecting Electrodes
5. Inspection and replacement of Shock bar mechanism (shock bars, rapping shaft,
inner arms, collecting hammer, emitting hammer, plain bearings)
6. Inspection and servicing of Rapping mechanism (CRM, ERM gear box, drive etc)
7. Inspection and replacement of Gas distribution screen
8. Cleaning and repairs of Flushing apparatus
9. Cleaning and checking of support insulators and replacement of damaged
insulators
10. Cleaning and checking of shaft insulators and replacement of damaged insulators
11. checking and replacement hopper heaters and their thermostats
12. checking transformer rectifier unit, control cubicle their protection and interlocks
13. Overhauling of rapping motors
14. Alignment of fields
15. Trail charging.
Ducting
Following job may be done for duct overhauling.
1. Cleaning , inspection and repair of duct

2. Checking of all hangers and supports of duct and rectify as necessary.
3. Checking and repairing of duct internal support pipes and stiffeners.
4. Cleaning, inspection & repair or replacement of expansion joint.
5. Repair & replacement of duct walls based on the thickness survey during walls.
6. Replacement of all duct manholes packing rope / gaskets.
7. R&M work for fabric expansion joints.
119
Damper/Gates
Following jobs may be done for damper and gate overhauling.
1. Servicing of actuators. Replacement of worn out parts.

