FTMG

CTDS

Project QAI
Engg.

Message by CTO
Mr. Debabrata Guha

Dear Colleagues,

Today, progress is synonymous with urbanization, higher

consumption of goods and services, industrialization etc.
Per capita electricity consumption is often used as a
measure of progress or growth. Unfortunately all the above
comes with an adverse impact on the environment,
specifically when it comes to fossil fuel based (thermal)
power generation.

We, as responsible professionals, have to be sensitive

towards the environment. "Responsible growth" and not
"growth at any cost", has to be our priority. We owe it to
our future generations.

In the developed countries electricity generation and

consumption has reached a level of saturation. In India,
we are still way behind the required energy generation (and consumption) to sustain the
intended economic growth rate. On personal consumption front, 'electricity for all' is yet
some distance away. Therefore, in India we need to add power generation capacity.
Coal based power plants will have to be built, as the renewable form of energy has its
limitations of predictability and continuity. India being a developing country, electricity
should also be available at an affordable cost.

All these together, pose a formidable challenge of producing affordable electricity with
minimum impact to the environment.

This edition of ‘Wattsup’, touches on the measures / technologies related to minimizing

the adverse environment impact of thermal power generation. In days to come with
newer technologies, I am sure more effective measures will be put in place.

Happy reading and all the best!!!

 FTMG
CTDS

Project QAI
Engg.

Message by Chief CE
Ms. Anjali Kulkarni

Dear Colleagues,
One of the greatest problems that the world is facing today is
that of environmental pollution, increasing with every passing
year and causing grave and irreparable damage to the earth.
Power plants, if not designed carefully, are major contributors to
environment pollution. Emissions from thermal power plants
include sulfur dioxide (SO₂), nitrogen oxides (NOx), carbon
monoxide (CO), particulate matter (PM) etc. Tata Power
constantly strives for utilizing technologies that can minimize the
emissions of these harmful components and protect the
environment. Hence, the ninth issue of ‘Wattsup’ is dedicated to
the Environment Protection Technologies.

In the technical section of this issue, we present to you a number

of technical papers, which will cover various technologies being
utilized as well as being studied further by Tata Power, for
reducing the environmental impacts like reduction in SOx, NOx, particulate matter etc. We hope
these technical articles interest you and provide an update on current developments in this area.

In an effort to provide knowledge sharing platforms, the Corporate Engineering Teams have been
arranging technical workshops, knowledge sharing sessions etc. Some of the outcomes have been
brought out in this magazine under section key highlights. The sections, 'Employee corner' and
'Fun at work' bring to you team's enthusiastic engagement in various organizational initiatives and
fun activities.

We again bring you a 'Technical quiz' on the topics covered in the current ‘Wattsup’ issue, which
awaits your attention! We have received an overwhelming response from the readers for the
Quizzes included in the last two issues. I thank all the readers for their great participation and
congratulate the winners of the first three correct entries. I look forward to your active
participation this time too!

Happy reading!!
 FTMG
CTDS

Project QAI
Engg.

Technical Article

Technologies for reduction in Particulate Matter from

Existing Thermal Power Plant
By Sanjay Raut, PE.
1. Preface
The Thermal Power Plants using coal as primary fuel face the challenge of
suspended particulate matter (SPM) through flue gas. The society felt the ill-
effects of pollution and therefore the authorities had to tighten the particulate
emission within limit. The pollution control legislation keeps on getting
stricter continually with the availability of better technology and resource. A
need has arisen to bring up the old pollution control equipment to the latest
level and the concept retrofitting evolved. The retrofitting concept have
revolutionized from the simple Part to Part replacement to renovation,
refurbishment, enhancement, upgradation, life extension, total replacement and incorporation of
latest techniques of energisation of TR sets for effective dust collection. This article details the
various technologies and retrofitting of old pollution control equipment for reduction of SPM.

2. Methods available for capturing SPM

There are many methods available for capturing the SPM from the flue gas:
• Cyclone separators: This technology uses inertial energy of suspended particles to separate
them from the medium. Cyclone separators are simple to operate and maintain and do not
require any auxiliary power. However, cyclone separators are not effective for capturing fine or
sticky particles.
• Fabric filter (baghouses): This technology uses mechanical filters made of fine fabric to
capturing the particles from the flue gas. This technology has very high efficiency (99.9%) for
both coarse and fine particles. However, fabric filter requires high maintenance, frequent
replacement and high auxiliary power consumption. Fabric material possess fire hazards during
operation.
• Wet scrubbers: This technology is based on the scrubbing of flue gas with spray of water. With
addition of chemicals to spray water this technology can be used for SOx control also.
• Electrostatic precipitators (ESP): Electrostatic precipitators use electrostatic attraction to control
particulate matter and can handle large volume of gases at low pressure drops. Electrostatic
Precipitators (ESP) is important device used to control the pollution by collecting dust particles
present in the flue gases. This technology has efficiency of >=99.5% up to 99.8%. It can
capture particles up to 10 microns size, below which it is difficult to capture.
To renovate the existing pollution control equipment, following methods are being practiced:
• Filling the dummy fields (casing without internals were installed at the initial stage)
• Introducing intermittent charging.
• Adding series fields to the existing ESPs.
• Addition of one more ESP pass parallel to the existing ESP.
• Replacing the internals and adding new internals by increasing the casing height.
• Introducing bag filter in the existing ESP casings.

3. Present Emission Norms

Ministry of Environment and Forest (MOEF) has updated environmental regulations applicable to
coal fired thermal power plants effective Dec 2015. The brief summary of present and revised
norms, as applicable to our power plants, is mentioned below.
Year of Param Present Norms Revised Norms
Commissioning eters (mg/Nm3) (mg/Nm3)
CGPL (Coastal Gujarat
Power Limited) – 5x 800 MW 2012 and 2013 SPM 50 50
Trombay Unit 5 – 500 MW 1984 SPM 150 100
Trombay Unit 8 – 250 MW 1990 SPM 100 50
Maithon Power Limited (2 x U1-2011
SPM 100 50
525 MW) U2-2012
Jojobera Unit 1 to 3 – U1-1996
1x 67.5 and 2x 120 MW U2-2000 SPM 75 100
U3-2001
Jojobera Unit 4 and 5- U4-2005
SPM 50 50
2 x 120 MW U5-2011
 FTMG
CTDS

Project QAI
Engg.

Technical Article
4. Need for Retrofitting
Precipitator is a static, effective dust-capturing device. After a passage of time, the
emission is more than what it is supposed to limit. It is acknowledged that the reasons could be
one or multiples of the factor outlined below:
• Change in environmental legislation.
• Change in fuel properties.
• Poor quality of fuel, alteration of fuel with respect to design.
• Change in boiler behaviour.
• Deterioration of boiler performance, use of multifuel firing, conversion of firing type and
change in the plant rating.
• Degradation of Precipitators performance due to:
• Poor electrical and mechanical condition like improper gas distribution, unstable
operating condition of precipitator, plant beyond serviceable conditions and ineffective
maintenance.

5. Basics of Electrostatic Precipitators (ESP)

The first patent for ESP was obtained by F.G.Cottrell in the year 1907 with application in chemical
industry. The latest ESP have evolved since then. The ESP consists of series of positively charged
electrodes (also known as Collecting Electrodes) which are in the form of plates. The negatively
charged electrodes also known as ‘Emitting Electrodes’, are placed in between two collecting
electrodes. The Emitting Electrodes are charged with very high voltage (80 to 110 KV) through
Transformers Rectifier set. This high voltage in the Emitting Electrodes with negative pressure
prevailing inside the ESP causes ionization of dust/ash particles of the flue gas. The negatively
charged ions (ash particles) gets attracted and deposited on the Collecting Electrode. The ash
accumulated on Electrodes need to be dislodged periodically. This is achieved by rapping the
electrodes based on the magnetic impulse or tumbling hammer system. The ash dislodged from
the electrodes is collected in the hoppers below and evacuated periodically.
The performance of an electrostatic precipitator is largely influenced by the following parameter
like inlet dust loading, resistivity of ash, flue gas temperature, sulphur content in coal, Na2O
content, moisture content in flue gas etc.

Flue gas temperature

Resistivity Vs Flue gas temperature Resistivity Vs Na2O Resistivity Vs Moisture Content
6. Renovation and Modernization (R&M) of ESP's to address Emission norms
Methods for R&M of the existing ESP are mentioned below:
6.1 Renovation of mechanical and electrical system.
• Filling of dummy fields: A number of earlier precipitator installations have been provided with an
added feature of dummy field either at inlet or outlet so that during later stages, these empty
sections can be filled with active components to provide additional collection area. Also,
anticipating the futuristic tough legislation, many plant owners for the green field application, today
specify the present emission with one field out of service per pass. This means, there will always
be one extra live field available and this may meet the future emission norms.
• Introducing intermittent charging: The precipitators installed in the early days were energized
with full wave TR sets. Most of the power supplies are provided with automatic spark limit control,
which uses SCR phase control to limit the power input to precipitators to the point of sparking. This
works well for low resistivity ash whereas there was a deficiency in the performance for high
resistivity dusts due to back corona. Increasing the power input beyond the onset of corona power,
not only wastes power but also degrades the precipitator emission. The intermittent charging
technique block certain cycles and allows current flow for a few cycles to achieve current limit. Its
aim is to produce high peak voltages and currents for a short time, while maintaining low average
current through the dust layer below the onset of back corona. This automatic optimization process
adjusts the charge ratio to eliminate back corona and results in better performance than the
conventional waveform.
• Refurbishment of existing ESP. The existing ESP components are replaced with improved
collecting electrodes or discharge electrodes or rapping system.
 FTMG
CTDS

Project QAI
Engg.

Technical Article
7. R&M of Jojobera Unit 1 ESP
The ESP of Jojobera Unit 1 was commissioned in December 1995. This ESP consists of
'Two Pass' of capacity 60% each. The design emission from Unit 1 ESP is at 150 mg/Nm3.
The performance of the ESP got deteriorated due to ageing of components. The particulate
emission norm applicable to Jojobera generating station was revised by MOEF as 75 mg/Nm3
while granting EC (Environmental Compliance) for Unit 5 in the year 2008. The Tata Power
management has decided to go beyond compliance requirement and adopt stringent norm of 30
mg/Nm3. The necessary work for R & M of Unit 1 ESP includes following:
• Addition of New stream which is necessary for enhancing the performance of ESP.
• The ESP was designed for Indian coal with ash content of 45% and inlet dust loading of 65.28
gm/Nm3. Due to deterioration in coal quality and mines availability, the ash content in coal has
increased to 60.15% (IB Valley Coal) which has resulted in increase in inlet dust loading on the
ESP. This requirement has to be met by providing an additional pass. Considering the above, it
was decided to add new stream parallel to the existing passes.
• Conventional single phase TR set to be upgraded with 3 phase TR set and controller system.
• Complete replacement of internals for existing streams of ESP including its associated
electrical and control system.
• Energy Performance Management System (EPMS) will help in optimising the power
consumption based on the SPM as measured at stack (opacity signal). An outlet emission
signal, 4-20 mA is connected to the number of ESP-rectifiers selected for this control.

8. Conclusion
This paper outlines briefly the various options available for Renovation & Modernization of the
existing ESP's being implemented. Based on the technology available and in-situ site condition,
options need to be evaluated and considered for retrofitting the existing ESPs to enhance the
performance■
 FTMG
CTDS

Project QAI
Engg.

Technical Article

Flue Gas De-sulphurisation technologies- Making air

cleaner than before
By Vaibhav Korgaonkar, PE.
1. Preface
Due to rapid industrialization and improved standard of the living of the
people, energy demand has increased significantly in last few years.
Considering major contribution of coal based thermal power generation in
India, the coal consumption has increased, so has air pollutant emissions
such as SOx, NOx and PM (Particulate Matter). Coal naturally contains a
significant amount of sulfur content which during combustion process gets
converted to sulfur dioxide (SO2) compound and released though flue gas
exhaust. This paper discusses the various abatement techniques used for SO2.

2. SOx emission by thermal power plants and its impact

As per CSE(Center for Science and Environment) report (2014-2015), Coal-fired power plants are
major source of air borne pollution including SOx, NOx and PM. The graph below indicates the
contribution of coal based thermal power plants in industrial pollution due to these pollutants.
Out of these pollutants, SO2 is one of the most
hazardous pollutant as it can have several ill
effects on the human health and
environment/ecology. Some of the hazardous
effects of the SO2 emissions are as follows:
• Impact on Human health: Long time
exposure of SO2 in air may lead to diseases of
eyes, nose, bronchus etc.
• Bad effects on vegetation: Decrease in
growth and production of plants by interruptions
in photosynthesis process. This also leads to
stunted plant growth, species decline etc. as
long term impacts.
• Bad effects on ecology: Destruction of ecosystem by acidifying land or river due to acid
rain or acid snow.
• Decreased visibility in surroundings: Decrease visibility by absorption or diffraction of sun light
in atmosphere along with floating particles.
• Creates corrosive environment: Corrosion of architecture, structures, buildings, equipment,
historical statues/ monuments which are national heritage.

3. Environmental norms for SOx abatement at Thermal Power Plants

Considering the impact of the coal based thermal power plant on the air borne pollution, the
Ministry of Environment, Forest & Climate Change (MoEF&CC) announced in December 2015
stringent standards for coal-based thermal power plants. The new standards aim to drastically
curtail emissions of particulate matter (PM), Sulphur dioxide (SO2), oxides of nitrogen (NOx) and
mercury. The emission norms are per MoEF notification in December 2015 are summarized in
below table:
Emission normsParticulate
for Thermal power
SO2plants (MoEF notification
NOx dated Dec 2015) Mercury
. Standards Matter (mg/Nm3) (mg/Nm3) (mg/Nm3)
(ppm)
Current Standards 150-350 None None None
New Standards
Units installed till 100 <500MW: 600 600 >=500 MW:
2003 >= 500 MW: 200 0.03
Units installed 50 500MW: 600 300 0.03
between 2004 to >= 500 MW: 200
2016
Units installed after 30 100 100 0.03
Jan 2017
The newly introduced norms for SO2 emissions would necessitate FGD (Flue Gas
Desulphurization) system installation for thermal power plants where the current emission levels
are above applicable norms.
 FTMG
CTDS

Project QAI
Engg.

Technical Article
4. Various technologies for SOx abatement
4.1 Wet FGD:
• The wet FGD makes use of reagent slurry for flue gas scrubbing process. Usually used reagent
chemicals are- Limestone (Ca(OH)2), Ammonia (NH3), Magnesium carbonate or Sodium
bicarbonate.
• Limestone based wet FGD generates gypsum as a by-product which can be used by cement
industry and other gypsum applications. Similarly FGDs based on Ammonia as reagent for
scrubbing flue gases generates Ammonium sulphate as byproduct which finds application as
fertilizer. The most popular reagent is Limestone due to easy availability, low cost and gypsum
generation as byproduct. Among Wet FGD installations globally, majority are limestone based
designs.
• Chemical Reaction-
• Limestone based FGD: CaCO3 + SO2+ 2H2O+ ½O2  CaSO4 2H2O (Gypsum) + CO2
• Ammonia based FGD: 2NH3+SO2+2H2O  (NH4)2SO4 (Ammonium Sulphate)

Typical process flow diagram of Wet FGD process using Limestone

4.2 Dry FGD
• Dry FGD uses Quick Lime (CaO) in dry powdered form for flue gas scrubbing process
• This technology is not very popular in thermal power plants due to difficulty in disposal and no
reuse of waste byproduct (Calcium sulphite).
• Chemical Reaction:
CaO (Dry Lime) + H2O  Ca (OH)2
Ca(OH)2 + SO2 → CaSO3 (Calcium Sulphite) + H2O
4.3 Sea water based FGD
• This technology makes use of
naturally available alkalinity of the
Sea water for scrubbing the flue
gases for absorbing the SO2.
• The seawater discharge post
scrubbing passes through aeration
and dilution stage. The pH and
dissolved oxygen levels of seawater
are maintained prior to discharge
back to sea. The SO2 is absorbed
and converted to sulphate which is
natural constituent of seawater.
Typical process flow diagram of Sea-water FGD
4.4 Other new technologies-
• Amine based FGD and activated coke based FGD are two newly developed technologies.
• Both of these regenerative reagent type processes produce the Sulphur rich gas or solution
which form Sulphuric acid as a byproduct. The Sulphuric acid can be stored and supplied for
use in for industrial processes.

5. Selection of FGD technology

Selection of FGD technology as a retrofit option mainly depends on following factors:
 Technical: Existing SO2 emission levels, SO2 removal efficiency, location of the plant
(inland/coastal/access to reagent source), space requirements, process water requirement,
wastewater quality/quantity & treatment required, outage requirements, layout feasibility,
quality/quantity of waste byproduct generated & its disposal/reuse, provenness of technology etc.
 Commercial: Cost of reagent chemical sourcing, availability of reliable suppliers for reagent,
feasibility of disposal/reutilization of waste byproduct generated, off-takers for byproduct, selling
price expected from waste by product, logistics arrangement for reagent & waste byproduct
generated.
 FTMG
CTDS

Project QAI
Engg.

Technical Article
 Economical: Capital cost, Operating cost (Cost of reagent chemical, cost of utilities
required and cost of increased Aux. power consumption), Impact on tariff, Development of
techno-economically feasible model for reuse of waste byproduct.
Considering the Sulphur absorption required to meet the new regulations, reagent availability,
saleability of by product, footprint, proven nature of technology and cost effectiveness, limestone
based wet FGD is generally considered techno-commercially optimum option for desulphurization
of flue gas for at inland power plants in India.
For coastal power stations having access to seawater, the Sea water FGD is optimum technology
option for desulphurization of flue gas considering the proven nature of technology, no reagent
sourcing/handling concerns, moderate footprint requirements, moderate to low auxiliary power
consumption, no issues with waste disposal and lower CAPEX/OPEX compared to other reagent
chemical based FGD technologies etc.
Tata Power has been pioneer in the SOx abatement using FGD system with it's Seawater FGD
installed at Trombay Unit 5 which is India's first FGD installation in thermal power plant. Various
other installations of Tata Power such as 2x525 MW Maithon Power Limited and 5x 800 MW
CGPL plant had maintained space provision for FGD retrofit.

6. Challenges in FGD retrofit in existing plants

 Limited area within existing unit and Layout Constraints: In case of limestone based wet FGD
substantial area is required for facilities like limestone handling/storage, gypsum handling/storage,
slurry preparation system, gypsum dewatering system, waste water treatment plant etc. Absorber
tower and GGH (Gas to Gas Heat Exchanger) need space close to chimney which becomes
difficult if sufficient space is not provided in original layout.
 The installation of seawater FGD as well needs substantial footprint for scrubber tower and
auxiliary systems, seawater supply and seawater treatment scheme etc.
 Sourcing of seawater for FGD: Seawater for FGD scrubber requirement is usually about 20-
25% of total CW flow rate of the unit. In case of OTC (Once Through Cooling) system based on
seawater it is generally possible to tap it from CW outlet by suitable means.
 Treatment of FGD outlet seawater: The seawater treatment needs an elaborate system for
dilution and aeration. Construction of the dilution and aeration basin alongside the existing outfall
channel/ seal well and its connection would be challenging task.
 Sourcing and Logistics of Limestone:The plant would need access to the limestone on
continuous basis for the operation of FGD. The same may be constrained in many areas due to
logistical issues / availability issues (For 1000 MW limestone requirement would be approx. 300
TPD)
 Disposal of gypsum: Large quantity of Gypsum will be generated on a daily basis that would
need large storage pond and evacuation facility (For 1000 MW Gypsum generated daily would be
approx. 550-600 TPD).
 Waste water treatment: The waste water from limestone FGD would require the treatment
system to effectively treat the effluent and maintain ZLD condition for plant. The waste water bleed
from FGD process will generally be less than 5-10 cum/hr for typical 500 MW unit FGD.
 Increase in Aux. power requirement (approx. 0.8 to 1.5% depending on the technology and
plant constraints) and may need major augmentation in electrical power supply system to meet this
Aux power requirement
 Increased OPEX for sourcing reagent for reagent scrubbing based FGD (Limestone). Some
portion of reagent cost can be offset by selling of the waste by-product if suitable means of off take
and reuse are established.