2. Checking/repair or replacement of gates/damper / shaft and bearings etc.
3. Repack glands with new graphite / carbon packing, as the case be.
4. Checking of seal air line
120
Annexure 10
UNIT AUXILIARIES POWER CONSUMPTION OBSERVATIONS ( UNIT#2 )
TEST 1 TEST 2 TEST 3
Phase Date Time Time Time P
S. NO. Description V kV I Amps PF F Hz P kW V kV I Amps PF F Hz P kW V kV I Amps PF F Hz
kW
1 BFP A R 9.1.07 11:00 6.5 140.3 11:05 6.5 139.8 11:10 6.5 135.8
Y 6.5 139.2 6.5 138.4 6.5 135.1
B 6.5 140.1 0.93 48.90 6.5 140.3 0.93 48.90 6.5 135.5 0.93 48.9
Average 6.5 139.9 0.93 48.90 1464 6.5 139.5 0.93 48.9 1460 6.5 135.4 0.93 48.9 1418
2 BFP B R 9.1.07 12:03 6.5 142.8 12:08 6.5 142.7 12:13 6.5 143.5
Y 6.5 141.2 6.4 141.1 6.5 142.3
B 6.5 141.2 0.94 49.20 6.4 141.4 0.94 49 6.5 142.0 0.94 48.90
Average 6.5 141.7 0.94 49.20 1500 6.4 141.8 0.94 49 1485 6.5 142.6 0.94 48.9 1509
3 BFP C R 9.1.07 12:36 6.5 130.7 12:41 6.5 137.9 12:46 6.5 130.2
Y 6.5 128.8 6.5 136.0 6.5 128.1
B 6.5 130.4 0.94 48.90 6.5 137.8 0.94 48.9 6.5 130.2 0.94 48.9
Average 6.5 130.0 0.94 48.90 1375 6.5 137.2 0.94 48.9 1452 6.5 129.5 0.94 48.9 1370
4 CEP A R 9.1.07 16:34 6.5 23.0 16:39 6.5 23.1 16:44 6.5 23.2
Y 6.5 22.8 6.5 22.7 6.5 22.8
B 6.5 23.1 0.87 48.80 6.5 23.2 0.87 48.90 6.5 23.1 0.87 48.80
Average 6.5 22.9 0.87 48.80 225 6.5 23.0 0.87 48.9 225 6.5 23.0 0.87 48.8 225
5 CEP B R 12.1.07 16:39 6.5 23.2 16:41 6.5 23.5
Y 6.5 23.0 6.5 23.3
B 6.5 23.2 0.88 48.90 6.5 23.6 0.88 48.90
Average 6.5 23.1 0.88 48.90 229 6.5 23.5 0.88 48.9 233
6 ID FAN A R 10.1.07 12:28 6.5 48.9 12:33 6.5 49.3 12:38 6.5 49.0
Y 6.4 47.7 6.5 47.9 6.5 47.9
B 6.5 48.3 0.75 48.90 6.5 48.4 0.75 49.1 6.5 48.3 0.75 49
Average 6.5 48.3 0.75 48.90 406 6.5 48.5 0.75 49.1 410 6.5 48.4 0.75 49 409
121
S. NO. Description V kV I Amps PF F Hz P kW V KV I Amps PF F Hz P kW V kV I Amps PF F Hz
kW
7 ID FAN B R 10.1.07 12:04 6.5 53.4 12:09 6.5 53.1 12:14 6.5 52.9
Y 6.4 52.5 6.4 52.1 6.4 51.9
B 6.4 52.7 0.78 48.90 6.5 52.4 0.78 48.8 6.5 52.3 0.78 48.8
Average 6.4 52.9 0.78 48.90 460 6.5 52.5 0.78 48.8 459 6.5 52.4 0.78 48.8 457
8 FD FAN A R 9.1.07 18:15 6.5 33.5 18:20 6.5 33.7 18:25 6.5 33.1
Y 6.4 32.9 6.4 33.2 6.4 32.5
B 6.5 33.4 0.86 48.90 6.5 33.6 0.86 49.4 6.4 33.0 0.86 49.1
Average 6.5 33.3 0.86 48.90 320 6.5 33.5 0.86 49.4 323 6.4 32.9 0.86 49.1 315
9 FD FAN B R 9.1.07 18:33 6.5 29.1 18:38 6.5 28.9 18:43 6.5 29.0
Y 6.4 28.3 6.4 28.2 6.4 28.1
B 6.5 29.1 0.85 48.90 6.5 28.8 0.85 48.9 6.5 28.9 0.85 48.5
Average 6.5 28.8 0.85 48.90 274 6.5 28.7 0.85 48.9 273 6.5 28.6 0.85 48.5 273
10 MILL A R 10.1.07 10:35 6.5 31.4 10:40 6.5 31.4 10:45 6.5 31.9
Y 6.4 31.1 6.4 30.7 6.4 31.3
B 6.5 31.0 0.78 49.10 6.4 30.9 0.78 49.20 6.5 31.5 0.78 49.00
Average 6.5 31.2 0.78 49.1 273 6.4 31.0 0.78 49.2 269 6.5 31.6 0.78 49 276
11 MILL B R 10.1.07 10:52 6.5 30.6 10:57 6.5 30.2 11:02 6.5 30.3
Y 6.4 29.6 6.4 29.6 6.4 29.6
B 6.5 30.1 0.78 48.90 6.5 29.8 0.77 48.90 6.5 29.9 0.77 48.90
Average 6.5 30.1 0.78 48.9 263 6.5 29.8 0.77 48.9 257 6.5 29.9 0.77 48.9 258
12 MILL C R 10.1.07 11:16 6.5 30.5 11:21 6.5 30.7 11:26 6.5 30.8
Y 6.5 29.6 6.4 29.6 6.4 29.7
B 6.5 29.9 0.77 49.00 6.5 30.0 0.76 49.00 6.5 30.2 0.77 49.20
Average 6.5 30.0 0.77 49 260 6.5 30.1 0.76 49 256 6.5 30.2 0.77 49.2 261
122
S. NO. Description V KV I Amps PF F Hz P kW V kV I Amps PF F Hz P kW V KV I Amps PF F Hz
kW
13 MILL D R 10.1.07 11:40 6.5 26.5 11:45 6.5 27.4 11:26 6.5 27.2
Y 6.4 25.9 6.4 26.7 6.4 26.5
B 6.5 26.0 0.73 48.90 6.5 27.0 0.74 49.00 6.5 26.8 0.74 49.00
Average 6.5 26.1 0.73 48.9 214 6.5 27.0 0.74 49 224 6.5 26.8 0.74 49 222
14 MILL E R 12.1.07 16:00 6.5 25.8 16:05 6.5 25.7 16:10 6.5 25.8
Y 6.5 25.4 6.5 25.3 6.5 25.4
B 6.5 25.7 0.73 48.8 6.5 25.6 0.72 48.80 6.5 25.6 0.73 48.90
Average 6.5 25.6 0.73 48.8 210 6.5 25.5 0.72 48.8 207 6.5 25.6 0.73 48.9 210
15 CWP A R 11.1.07 12:13 6.5 57.1 12:15 6.5 57.2
Y 6.5 55.9 6.5 55.7
B 6.5 56.1 0.83 48.9 6.5 56.2 0.83 48.9
Average 6.5 56.4 0.83 48.9 527 6.5 56.4 0.83 48.9 527
16 CWP B R 11.1.07 12:24 6.5 57.5 12:29 6.5 58.0
Y 6.5 56.3 6.5 56.9
B 6.5 56.0 0.83 49 6.5 56.6 0.83 49.1
Average 6.5 56.6 0.83 49 529 6.5 57.2 0.83 49.1 534
17 PA A R 9.1.07 17:57 6.5 28.8 18:02 6.5 28.8 18:07 6.5 28.8
Y 6.4 28.0 6.4 28.0 6.4 28.2
B 6.4 28.6 0.78 49.8 6.4 28.5 0.78 48.9 6.4 28.5 0.78 48.8
Average 6.4 28.5 0.78 49.8 248 6.4 28.4 0.78 48.9 247 6.4 28.5 0.78 48.8 248
18 PA B R 9.1.07 17:37 6.5 33.0 17:42 6.5 33.1 17:47 6.5 33.2
Y 6.4 32.2 6.4 32.3 6.4 32.4
B 6.5 32.8 0.84 48.9 6.5 32.9 0.84 49 6.5 33.1 0.84 49.1
Average 6.5 32.7 0.84 48.9 307 6.5 32.8 0.84 49 308 6.5 32.9 0.84 49.1 310