7. Way forward and conclusion

As the FGD technology has not been widely used in Indian power sector, the CAPEX and OPEX
requirements in the Indian context are yet to be established and may vary site to site. However the
recent movement of power industry towards implementation of SOx abatement technologies will
play a vital role in minimizing the impact of thermal power plants on environment and build cleaner
future.
For inland power plants the limestone based wet FGD is most popular choice considering the
techno- commercial advantages such as availability of Limestone and reusable byproduct Gypsum
whereas for coastal power plants seawater FGD is generally considered most optimum solution.
There are several other alternate technologies such as Ammonia based FGD, Amine based FGD
and Activated coke based FGD which may also become feasible in future, if the means for
disposal/consumption of waste byproduct (ammonium sulphate or sulphuric acid) are established.
The choice of techno-commercially best suited technology needs to be made considering techno-
economic analysis for the specific plant.
Presently Project Engineering is finalizing the techno - commercially best suited and optimum
design solution for FGD implementation at our operating thermal power stations■
 FTMG
CTDS

Project QAI
Engg.

Technical Article

NOx - Emission & Abatement in Thermal Power Plants

By C P Tiwari, CTDS.

1. Preface
Ministry of Environment, Forest & Climate Change (MOEF & CC) issued
notification on 07th December 2015 in which Environment (Protection) Rule
1986 has been amended. As per notification, limit of Nitrogen Oxides (NOX)
emissions from Thermal Power Plants (TPPs) have been notified. Due to
above notification, NOX emission has become an important consideration in
design and operation of Boilers installed in TPPs.
This paper discusses about basics of NOX, National & International norms
for NOX emission from Thermal Power Plants (TPPs), Type of NOX,
Technologies for NOX abatement and effect of NOX on human health &
atmosphere.

2. Nitrogen Oxides (NOX)

Nitrogen Monoxide (NO) and Nitrogen Dioxide (NO2) are byproduct of combustion process of any
fossil fuel collectively referred to as Nitrogen Oxides (NOX). NOX is formed by the reaction of
atmospheric nitrogen or fuel nitrogen at high temperature. At ambient conditions, nitrogen and
oxygen in air are stable and non-reactive.

3. National & International limit for NOx emission from TPPs

As per notification dated 07th Dec 2015, NOx limit for TPPs in India is as under:

TPPs installed before 31st TPPs installed after 1st TPPs installed after 1st
December 2003 - 600 Jan 2004 till 31st Jan 2017 - 100 mg/Nm3
mg/Nm3 December 2016 - 300
mg/Nm3
International limit for NOX emission is as under:
World Bank: with Volatile Matter > 10%, 750
China: for unit installed before 2004, 200 mg/
mg/ Nm3 and with Volatile Matter <10%, 1500
Nm3 and for unit after 2004, 100 mg/ Nm3.
mg/ Nm3
International NOx Standard
European Standard: for 50 - 100 MW Unit -
USA: 117 mg/ Nm3 300-400 mg/ Nm3, for more than 100 MW -
200 mg/ Nm3
4. Type of NOX
Depending on origin of formation, NOX can be categorized as Fuel NOX and Thermal NOX.

Fuel NOX Thermal NOX

N2 for NOX formation originates from N2 for NOX formation originates from
originally bound compound of fossil fuels atmospheric air. Thermal NOx is
and account for up to 80% of total NOX in dependent on combustion temperature,
uncontrolled combustion. Fuel NOX is N2 and O2 concentration & time and
high for coal having high reactive nitrogen increases with increase of any of these
generally in proportion to volatile matter. parameters.
5. Factors affecting NOx formation
Factors affecting Fuel and Thermal NOx formation are as under:
• Coal with lowest fuel nitrogen content and lowest fuel oxygen / nitrogen ratio will generally
produce lowest NOX.
• Fuel NOX formation depends on availability of oxygen to react with the fuel nitrogen during
combustion. The compound that evolves from coal particle like HCN or NH3 will convert to NOX in
air rich atmosphere.
• Fuel NOX can be minimized by controlling the quantity of air permitted to mix with the fuel in
early stages of combustion. Low NOX burners are designed to minimize volatile Nitrogen
conversion to NOx by establishing early ignition and O2 staging.
• The contribution of Thermal NOX to total NOX can be minimized by operating boilers at lowest
permitted excess air & minimizing gas temperature throughout furnace by using low turbulence
diffusion flame and large water cooled furnaces.
 FTMG
CTDS

Project QAI
Engg.

Technical Article
6. Technologies for NOx Abatement
Technologies for NOx abatement can be broadly classified into following categories:
• Combustion Control like Combustion Tuning, Low NOx Burners & Air Staging
• Post Combustion Control like Selective Non Catalytic Reduction (SNCR), Selective Catalytic
Reduction (SCR) & Hybrid System

6.1 Combustion Control like Combustion Tuning, Low NOx Burners (LNBs) & Air Staging
Low NOx Burners (LNBs) regulate the initial fuel-air mixture, velocities, and turbulence to create a
fuel-rich flame core, and control the rate at which additional air required to complete combustion is
mixed. This ensures early de-volatilization of coal & avoids highly oxidized environment conducive
to NOx formation.
Air Staging & Advanced Over fire Air (AOFA) technology involves injection of air above the primary
combustion zone to allow the primary combustion to occur without amount of oxygen needed for
complete combustion. This oxygen deficiency reduces fuel NOx formation. Over fire air injected at
high velocity, creates turbulent mixing to complete the combustion in a gradual fashion at lower
temperatures to mitigate thermal NOx formation. Usually, AOFA is used in combination with LNBs
and can reduce NOx up to 60% when system is supplied and installed in new Boilers. In retrofit,
maximum possible NOx reduction using combustion control techniques depends of furnace size,
furnace height, coal quality etc. In general, in applying combustion control techniques, unburnt
carbon in fly ash increases. Increase in unburnt carbon due to use of combustion control
technologies for NOx control shall be one of the important consideration.
6.2 Selective Non Catalytic Reduction (SNCR), Selective Catalytic Reduction (SCR) & Hybrid
System
The SCR and SNCR technologies can be used alone or in combination with combustion control
technologies or SNCR along with SCR (Hybrid System). These processes use ammonia or urea in
a reducing reaction with NOx to form elemental nitrogen and water.
The SNCR system can only be used at high temperatures (800 ºC –1200 ºC) where a catalyst is
not needed. Generally, SNCR systems alone can achieve NOx emission reductions of 30%–50%
percent. Use of SNCR system was limited to smaller unit size. However with new technologies of
ammonia injection into furnace (like Umbrella SNCR System developed by Alstom / GE), SNCR
System can be used in large unit also.
The SCR system is
typically applied at
temperatures between
300 ºC – 400 ºC. The
SCR system is located
between downstream of
the boiler economizer
and upstream of the Air
Preheater.
In SCR catalyst is
utilized which promotes
a chemical reaction
between nitrogen oxides
(NOx) and ammonia
(NH3) to produce
nitrogen (N2) and water
vapor (H2O). The NOx SNCR System
reduction reaction takes places as the flue gas passes through the catalyst in the SCR reactor. In
addition to NOx reduction process, certain undesirable reaction also take place like formation of
Ammonium Bisulphate. Ammonium Bisulphate will foul in air preheaters and will reduce its
efficiency. Ultimate Goal of SCR designer is to minimize undesirable reaction and ammonia slip.
SCR catalyst of
varying configurations
and formulations are
available from a
number of
manufacturers
worldwide and must
be selected to meet
the specific
performance
requirements.
SCR System
 FTMG
CTDS

Project QAI
Engg.

Technical Article
SCR catalyst for Indian coal ash is not yet proven and different types of catalyst are being
tested in one of the NTPC project for deciding type of catalyst to be used for Indian coals.

SCR Catalyst
Ammonia storage and injection system is required in both SCR and SNCR System.

SCR System SNCR System

• NOx reduction - 80% to 95%
• Aux Power Increase - up to 0.5%
• Reagent - Ammonia or Urea
• Reaction Temperature - 300 0C - 1200 0C
• Capital Cost - High compared to SNCR
• Catalyst - Required, contains heavy metal.
• Disposal and recycling of catalyst is
required.
• Life of Catalyst - 6 to 10 years
• NOx reduction - 30% to 50%
• Aux Power Increase - up to 01% - 0.3%
• Reagent - Ammonia or Urea
• Reaction Temperature - 800 0C - 1200 0C
• Capital Cost - Low compared to SCR
• Catalyst - Not Required

Comparison of SCR and SNCR System

7. Effect of Nitrogen Oxides (NOX)
In atmosphere, NOX and volatile organic compound (VOCs) react in presence of sunlight to form
ground level ozone, the major constituent of photochemical smog. Unlike ozone in the
stratosphere, ozone at ground level has strong negative impact on human health and environment.
It impairs lungs function and aggravates heart diseases, respiratory diseases such as Asthma and
Bronchitis. NOX reacts with oxygen and other compound of air to form nitrates which coalesces
into fine particles which is also a main cause for respiratory diseases. NOX also contributes to acid
rains which can destroy fish and other form of fresh and coastal water life and damage building,
material, forest and agricultural crops.

8. Conclusion
NOX emission in TPPs is becoming an important issue due to focus on reduction of gaseous
emission across globe. It has become an important issue in Indian context due to recent
environmental norms.
NOX generated in TPPs consist of Thermal and Fuel NOX. NOX reduction in TPPs is possible by
using combustion control technologies like Low NOX Burner, air staging etc. or by using post
combustion technologies like SCR and SNCR. SCR technology is widely viewed as most effective
NOx abatement technology with NOx removal efficiency 80% - 95% especially for future units with
NOx limit of 100 mg/Nm3. However for existing units in India for which NOx limit is 300 mg/Nm3, low
cost combustion control technologies like LNBs, air staging etc. shall be used for reducing NOx
level to lowest value possible. Incase even after using combustion control technologies, NOx
emission is not reduced to desired limit, other NOx abatement technologies will be used.
Measurement of NOX is also an important issue. It is very important to use right conversion factor
for converting NOX usually measured in ppm to mg/Nm3■
 FTMG
CTDS

Project QAI
Engg.

Technical Article

ReACT - Integrated Gaseous Emission abatement

Technology By C P Tiwari, CTDS.

1. Preface
In the recent environmental notification, Ministry of Environment and Forest
(MOEF) has specified limits for emission of Nitrogen Oxides (NOx) and
Sulfur Oxides (SOx) and Mercury (Hg) from Thermal Power Plants (TPPs)
emission. As per this notification more stringent limit for Suspended
Particulate Matter (SPM) will be applicable for existing as well as new
plants. The new MOEF notification necessitates requirement of Integrated
Gaseous Emission abatement technology for existing as well as new TPPs.