Phase Date Time Time V P Time V
S. NO. Description V kV I Amps PF F Hz P kW I Amps PF F Hz I Amps PF F Hz P kW
KV kW kV
123
19 SA FAN 1 R 10.1.07 13:05 0.4 34.5 13:10 0.4 34.5 13:15 0.4 34.8
Y 0.4 34.3 0.4 34.3 0.4 34.6
B 0.4 35.2 0.76 49 0.4 35.3 0.76 48.9 0.4 35.5 0.77 49
Average 0.4 34.7 0.76 49 19 0.4 34.7 0.76 48.9 19 0.4 35.0 0.77 49 19
20 SA FAN 2 R 10.1.07 15:30 0.4 33.1 15:45 0.4 32.2 15:50 0.4 33.1
Y 0.4 30.9 0.4 31.0 0.4 31.0
B 0.4 33.6 0.74 49 0.4 33.3 0.74 49 0.4 33.3 0.73 49
Average 0.4 32.6 0.74 49 17 0.4 32.2 0.74 49 17 0.4 32.5 0.73 49 17
124

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JOJOBERA THERMAL POWER STATION

(TATA POWER COMPANY LIMITED)

Auxiliary Power Consumption

Turbine Heat Rate and Efficiency

(1) Main Plant Area

(b) Ash Handling Plant & Other auxiliaries pump

(d) Compressed Air System

(e) Cooling Tower

Date PLF APC

09.01.07 100.03 8.97

10.01.07 99.91 8.68

11.01.07 100.14 8.67

12.01.07 99.06 8.70

The power consumption pattern of major auxiliaries are given below:

Specific energy Consumption of BFPs,

Specific Energy Consumption of CEPs,

Power Consumption in FD FANS, kW

Power Consumption in PA FANs, kW

Power Consumption of SA FANs, kW

AUXILIARY POWER CONSUMPTION

The comparative study of all BFPs is given below.

S.No Description Units BFP A BFP B BFP C

(a) Deterioration in performance of BFP

The energy saving potential is calculated below.

Designed SEC = 7.3 kW/T of feed water

Annual energy saving potential = 57*5300

Designed SEC = 7.3 kW/T of feed water

Designed SEC = 7.3 kW/T of feed water

The comparative study of all CEPs is given below.

S. No Description Units CEP A CEP B

SEC of CEP A = 0.68 kW/T of water flow

The comparison study of ID Fan is given below.

S. N0. Description Units A B

Expected saving in Power consumption = 67 kW

The comparative study of all FD fans is given below

S. N0. Description Units FD FAN A FD FAN B

Expected saving in Power consumption = 100 kW

PRIMARY AIR FAN

The comparative study of PA fans is given below:

S. N0. Description Units PA FAN A PA FAN B

COAL MILLING SYSTEM

Comparative study of all mills is shown below

MILL MILL MILL

Therefore considering all above it is recommended

The energy saving potential by three mill operation is given below:

CIRCULATING WATER PUMPS

OTHER SAVING POTENTIAL

(i) On line energy monitoring/management system

It is claimed by the vendors that it is possible to conserve 0.5 – 2% of annual electricity

Auxiliary power consumption of unit 2 for 2005-06 : 72.33 MUs

Wagon tripler-2→ Conveyor-1B→ Conveyor-1A→ Conveyor-2→ Primary Crusher-B→

Uncrushed Coal stacking

Wagon Tripler-1 → Apron feeder (AFD)-A → Conveyor-1A→ Conveyor-2→ Conveyor

Wagon tripler-2→Apron feeder (AFD)-B → Conveyor-1B → Conveyor-1A→ Conveyor-2→

Uncrushed Coal Reclaiming

Uncrushed coal yard→ Apron feeder (AFD)-C→ Conveyor-2→ Primary Crusher-A/B →

Crushed Coal stacking

Wagon Tripler-1 → Apron feeder (AFD)-A → Conveyor-1A→ Conveyor 2→ Primary

Wagon tripler-2→Apron feeder (AFD) B → Conveyor-1B → Conveyor-1A→ Conveyor 2→

Crushed Coal Reclaiming

Stockyard-1→ Conveyor11→ Conveyor-6→ Conveyor-7A/7B→ Conveyor-8A/8B→

Stockyard-2→ Conveyor15→ Conveyor-7A/7B→ Conveyor-8A/8B→ Conveyor-9A/9B

EQUIPMENT UNITS SEC kW