ReACT - Regenerative Activated Coke Technology is an integrated gaseous emission

abatement technology, developed by J Power Japan. Hamon Research-Cottrel is Licensee of
ReACT since 2010. This paper discusses how ReACT technology can be utilized to reduce the
environmental impact of TPPs.

2. Brief of Technology
ReACT is Integrated Multi-pollutant Control Technology in which Flue Gas (FG) flows over moving
bed of Activated Coke (AC) having very high specific surface area up to 300 m3/gm. Contact of FG
with AC provides mechanism for efficient absorption of SOx, Hg, SPM and surface promoted
catalytic and non-catalytic NOx reduction (low temperature SCR reaction). In order to promote the
reaction and absorption process, ammonia is also injected in FG stream. SOx is absorbed in AC
as H2SO4 or Ammonium Bisulphate (NH3)2SO4. AC also absorbs all forms of Hg and other acidic
gases. In presence of Ammonia, NOx is reduced to N2.
Absorption Stage Generation Stage By-Product Recovery Stage

During regeneration, AC is heated, absorbed species leaves and decomposes. H2SO4

decomposes to H2O and SO3. Ammonium Bisulphate (NH4)2SO4 decomposes into NH3 and SO2.
NH3 is reabsorbed in AC & improves later activity of NOx reaction. Sulfur rich gas is feedstock for
acid plant. Sulfuric acid is by product of process.
During the regeneration process, fines of AC is generated which can be used in boiler as fuel or
some other purpose. Make-up of fresh AC is required to compensate the loss due to fines.

3. Benefit of Technology
ReACT Technology has following benefits:
• Integrated Multi-pollutant Control Technology - Control of SOx, NOx, and Hg. System also works
as flue gas polisher.
• Little or no water use.
• Acid - Saleable by product.
• No change in existing Ash Handling System, Boiler and ESPs
• No change in flue gas temperature. Lining in stack is not required.
• Avoidance of Limestone and Gypsum (By Product) handling system & its related pollution
associated with wet lime stone FGD
 FTMG
CTDS

Project QAI
Engg.

Technical Article
• Small foot prints - Estimated space requirement for 2 x 525 MW Maithon project is
6000 to 7000 m2 (less than 2 acres)
• System is designed for full load flue gas flow with maximum SOx concentration. At part load,
system efficiency further improves.
• Minimum waste from system - closed loop for purged gas, AC fines used in boilers, No solid
waste.
• Acid is by product of process. Need not to consume chemicals for neutralization of Sulfur
captured during process.
• Technology can be used for >95% SOx control, 20% to 80% NOx control, flue gas polishing and
>95% Hg Control.

4. Operating Cost Components

Operating Cost in ReACT system includes:
• Ammonia consumption
• Activated Coke make-up
• Higher ID Fan Power Consumption (applicable in Green Field Projects)
• Booster Fan Power (applicable in retrofit projects)
• LDO consumption for regeneration.
• Auxiliary Power Consumption for Regeneration

5. Operating Plants with ReACT Technology & Demonstration Projects

ReACT Technology is already operating in J Powers 2 x 600 MW Isogo (First unit 2002, Second
Unit 2009) in Japan. Hamon USA are in final stages of commissioning of ReACT system for 1 x
360 MW coal fired power plant as Wisconsin, USA.

6. ReACT System for 2 x 525 MW Maithon Plant

Feasibility of installing ReACT System for 2 x 525 MW Maithon Plant is being studied along with
Hamon-Research Cottrell India Pvt Limited. Following design parameters are being considered for
preliminary design of ReACT System:
• Inlet concentration of SOx: 1400 mg/Nm3
• Inlet concentration of NOx: 529 mg/Nm3
• Flue Gas Flow - 522 Nm3 / sec
• Flue Gas Temp -120 0C
• Outlet concentration of SOx and NOx for design of ReACT: 180 mg/Nm3 and 280 mg/Nm3
respectively.
Presently Maithon Boilers are designed for NOx emission up to 880 mg/Nm3 which will be reduced
below 500 mg/Nm3 using various in furnace control like combustion optimization, low NOx burner
etc.
Design outlet SOx and NOx level have been considered 20 mg/Nm3 less than the new
environment norm.
Details of Proposed ReACT System for each 525 MW Unit
Moving Bed Absorption Budgetary capital cost,
3 x 12 (size 4.2m x 4.2m x 18m) Operating Cost including
Cartridge for each 525 unit:
No of regenerator per unit: 3 Nos cost of AC, source of AC
etc. is being discussed
AC required (first fill) 4500 T
with Hamon-Research
AC make-up requirement: 0.5 T/hr Cottrell for completing
Ammonia Consumption 642 kg/ hr techno-economic analysis
of ReACT System for
H2SO4 Production Rate 90 - 100 TPH
Maithon Project.
System Pressure Drop 3 Kpa
7. Conclusion
ReACT is a promising technology as this can be used for integrated SOx, NOx, Hg control and FG
Polishing. For optimum sizing of ReACT system, NOx at inlet of ReACT system shall be less than
529 mg/Nm3 to get outlet NOx level less than 280 mg/Nm3. This will be achieved by combustion
optimization, using Low NOx Burners (LNBs) and air staging. Major consumables in ReACT
system is activated coke for which domestic supplier is not available and presently we need to
depend on Chinese supplier. Hamon Research Cottrell is already in discussion with Indian
manufacturers for manufacturing activated coke of required specification in India. Once such
suppliers are available, cost of activated coke as well as techno-economic of ReACT system may
be viable and competitive compared to SCR & FGD System for Indian Projects■
 FTMG
CTDS

Project QAI
Engg.

Technical Article

Air Cooled Condenser

By Dheeraj Pareek, QAI.

1. Preface
Is there enough potable water to fuel India's power expansion? Avoid usage
of more water and start conserve water…. The production of electricity
requires reliable, abundant, and predictable source of freshwater, a precious
resource which is limited throughout the world. The process of power
generation from fossil fuels such as coal, oil, and natural gas are all water
intensive. Particularly in country like India, which has nearly 330 GW
installed power generating capacity, out of which nearly 220 GW are thermal
power plants. A huge amount of water is required only for cooling purpose.

Water is one of the key input requirements for thermal power generation, for process cooling in
the condenser, ash disposal, removal of heat generated in plant auxiliaries, and various other
plant consumptive uses. For power plants located on main land, the raw water is generally drawn
from fresh water source such as river, lake, canal, reservoir, and barrage. For power plants
located in coastal areas, water for cooling of condenser and auxiliaries is drawn from the sea or
creek which provides for water requirement of the wet ash handling system also. The requirement
of water for other plant consumptive uses is met from an alternative source or by installing
desalination plant.

Coal bearing states like Orissa, Jharkhand and Chhattisgarh are already facing difficulties in siting
thermal power plants due to non-availability of water. Also, in states like Rajasthan, the land is
available in plenty but there is scarcity of water. Naturally drinking and irrigation uses of water
have got priority over industrial uses. Thus, there is a need to minimise consumptive water
requirement for thermal power plants.

In such areas where there is acute shortage of water, use of dry cooling system for condenser
cooling can be explored as it helps us to save huge quantity of water with respect to conventional
cooling system. This articles discusses the use of dry cooling system to minimise water usages in
power plants.

2. Conventional cooling water system

Cooling water is required for condensing of steam in a surface condenser and for secondary
cooling in heat exchangers of equipment cooling system for plant auxiliaries. Typically, 3.5 m3/hr
water is required for a coal based thermal power plant with cooling towers. For a typical 500 MW
coal fired unit, the amount of cooling water required for condenser and auxiliary cooling is of the
order of 60,000 m3/h with temperature rise across the condenser about 9.50C. Once through type
cooling systems were installed in only coastal thermal power plants using sea water with max
temperature rise of 70C.

3. Water minimisation by use of dry cooling system

In a conventional wet cooling tower, hot water is cooled by direct mixing with ambient air resulting
in evaporation of a part of circulating water, and make up water is required to compensate for loss
of water due to evaporation, drift and blow down water.
Dry cooling systems do not require any make up water as rejection of power cycle waste heat
from condenser to atmosphere takes place by sensible cooling in finned tubes by ambient air and
no evaporative cooling is involved.
Dry cooling systems can be broadly classified in two
categories viz.
• Direct dry cooling system
• Indirect dry cooling system
In direct dry cooling system (refer fig.1), exhaust steam
from turbine is directly cooled in a system of finned tubes
by ambient air using mechanical draft fans or natural
draft hyperbolic tower. In an indirect dry cooling system
(Heller system), exhaust steam from the turbine is cooled
by water in a surface or jet condenser and hot water is
cooled by air in finned tube bundles using mechanical
draft fans or natural draft hyperbolic tower.
 FTMG
CTDS

Project QAI
Engg.

Technical Article
In case dry cooling system is adopted for the condenser, wet cooling tower is required
only for ACW (auxiliary cooling water) flow and requirement of plant make- up water is
considerably reduced. Since Cooling Tower (CT) make up water constitutes major part of plant
consumptive water, use of dry cooling system results in reduction of plant consumptive water by
about 70%. The requirement of plant consumptive water can be further reduced by adopting dry
cooling mode for ACW flow also, using air cooled heat exchangers.

Direct dry cooling system:

In direct dry cooling system, exhaust steam from LP turbine is directly cooled in a system of finned
tubes by ambient air. Mechanical draft or natural draft in a hyperbolic tower can be used to move
the air through fin tube heat exchange elements. Majority of direct dry cooling installations employ
mechanical draft fans and are termed as air cooled condensers (ACC).

A typical schematic of direct dry cooling ACC is indicated below (refer fig.2). The finned tubes are
generally arranged in the form of an ‘A’ frame (or delta) over a forced draft fan with steam
distribution manifold connected horizontally along the apex of ‘A’ frame. An ACC for a typical
power plant consist of several such ‘A’ frame structures each comprising of several cells. Each cell
consists of a number of finned tube bundles arranged in parallel along two walls of ‘A’ frame cell.
Steam flowing down inside the tubes condenses due to the cooling effect of ambient air drawn
over external finned surface of the tubes by the fans. The condensate drains from finned tubes
into condensate manifolds and then drains into a condensate tank before being pumped to the
conventional condensate cycle. To reduce pressure drop in steam conveying system, ACC needs
to be installed close to the turbine hall.

Fig.2 Schematic of an Air Cooled Condenser

• The inclined exhaust duct routing reduces the steam side pressure drop between turbine and
condenser and saves duct material as well as man power for manufacturing and erection.
• The supporting structure of the Air Cooled Condenser platform was derived from nature and
therefore called “bionic design”. This design reduces the number of foundations and saves
structure material as well.
Some of finned tubes used in ACC:
Alex tube
• Flat shape steel with aluminium coating.
• Meandering form of aluminium fins.
• Connection by brazing.

A tube
• Elliptical core steel tube.
• Rectangular steel fins.
• Connection by hot dip galvanizing
 FTMG
CTDS

Project QAI
Engg.

Technical Article
4. Benefits of ACC:
• No need for water availability on site, Good amount for water saving.
• Flexibility in the selection of the power plant site (grid proximity, land cost, fuel source proximity)
• High performance finned tubes with excellent cleaning ability for long term availability.
• A-Frame supported tube bundles, allowing heat exchanger free thermal expansion for maximum
reliability.
• Long-term mechanical and thermal integrity.
• Reduction of operating floor height

5. Challenges of ACC
• Large capacity steam condensing for maximum electrical output.
• Coal mine areas are dusty with corrosive environment.
• Diverse and challenging climates, from hot to freezing conditions with risks of mechanical wear.
• Base load operation requiring high availability.
• Higher CAPEX, therefore higher tariff.

Note: The condenser pressure achievable in dry cooling system is considerably higher than in wet
cooling system and consequently dry cooling systems result in reduced power output (about 7%)
and increased heat rate by 7% (lower efficiency) of the unit besides higher capital cost (estimated
Rs.190 Cr to Rs. 250 Cr). Auxiliary power consumption as percentage of gross unit output is 6.25
to 6.5 %, with Turbine Driven BFPs (TDFP). Figures/Nos. indicated above are for typical 500MW
size unit.
ACC installations at some coal fire power plants

4 x 600 MW, Jinjie, China 2 x 600 MW SP Datong Gen. Co. Ltd., China

4 x 600 MW, Zhenglan, China 6 x 800 MW, Medupi, South Africa

6. Conclusion
There are considerable number of dry cooling installations including for large size units (≥ 600
MW) operating in different parts of the world. In India also, some small size combined cycle plants,
captive power plants and industrial units have been provided with air cooled condensers.
Recently, NTPC has also ordered 3 x 800 MW units with ACC for their Jharkhand project.
Exploring this technology for preserving water sources for higher capacity power plants can be
studied further.■
 FTMG
CTDS

Project QAI
Engg.

Technical Article

CFB Technology: A Better Alternative for Meeting New

MoEFCC Norms for NOx By Dipankar Das, PE.

1. Preface
Govt. Of India, Ministry of Environment, Forest & Climate Change
(MoEFCC) has revised the Environmental norms for Thermal Power Plants
(TPPs). The norms mentions that all the Thermal power plants which are to
be installed post Dec 2016 shall meet gaseous emission SOx, NOx less
than 100 mg/Nm3, PM less than 30 mg/Nm3 and Mercury less than 0.03
mg/Nm3.

The revised MoEF norms issued for gaseous emissions had originated
discussions between OEMs & Plant Owners for evolving a feasible and techno - economical
solution. The recent emission norm for SOx, NOx of <100mg/Nm3 makes it essential for a plant
user to analyze both pollution control equipment as well as the source of Coal. Generally the Plant
owners often have less control on the coal quality except for calorific value and moisture. There
are various technologies available for Fossil fuel fired Boilers viz. PF Boilers, CFBC Boilers etc,
Circulating fluidized bed is a relatively new technology with the ability to achieve lower emission of
pollutants.
In CFB, the furnace is pressurized and furnace gas is recirculated to capture the unburnt carbon
and to increase the thermal efficiency of the boiler. The fluidized action promotes complete coal
combustion at relatively low temperatures, and provides a means to transfer combustion heat
efficiently from the bed to the steam tubes. Limestone is added in the furnace for achieving the
desired SOx limit. Circulating fluidized bed (CFB) offers fuel flexibility, Low temperature
combustion, In-furnace Sorbent addition and effective Ca/S utilization which needs moderate
investment on tail end Pollution equipment and operating expenditure.
In the present scenario, for larger size units, adoption of supercritical PF (pulverized fuel) firing
technology with FGD for external desulfurization and SCR/SNCR for De NOx system is preferred.
However in mid-range utility segment CFB has been a decent alternative due to capability of in-
furnace emission control, low temperature combustion resulting low NOx emission, better air
staging, in furnace SOx reduction (up to 95% reduction) due to limestone addition in furnace etc.
The paper discusses how CFB boilers are helpful in NOx emission in thermal plants

2. NOx Emission
The predominant form of NOx is NO, NO2 with traces of other forms of NOx is also present. NOx
emissions from the fired process are typically 90 - 95% NO and balance NO2. However when flue
gas leaves the stack most of the NO is eventually oxidized to NO2.There are two principal
mechanism of NOx formation in steam generation i.e. Thermal NOx and Fuel NOx. Thermal NOx
refers to the NOx formed through high temperature oxidation of nitrogen found in the combustion
air. Normally thermal NOx formation increases significantly above a temperature of 1150 deg C.
Fuel NOx refers to conversion of fuel bound nitrogen to NOx during combustion process.

Nitrogen found in the fuel is typically bound to the fuel as an organic compound. The majority of
NOx formation from fuel bound nitrogen occurs through a series of reaction which can be broadly
described in two separate paths. The first path involves the oxidation of volatile nitrogen species
during the initial phase of combustion. During the release and prior to the oxidation of the volatile
compound, nitrogen reacts with several intermediate compound in the fuel rich flame region which
then oxidized to NO and reduced to N2 in the post combustion zone. However the formation of NO
or N2 strongly depends on fuel/ air ratio. The second path involves release of nitrogen radicals
during combustion of char fraction of the fuel. The fuel bound nitrogen releases free radicals viz.
HCN, NH3, NH which participates in series of reaction to form NOx. It may be noted that hardly 15-
20% of fuel bound Nitrogen is eventually converted into NOx and remaining gets reduced into
molecular nitrogen due to presence of large amount of char present in the Bottom furnace. It is
also evident that fuel with more volatile matters (VM) evolves more NOx.
CFBC Boiler operates at a bed temperature of 800 - 920 0C wherein PF Boilers operates at a
temperature of 1300 - 1450 0C. The thermal NOx formation is high in PF Boilers due to high
operating temperature which is negligible in CFBC Boiler due to lower operating temperature.
 FTMG
CTDS

Project QAI
Engg.

Technical Article
Below Table gives an approximate idea for NOx emission w.r.t VM.

Indonesian Washery
Indian Coal Petcoke Lignite
Coal Rejects

Volatile Content 16-20% 20-30% <8% >30% 16-20%

Fuel Bound 0.5-1.5%

0.5-1.5% 0.7-1.2% <0.3 0.5-1.5%
Nitrogen
NOx* Emission
(mg/Nm3)
150-200 175-250 75-100 200-300 150-250
CFB@6% O2
vol.dry

New MoEF Norm 100 mg/ Nm3

NOx reduction in CFB can be possible (without external system) by methods like Air staging,
Reducing the combustion temperature, Reducing Excess air etc.

Air staging is a common technique in boilers, however achieving a perfect balance between NOx
reduction and CO reduction and unburned combustible is highly empirical in nature. Based on fuel
quality changes operation changes may be required to achieve the best of all the three. Typically
the primary air to total ratio is maintained between 50-70% based on the fuel reactivity. It was
proven that the air staging technique is effective when the fuel has higher amount of Volatiles. The
bottom portion of CFB is operated below Stoichiometric limits which generates CO and Char. The
NO formation from fuel volatiles are partially reduced by unreacted char. Strong intensity of air
staging affects CO formation also.

Figure 1 below shows the relation of NOx, CO with equivalence ratio. Equivalence Ratio is the
ratio of actual fuel/air ratio to the stoichiometric fuel/air ratio. NOx is found to be lower, when the
equivalence ratio is more than 1. It is obvious that fuel rich zone can encourage lower NOx
formation, however after a particular limit of excess air (fuel lean zone), the NOx stops reducing
due to the reason that
the higher dilution air
restricts combustion and
combustion
temperature. Thus the
CFB bottom zone is
operated below
Equivalence ratio of 1
and the remaining
Fig.2 Schematic of an Air Cooled Condenser
stoichiometric and
excess air is admitted
well above the PA zone
to reduce overall NOx
emission.
Fig 1. Emission Vs Equivalence Ratio

3. Effect of CaO on NOx formation

With new environmental norms, it is imperative to maximize the SOx control to reduce the
requirement of external flue gas desulphurization (FGD) system. However it is to be noted that
after 92% Sulphur capture the requirement of Limestone exponentially increases which leads to
increase in CaO in bottom ash. The CaO catalyzes the fuel volatile release viz. NH3 and forms NO
and HCN converts to NO2 as mentioned in Figure (2). Therefore a tradeoff to be done for high
Sulphur fuel for optimized NOx & SOx emission.
4. Conclusion
Systems like SCR, SNCR are available for external NOx control.
SCR is a catalyst based system with substantial investment and
higher CAPEX. Additionally SCR systems are yet to be proven
for high ash Indian coals in terms of Erosion, Catalyst plugging
etc. In CFBC Boiler due to low combustion temperature, better
air staging the NOx formation is comparatively lower than PF
Fig 2. Fuel NOx release Boilers and the current environmental norms can be met with
combination of SNCR■
 FTMG
CTDS

Project QAI
Engg.

Technical Article

Environmental friendly technologies for Coal handling

system dust control. By Debasish Biswal, PE.

1. Preface
Coal handling plant (CHP) is a major source of fugitive emissions including
coal particles, dust etc. due to multiple handling (unloading, unloading and
transfer) of coal. Coal, which is received within the plant, contains some
amount of fines (about 3 to 4% of total coal received), defined as coal
particles which are less than 1 mm size to few microns. During handling of
coal within the plant, these fines escape into the nearby atmosphere due to
surrounding wind and cause nuisance.
Also, the coal carrying equipment are not water tight and are prone to leakages with usage, and
hence, some amount of coal leak during the process of handling. This results in wastage of coal
and since, these fines are very vulnerable to fire, creates potential fire hazard. Fine coal dust can
settle in nearby households, thus creating nuisance value and posing a health hazard. This is also
applicable for employees within the plant premises, who spend considerable amount of time
breathing the dust contaminated air.
In order to avoid the above damages to health and environment, loss of coal and unsafe
conditions, different environmental friendly technologies, primarily aiming at minimizing the fugitive
emissions and spillage, are utilized in the coal handling plant and a brief in-sight to them has been
included in this article

2. Environmental friendly technologies for minimizing the coal spillages and fugitive
emissions
The precautions that could be taken while designing coal handling system as well as various
technologies that could be used to minimise the spillage as well as fugitive emissions are detailed
below:
2.1 Avoiding multiple and manual handling of coal:
As a common practice, coal is received within the plant through various logistics solutions viz
wagons, trucks and for a power plant through nearby port or jetty, through barges. All the above
logistics solutions demand well-defined mechanical handling system for minimizing manual
handling of coal (with the help of mobile yard equipment like dozers, pay-loaders, labourers etc.).
For example, a wagon tippler system or a barge unloader eliminates the need of manual handling
of coal. The coal from wagons or barges are mechanically unloaded and directly fed to the coal
conveying system. This avoids spillage of coal with a well-designed conveyor system and fugitive
emissions are controlled with the help of dust suppression systems. On the other hand, unloading
of wagons along a railway siding, with the help of labourers, mobile yard equipment would result
into spillage of coal, which is a direct loss of asset and source of fugitive emissions. The trucks
which would carry coal from siding to plant will be additional source of fugitive emissions as the
carrier is open to atmosphere.
The design of the CHP (Coal Handling Plant) must ensure the following to minimize loss of coal
and fugitive emissions:
a) The conveying system is designed as per relevant standards and practical experiences to
avoid spillage of coal while conveying from one place to other. Adequate skirt length must be
provided to contain coal on the conveyors when coal is received from a chute to a belt
conveyor.
b) The length of chute (height from one transfer point to another) must be optimized and design
of the chute must ensure that the velocity of coal at the end of the chute is same to that of
receiving conveyor. A chute must also ensure centre-line feeding of coal onto the chute to
avoid spillage from edges.
c) System design must also ensure that rate of feeding of a chute must be same as the
evacuation rate of the receiving conveyor. Also the storage in the chute must be decided
considering the stoppage time of the feeding and receiving conveyor.
d) As far as possible, conveyors must be housed within enclosed galleries with sufficient
mechanical ventilation systems while restricting contact of coal with natural strong winds.
e) Coal must be stocked at minimum number of locations which are well accessible through
mechanical yard equipment like the stacker, stacker cum re-claimers. Transfer of coal from
one location to other location, again adds to loss of coal and emissions.
f) In case, stocking and handling of coal at multiple locations within the plant is essential, it must
be designed with suitable and sufficient type of dust suppression systems.
 FTMG
CTDS

Project QAI
Engg.

Technical Article
g) While deciding the coal stockyard location, the wind-rose must be referred to minimize
exposure of coal with strong winds for maximum duration of a year.
h) Stock yards must be located away from nearby habitats to minimize the risk of carrying over of
fugitive emissions.
i) The maximum height of coal stock-pile must not exceed the height specified by local pollution
control board (max 10 metres in most areas in India).
j) In case, the above conditions are not achievable, due to certain constraints, a wind barrier
must be designed (at least 3 metre high than highest height of coal stockpile) and installed,
surrounding the CHP, in the dominant direction of wind. This would reduce carrying over of
fugitive emissions to nearby areas.
2.2 Pipe Conveyors:
As a significant jump in minimizing spillage and loss of coal during the process of conveying from
one location to another, the technology of pipe conveyors is being adopted. In contrast to trough
type conveyors, which is open and provides a possibility of spillage of coal (beyond its edges) due
to defined width and profile, the pipe conveyor carries the coal in a completely enclosed pipe like
structure, wherein both the edges of the conveyor overlap to create a closed containment, thus
containing the entire load of coal, eliminating contact of coal to wind and chances of spillage of
coal beyond the edges. It is possible to achieve zero loss of coal (spillage or emissions) with a
pipe conveyor. The pipe conveyor is similar to a trough conveyor for initial 45 metres to 65 meters
at its receipt and discharge end, depending on the tonnage of pipe conveyor. However, the above
lengths are, generally, located, within enclosed conveyor galleries and hence, emissions during
transfer of coal are minimized. Due to zero spillage from these conveyors, it is suitable to carry
coal over environmentally sensitive areas like open water resources, forest land etc. Pipe
conveyors also allow coal to be carried at steeper angles and can change direction with certain
minimum radius, thus, sometimes, allowing optimization of CHP layouts, reducing the requirement
of land for the power plant. The cross-section of a troughed conveyor and pipe conveyor is
provided below:

Pipe conveyor C/S Trough conveyor C/S

2.3 Screw type Barge Unloaders:
For power plants, which receive coal through barges, grab type unloader are put to use. It’s a
technology that has been put to use due to its ruggedness as it is not highly dependent on the type
of coal, size of coal, foreign material and has long life. However, these grabs, though, designed as
water tight enclosures, leak coal from the mating surface of the either halves of the grab, within few
days of operation. This leaked coal, mostly, drops into water, thus polluting the water body. Hence,
as a more environmentally friendly technology of unloading coal from barges, screw type
continuous unloaders have been developed and installed. The screw type unloader uses a
specially designed rotating feeding head and a screw conveyor, called as the vertical screw,
followed by horizontal and gantry screw conveyors to unload coal from barges. All the above screw
conveyors are completely enclosed within casings and hence, no coal can escape the machine
unless the final discharge is reached. This completely eliminates possibility of leakage of coal at
any point of conveying coal from barge to conveyor. Though, these type of unloaders demand coal
size of - 50 mm, free from any foreign material with maximum moisture of 35%, they provide a
much cleaner and intensively environment friendly methodology for unloading coal from barges.
2.4 Dust Suppression system:
Complete elimination of fugitive emissions while handling of coal is not possible. This is because
of presence of fines and generation of fines during handling of coal. It is essential that coal is
transferred from one place to another in some or other way of conveying/handling. This demands
that the coal is passed through numerous transfer points, wherein it is dropped from a height to a
receiving conveyor or equipment. Also, coal is crushed to achieve a definite size which further
increases percentage of fines. Hence, to contain and control fugitive emission of fines, water
based dust suppression systems are provided. Dust suppression systems are typically provided at
every unloading and handling point/location in the CHP viz the wagon unloading facility, receiving
 FTMG
CTDS

Project QAI
Engg.

Technical Article
and discharge point of conveyors, on the boundary coal stockpiles, discharge of boom
conveyors of yard equipment, truck unloading hoppers etc. The water based dust
suppression system can be implemented in following ways: The clearance is kept in-order to
prevent damage to belt surface
• Plain water based dust suppression system: It is provided with the help of water jet nozzles,
sprinklers wherein the amount of fugitive emissions are significantly higher viz
the wagon/truck unloading stations, stockpiles etc. High pressure water (low flowrate) is
discharged through sprinklers/jet nozzles to create a blanket of water to contain the fugitive
emissions. The droplets are heavier than the fugitive particles and hence help in settling them
down. The system is designed to cover the complete stock pile/coal unloading station with the help
of a network of nozzles. During the process, the coal is also wetted, reducing further possibility of
emissions in the downstream handling process.
• Dry Fog Type Dust suppression (DFDS) system: It is provided with the help of air-water jet
nozzles. Water and air are introduced into the same nozzles and the high pressure air atomizes
the water into very fine droplets (less than 1 microns) to form a blanket of atomised water. This
contains the minute fugitive particles and prevents emissions. This type of system is installed
wherein the amount and size of fugitive emissions are relatively smaller viz at the discharge and
receipt end of conveyors.
• Combination of above two technologies: After prolonged use of only DFDS system at the
receiving and discharge end of conveyors, it has been observed that its efficacy is limited and
significant emissions occur during transfer of coal through conveyors. Hence, as a new trend,
specially designed plain dust water system is installed at the discharge of conveyor and DFDS
type system is installed at the receipt end. A combination of these systems have proven to be
highly efficient in minimizing emissions. Also the system does not require any electrical valve
operations, instrumentations and power etc. to operate. Most of the dust suppression systems fail,
due to premature failure of the supporting operating systems and hence lead to the complete
system unavailable after a few days of installation. However, the newly installed system is
completely mechanical and operates with tap off from service water and service air system
provided along the conveyors. The actuating mechanism is a runner wheel which remains in
contact with the non-carrying side of the conveyor and actuates the dust suppression system as
soon as the conveyor is in motion. This helps in wetting the belt and reduce emission of dry coal,
which gets stuck to the conveyor when the conveyor is stopped after operations. A schematic of
the system is provided below:

PWS and DFDS Schematic

2.5 Belt Wash Box System:
Belt wash box is an equipment which cleans the carrying surface of the belt during return travel. It
so happens that minute particles of coal which are not heavy enough to be discharged into the
discharge chute, remain attached with the surface of the belt due to adhesive forces within coal
and the top rubber surface. Though scrappers are provided before and after the bend pulleys, they
are not in complete contact with the surface of the belt and hence, cannot completely clean the
belt.
 FTMG
CTDS

Project QAI
Engg.

Technical Article
due to continuous scrapping of belt. The wash box is installed in the path of return
conveyor wherein the carrying surface of the conveyor is scrapped by an inbuilt acrylic
scrapper and washed with the help of high
pressure (3 bar) water jet nozzles. The high
pressure water ensures dislodging of the
sticky coal on the surface while the acrylic
scrapper, which is in absolute contact along
the surface of the belt, cleans the belt more
efficiently than other scrapers. The discharge
of the wash box is routed to nearest drains.
This system, ideally, ensures a completely
clean and wetted belt in the return side
avoiding any emissions that could occur due
to coal sticking onto surface of the belt.

2.6 Junction tower sealing, cleaning and ventilation system:

Junction tower are the technological structures wherein the transfer of coal takes place from one
conveyor to other, sometimes through certain equipment viz the screens, samplers, crushers etc.
and hence are the major source of fine fugitive emissions. Therefore it is essential to contain the
fugitive within these towers and handle them suitably. To achieve the same, two methodologies
are to be adopted:
• Sealing and cleaning of junction towers: The junction towers must be sealed at all locations for
except the doors and access points. Proper and sufficient sheeting must be ensured to cover the
junction towers all around. The monorail doors, the access doors must be kept shut when not in
use. The conveyor entry and exit points may also be concealed with doors. The windows must be
fixed with non-openable glass with proper access to all windows to replace the window glass in
case of damage. Proper service water system with drains on all floors of the junction towers must
be provided to clean the junction tower of any spillages which might occur during transfer of coal.
As a whole, it must be endeavoured not to leave unnecessary openings in the junction tower to
allow coal dust to escape the junction tower.
• Ventilation system: Junction tower ventilation system has been used for the 1st time in CGPL
Mundra Pipe conveyor Project to pull the fine dust particles which still manage to escape despite
installation of the already discussed water based dust suppression systems. Suction air ducts,
which are connected to an induced draft fan, creates a low pressure zone on the working floors of
the junction towers and hence, suck the coal fines. The fines are collected through a bag filter
system and through a rotary air lock valve, is discharged into a container, which may be put back
to stockpiles or conveyors.

3. Conclusion
The combination of the above mentioned technologies certainly helps in making the coal handling
plant more environmentally friendly and will lead to more conducive and healthy working
conditions■
 FTMG
CTDS

Project QAI
Engg.

Technical Article

Environment Friendly Transformer Oil - Ester fluid

By Pramod Tupe, CTDS.

1. Preface
Power transformers are the key elements in any electrical power network
and developed significantly in design and insulating material used, since
their invention over a century ago. However, the use of mineral oil as an
insulating and cooling medium remained virtually unchanged till the global
oil crisis in 1970s which triggered the search for alternative fluids and driven
by growing desire for environmentally-friendly solutions over recent
decades. Many companies in Transformer manufacturing as well as
Insulating oil industries have taken lead in this area and developed ESTER
fluid as dielectric insulating oil. Likewise, many power utilities are focusing
their attention on enhancing the environmental, safety and operational performance of both new
and existing power transformers; in order to deliver more reliable, cleaner power to their
customers. In this article, an attempt is made to collate development of environmentally-friendly
Ester oil and its field experience in brief.

2. Mineral Oil & its environment impact

Mineral oils are composed of saturated hydrocarbons called "paraffins", whose general molecular
formula is CnH2n+2. Other hydrocarbon compounds like "naphtenic" CnH2n and "aromatic" CnHn
are also used as insulating oil. However, all above Mineral oils are obtained from petroleum crude
oil products. Unfortunately, the Mineral oil is having limited biodegradability and can impact on
environment heavily, in case of careless spillage or inappropriate disposal. Additionally, quantity
of oil used in Transformers (for example, 90MVA, 110/22kV Power Transformer is having 40-50
KL while 250MVA 220/110kV ICT is having 75-85 KL) intensifies the hazard. Commonly used
mineral transformer oil has an ecological threat index twice higher than water and the same may
be increased up to three times due to presence of polycyclic aromatic compounds in some aged /
long operated Transformers.

The Mineral oil leaked from Transformer to the soil are major source of its contamination
(Degradation of oil-soaked layer) and in consequence, the contamination of water bodies occurs.
As per OECD 301 standard, the biodegradability factor is only 10% which indicates that after 28
days from the entering the oil to the environment, only small part of this fluid surrenders to self-
degradation. Moreover, the mineral oil need to be disposed-off after its useful life, certain
precautions are necessary to avoid risk of environmental pollution and legal requirements as
applicable to industrial and other lubricants. Another environmental issue associated with Mineral
oil is combustibility property due to its low flash point. Fire in failed transformer are very dangerous
and cause air pollution.

3. Alternative solution for Transformer insulating oil

Environmentally friendly insulating fluids, which are an alternative to Mineral oils, are the
Synthetic Esters and Natural Esters. The base of Natural Esters are vegetable oils produced
from plants. Ester fluid is not listed as hazardous by international authorities such as EPA
(Environmental Protection Agency) and OSHA (Occupational Safety and Health Administration).
Thus emerging as one of the cleanest types of product available on the market today, which is
safe for people and the environment.

The term "Ester" comes from chemical linkage formed from the reaction of an alcohol & an acid.
Synthetic esters are manufactured from organic acids and alcohol to give chosen properties.
Natural esters are derived from refined seed oils (examples rapeseed, Soya, Sunflower, canola
and corn). In past, Synthetic Ester fluids have used in traction, wind turbines, offshore platform
etc. and having service history of more than 35 years. Natural ester only marketed since late
1990’s

Properties of Ester Fluid

In the Table 1, the basic physical-chemical and dielectric parameters for both esters and mineral
oil are summarized (Ref. FR3 Data Sheet 2008, Midel 7131 Data Sheet 2010).
From Table -1, it is important to notice that biodegradability and flash point properties of both
types of Ester oil are superior to Mineral oil on account of ecological aspects, thereby ester fluid
offers alternative solution as insulating oil in the places having restricted environmental regulation.
 FTMG
CTDS

Project QAI
Engg.

Technical Article
The better properties of esters are also visible looking at the intensity of the smoke emitted
by the burned liquids. In the case of Mineral oil, smoke is black and very dense while for

Table 1: Basic parameters of synthetic ester, natural ester and mineral oil.
Synthetic Natural
Property Unit Mineral oil
ester ester
Physical - Chemical properties
Density at 20 o C Kg / cm3 0.97 0.92 0.88
Specific Heat at 20 o C J / kg K 1880 1848 1860
Thermal Conductivity at 20 o C W/m 0.144 0.177 0.126
Kinematic Viscosity at 20 o C mm2 / s 70 85 22
Pour point oC - 60 - 21 - 50
Fire point oC 316 360 170
Flash point oC 260 316 150
Fire Hazard classification to IEC 61100
-- K3 K2 --
/ IEC 61039
Biodegradability % 89 97 10
Excellent Oxidation Good
Oxidation Stability --
stability susceptible stability
Dielectrical Properties
Breakdown voltage kV >75 >75 70
Dielectric dissipation factor at 90 o C -- <0.008 <0.003 <0.002
Permittivity at 20 o C -- 3.2 3.1 2.2

the both esters smoke is emitted in smaller amounts and its density is also much lower. In
percentages, the volume of waste gases emitted by the burned Ester oil in comparison to the
gases emitted by burned Mineral oil is only about 15%. Ester fluids are classified under Less
Flammable Insulating Fluids (K Class Liquids) with a fire point greater than 300 °C and are
manufactured in accordance with IEC 61099 (for synthetic esters) and IEC 62770 (for natural
esters).

From the insulating property point of view, the most important parameter for transformer oil is
breakdown voltage. For the Mineral oil, its strength goes down with increase of moisture content,
whereas Ester oil delivers constant value of breakdown voltage for moisture content up to 600
ppm. The higher value of electrical permittivity of the Ester oil than the Mineral oil, thus help in the
stress distribution in Transformer insulation (cellulose - oil) system. Its unique ability to absorb
moisture contained in aging paper without deterioration of dielectrical strength, can extend
insulation life by a factor of as much as five. It also chemically helps to prevent long cellulose
paper molecules from aging due to heat exposure. These properties can result in an increase of
overloading capability and longer transformer insulation life. The results are lower lifecycle costs
and better use of your assets. In past, the transformer industry has reported the failure of
Transformer units due to the presence of corrosive sulphur. Ester fluid have been tested by
independent laboratories and found to be non-corrosive as per ASTM D1275 and IEC 62535.

Although there are many positive properties of the Ester fluids, their lightning impulse strength is
not as good as Mineral oil. Therefore necessary electrical clearances need to be considered while
design stage. Moreover, Ester fluids are characterized by higher density and viscosity, thereby
contact with the surface of heating elements (used during production process) is much longer. This
leads to overheating of Ester fluid and resulting into increase in dielectric dissipation factor. Thus,
production of Ester fluid becomes complex in relation with Mineral oil.

On other hand, the higher density of Ester fluid impacts free circulation of insulating oil in the
cooling ducts as compare to Mineral oil. Thereby, during designing of power transformer filled with
Ester fluid should consider this property to provide the correct circulation of the cooling fluid both in
the natural and forced type construction. This leads to wider cooling ducts and high auxiliary power
requirement with respect to Mineral oil.

4. Cost Benefits of Ester Fluids

As a result of higher raw material & production costs, the initial cost of Ester fluid is higher than
Mineral oil and the same can be compensated by taking advantages in optimized transformer
 FTMG
CTDS

Project QAI
Engg.

Technical Article
design, extended insulation / asset life and reduced maintenance. The benefit of Ester
fluid's dielectric properties allow smaller transformer design for transformer ratings,
which may result in a lower cost per KVA. For utility or industry customers who have to install
transformers in urban areas where land is expensive, reducing the land required will provide
significant savings.

Present Central Electricity Authority (CEA) regulations in India mandates use of fire protection
systems for transformer capacity more than 10 MVA and above or with capacity more than 2000
Ltrs. In addition to that only dry type transformers are allowed for indoor applications. IEC 61936-1
also allows reduced minimum separate clearance for K class liquid filled transformers and The US
NEC (NFPA 70) allows for indoor installations of less flammable liquid filled transformers without
fire suppression systems. Such guidelines for ester filled transformers are at present not available
in India and there is an emerging need for that. Incidentally, BIS is shortly coming out with National
standard for Distribution transformers up to 2500 kVA, 33 kV filled with Ester liquids.

5. Field experience of Easter filled transformers

Natural and synthetic Esters have built up experience in distribution and small power transformers.
Presently, Transformer manufactures / Utilities are moving towards higher voltage classes and
larger power transformers with realisation of installation advantages from fire safety and
environmental benefits. The below table -2 shows a selection of power transformers with synthetic
and natural ester installed over the past 25 years.

Table 2: Power Transformer installed over the past 25 years (Source : MIDAL database)
Tata Power Delhi Distribution Limited (TPDDL) has already carried out trials with both types of
Ester fluid for small single phase distribution transformers and standardized on natural Ester oil.
The biodegradable oil retro-fill has helped them in addressing issues like overloading, safety,
mineral oil dispose-off problems and other environmental concerns.

In our Distribution system, four 20/28MVA Natural Ester filled transformers were installed in
Mumbai as green initiative. Such transformer design provides increased capacity by 8 MVA, while
reducing the footprint by 17%; it yields cost-savings of about 16% and reduces noise level from 73
db to 59 db. In EHV Power Transformer category, an attempts are made to introduce Ester fluid
filled transformer, however cost run-over is around 20%.

6. Conclusion
Biodegradable ester fluids are good alternative to mineral oil, especially in the situations when the
power transformer has to be installed in urban areas with catastrophic consequences in case of
fire. With the many positive aspects like the higher biodegradability, high flash point and good
breakdown strength, its negative parameters like worse cooling property, concentrated heat flux,
low lightning impulse strength etc. should be taken into account in the design phase and during
operation & maintenance of the transformer with Ester fluids. Power utility companies that have
used Ester fluid in transformers, have reported major benefits like reduction of installation costs,
higher transformer reliability and availability as a result of reduced maintenance requirements. In
the longer term, they can expect extended operational lifetime, as well as reduced risk of fire and
explosion and lower costs related to environmental compliance■
 FTMG
CTDS

Project QAI
Engg.

Key Highlights
Presentation on "Protection and Automation - Tata Power
Perspective“ by Mr. Amok Agarwala and Mr. T Murlikrishna
Mr. Amok Agarwala and Mr. T
Murlikrishna made a presentation at
National Seminar on 'Smart Grid
Technologies and Standards' in
march 2017 at Vadodara. The
seminar was organized by IEEE and
hosted by GETCO. The presentation
highlighted the issues concerning
the utilities in upgrading Protection
& Automation. The presentation was well appreciated by the
attendees.

Workshop on Communication Technologies

Technical workshop on
communication technologies was
organized by Communication team
at Khopoli for Engineers and staff
from Khopoli, Bhira and Bhivpuri.
Training on 23rd June 2017 on various
communication technologies and
introduction to different fiber optic testing instruments along with hands
on demo of Optical time domain reflectometer, Power meter, Fusion
splicing was given. The session has increased awareness level of the
team on communication technologies and cyber security and would
help them in effectively managing hydro centralization automation
network.

Release of report on “compendium of

Boiler tube leaks FY 16 & 17 "
A report on "Compendium of Boiler tube leaks
FY 16 & 17" prepared by CTDS was released by
COO & ED Mr. Ashok Sethi on 9th June'17.

Lecture on ' Commissioning &

Operating Experience of India's first
830 MW units at super critical units "
Mr. Unni Gopalakrishnan delivered a
lecture on ‘Commissioning & Operating
Experience of India's first supercritical 830
MW units', during the NTPC Operations
Heads' Conference on 29th May'17 at
PMI, Noida.
 FTMG
CTDS

Project QAI
Engg.

Training on “Hydro maintenance and operations”

A two days training on ‘Hydro

Maintenance and Operations’ was
given by experts from CTDS Mr. A. K.
Sinha, Mr. Himanshu Marmat and
External Hydro expert Mr. R.C. Sharma on
7th and 8th June 2017 at Khopoli.

A session on ‘Adoption of
good practices in power
industry’ at NCQM

Ms. Anjali Kulkarni, Chief-Corp

Engg. delivered session on
‘Adoption of good practices in
power industry’ at NCQM
(National Centre for Quality
Management) AGM (Annual
General Meeting) on 12th
August, 2017.
The session covered good
practices adopted by
corporate engineering’s various
verticals for addressing several business challenges and achieving
improved performance. Session was widely appreciated by
professionals from various industry.

A training session on " Design of

Wind Turbine Foundation "

A training session “Design of

Wind Turbine Foundation” was
organized for civil group. Dr.
Sanjay Chakarmane, Professor,
Structural Engineering, IIT
Roorkee was invited. The
training session mainly delved
into inputs required, design
philosophy and expected
results for the foundation. A
case study was taken up for
further understanding and
deliberation.
 FTMG
CTDS

Project QAI
Engg.

"Technical Paper on "Challenges in Restoration

of Transmission Lines"
Mr. Sandeep Deshmukh
presented Technical Paper on
"Challenges in Restoration of
Transmission Lines - Case Study in
Mumbai" during 5th National
Conference on "Innovations &
Best Practices in Design,
Construction O&M &
Environmental Considerations for
EHV & UHV Transmission Lines".
The conference was conducted by CBIP New Delhi on 22nd June.17.

Knowledge Sharing session

on ̋Basics of Protection &
Relay co-ordination and
Condition Monitoring of
switchgear & Transformer
A Knowledge sharing session on
‘Basics of Protection & Relay co-
ordination and Condition
Monitoring of switchgear &
Transformer’ was conducted by
Ms. Shraddha Mahurkar & Mr. Binoy Kalaria on 30th June 2017 at Godrej
premises for Godrej O&M engineers upon their request. The session was
coordinated by Mr. Mattoo from Distribution East team and covered
protection, relay coordination & condition monitoring aspects as
applicable to Godrej. A case study for Relay coordination of Godrej 22
kV network was explained. Godrej officials appreciated team's
initiative and inputs.

ISO 9001:2015 - Transition Auditors certificate course

QA&I team arranged Transition Auditors Certificate Course to enhance
their knowledge on ISO 9001-2015 edition. The course was conducted
by faculty Mr. B. Banerjee, Registered QMS Lead Auditor from National
Centre for Quality Management (NCQM). Entire QA&I team attended
the two days training program organized on 28th and 29th June 2017
which will help team to improve their skills and make themselves aware
with the amendments made in latest edition of ISO 9001:2015.
 FTMG
CTDS

Project QAI
Engg.

Employee Corner

Mr. Sheshrao Suryawanshi (CTDs), Mr. Dayanand Wanmore (PE)

and Mr. Paresh Gohil (QA&I) participated in Customer Acquisition &
Retention drive as company's initiative to support Distribution division
and received the reward for excellent contribution towards "Best
performing zone Operation Grounding" on 29th March 17 at R & R
function held at Dharavi.

Mr. Paresh Mestri and Mr. Aniket Rajoba obtained Associate

membership and Chartered Engineer Certificate from Institute of
Engineer.

Mr. Dhawal Pandya (QA&I)

represented Tata Power in Tata
Inter-Company Badminton
Tournament held at Andheri
Sports Complex on 24th to 26th
March 2017. Tata Power team
played well and reached up to
quarter finals of the tournament
 FTMG
CTDS

Project QAI
Engg.

“SARGAM” is a company wide initiative for encouraging the music

talent within the organization. Annual show of ‘Sargam – Nite’ was

held at Y B Chavan auditorim on 16th June 2017. Mr. Anand

Buddhiwant, Ms. Madhura Korantak, Ms. Deepa Joshi (PE)

participated in the show.

Traditionally seniors have been recognizing their juniors for their efforts.
PE decided to go for a 360 degree turn. A poll was conducted for

judging seniors under various categories. Mr. Sandeep Deshmukh

& Mr. Shivprasad Lakhapati were chosen as role models and were

facilitated by ‘SAMMAN’ trophy & Certificate in PE Department

meeting.

Mr. Sujit Jha (QA&I) successfully completed his Post Graduate

Diploma in Management from IMT Ghaziabad. His specialization in
one year course was Operation Management.

Mr. Sanjay Prasad (Electrical Testing) and Ms. Shruti Marathe

(QA&I) qualified in Silver Level for TBEM Assessment training.
 FTMG
CTDS

Project QAI
Engg.

Farewell of Mr. Rajendra Shintre on 29th June 2017

Vishal weds Shubhangi Asha weds Abhit

Aarush son of Mr. Amar Chavan Daughter of Mr. Jitendra Shinde

 FTMG
CTDS

Project QAI
Engg.

Fun At Work

Fun at work program at Trombay.

Holi Celebration at CENTEC

Birthday Celebration at CENTEC

 FTMG
CTDS

Project QAI
Engg.

Earth Day Walk was conducted at CENTEC on

21st April 2017 in Technopolis premises.

Lunch with MD was

organised for 11
Employees at CENTEC
on 11th May 2017. CEO
& MD Mr. Anil Sardana
Interacted with the
employees.

Evacuation mock drill

was conducted in Fire
Service Week- 14th
to 20th April 2017
at CENTEC in
presence of Mr.
Sanjay Kale Head
Fire & Safety.
 FTMG
CTDS

Project QAI
Engg.

Fun At Work

Team members from

Testing, PE and other
department of Tata Power
participated in hiking to
Gorakhgad on 25th June
2017

Team members from

Testing and PE went on
a family Monsoon Picnic
to Kondeshwar.
Everyone enjoyed
mesmerising beauty of
waterfall and nature
around. A sapling
plantation drive was
also conducted on the
way back.
 FTMG
CTDS

Project QAI
Engg.
Quiz
Dear Readers,
We are happy and thankful to all of you for giving an overwhelming response to the quiz in
Wattsup issue 8. The first three correct entries are :

1. Sanjay Neve Team Lead - Corp Environment & Climate Change.

2. Shambo Bhattacharya Lead Engineer – CHP, MPL.
3. Bathini Venkateshwarlu Lead Engineer – EMD, CGPL.

The winner’s prizes are on the way. Do not forget to participate in the quiz and send your entries to
wattsup@tatapower.com. First three correct entries will get prizes.
SN Questions

1 -----------------type of system is installed wherein the amount and size of fugitive emissions are
relatively smaller viz. at the discharge and receipt end of conveyors .

2 Biodegradability of Natural oil is ------- whereas of mineral oil ------.

3 For a typical 500 MW coal fired unit, the amount of cooling water required for condenser and
auxiliary cooling is of the order --------------- with temperature rise across the condenser about 9.50C .

4 CFBC Boiler operates at a bed temperature of ---------------wherein PF Boilers operates at a

temperature of ------------------.

5 Ministry of Environment and Forest (MOEF) has updated environmental regulations applicable to coal
fired thermal power plants effective Dec 2015. Basis this, the revised norms for SPM for CGPL
Thermal power plant is --------

6 As per notification dated 07th Dec 2015 by MOEF & CC, NOx limit for Thermal Power plants installed
after 1st Jan 2004 till 31st Dec’ 2916 is ----------.

7 The volume of waste gases emitted by the burned Ester oil in comparison to the gases emitted by
burned Mineral oil is only about --------.

8 For optimum sizing of ReACT system, NOx at inlet of ReACT system shall be less than 529 mg/Nm3 to
get outlet NOx level less than ----------------.

9 There are two principal mechanism of NOx formation in steam generation, and they are- --------------.

10 In ReACT system, to promote the reaction and absorption process of NOx, SOx, and other emissions --
----------------is also injected in FG stream.