KARNATAKA POWER CORPORATION LTD

WELCOME TO PRESENTATION ON DG PLANT , YELAHANKA, BANGALORE-64

1

INTRODUCTION
The 120 MW Diesel Engine Power Station was set

up by the Karnataka Electricity Board in Yelahanka Bangalore-64 ,during 1992-93.

The

Plant

was

functioning

under

erstwhile

Vishweswaraya Vidyuth Nigama Ltd (VVNL).

VVNL is amalgamated with KPCL on 27th Dec, 2006

hence DG Plant is now under the administrative control of KPCL.

The DG Plant Yelahanka houses six DG sets of

21.32 MW (Installed capacity) each.

2

Low Sulphur Heavy Stock (LSHS) with <1% Sulphur is used as primary fuel. HSD oil is used for initial startup and for low loads operation as secondary fuel. LSHS is supplied by IOCL from the infrastructure put up in DG Plant land on lease under long term agreement. HSD is supplied from IOCL Devangunthi terminals by road.

Salient Features of DG Plant,Yelahanka

Area of Land Project cost Installed Capacity Year of Commission

: 102 acres : Rs. 265 crores : 6 x 21.32 MW=127.92MW : 1992-1993 (Now renamed as MAN Diesel SAS)

Engine Manufacturer/Supplier : M/s. SEMT Pielstick, France. Type of Plant Operation : On base Load at 18 MW /UNIT (6x18MW)As per recommendation of OEM supplier due to ISO conditions
4

COMMISSIONING DATES

Unit-6 Unit-5 Unit-4 Unit-3 Unit-2 Unit-1

31.03.1993 14.05.1993 27.07.1993 19.10.1993 26.11.1993 31.01.1994

Details of systems

Mechanical systems : Diesel Engine Type : PC 4.2B V 570 , 4 stroke single acting. Number of cylinders: 18 in Vee of 45 0 Continuous rating: 1650 HP(1215 Kw), Rotation speed: 428 RPM Bore -570mm Stroke: 660mm Swept volume: 168.4 dM3 Thermal Efficiency: 46.7%

Diesel engines

Main Piston Speed 9.4 m/s Mean Effective pressure 20.2 Bar at 100% load Compression Ratio 13.3:1 Max pressure 14.5 MPa Exhaust Gas Flow 137421Kg/hr Overload acceptance 10% for one hr in Every 12 hrs
7

SYSTEMS INSTALLED FOR DG SETS

AIR INTAKE SYSTEM COMPRESSED AIR SYSTEM FUEL SYSTEM EXHAUST SYSTEM LUBE OIL SYSTEM JACKET WATER COOLING SYSTEM INJECTOR COOLING WATER SYSTEM STEAM SYSTEM PLANT WATER SYSTEM

UNIT AUXILIARIES

TURBOCHARGERS LUBE OIL SEPARATORS THERMOSTATIC VALVES RADIATORS REGULATION VALVES AIR REGULATION VALVES STEAM DRUM CONDENSATE DRUM CONDENSATE RECOVERY TANK OIL BATH AIR FILTERS OIL FILTERS
9

FUEL HANDLING SYSTEM

LSHS is received by IOCL,from Gujarat Refineries Limited (GRL), through railways. Each railway rakes contain about 70 Wagons of capacity 20 Tons each.

LSHS is unloaded and stored in IOCL depot in 2 Nos. of Storage tanks of 5000KL capacity each and supplied to DG Plant through pipe line. The transferred quantity, for the billing purpose will be reckoned from this tank through dip level method and weight basis taken jointly by the IOCL and KPCL representatives. LSHS is taken for plant operation through 365KL and 1065KL tanks of KPCL Store by means of 25HP capacity pumps, as and when required by DG Plant.

10

FUEL HANDLING SYSTEM 365KL or 1065KL tanks

are electrically heat traced and temperature maintained at 580 C and fuel transferred to station tanks viz.,settling tanks 200KLx2 and service tanks 100KLx2.

As per the requirement of plant, the fuel after reaching sufficient viscosity and cleanliness (Centrifuging on line in fuel treatment plant) pumped to Fuel header in the plant.
11

LUBE OIL SYSTEM

LUBE OIL SYSTEM: The lube oil SAE 40 grade is supplied by M/s IOCL and M/s HPCL by road from tank trucks, of 16 to 20KL capacity and stored into tanks of 50KL capacity (2 nos.) The oil is then transferred to each Unit tanks of 40 KL Capacity . The lube oil is centrifuged before circulation in Engine.
12

EFFLUENT TREATMENT PLANT(ETP)

The fuel/oil spillovers received from the following are reclaimed through ETP a) Drip tanks (2nos.) from the engines and separators. b) Sample fuel valve of the engines. c) From excess return from Service tank.

13

ELECTRICAL SYSTEMS
1.ALTERNATOR Apparent power :23690 KVA, Voltage-11Kv,current,1243 amp, Frequency-50Hz,Insulation:classF, Rotor -14 poles, 2.OUT DOOR YARD-11/66KV 3.INSTRUMENTATION & PROTECTION SYSTEM.

14

ALTERNATOR:
Manufacturer Excitation System Voltage Regulator

M/s GEC Alsthom, France. less excitation with rotating diodes mounted on Rotor Shaft. Thyristors type suited for parallel operation with the grid. 23690 KVA 21321 KW 11000 V 1243 A 0.9 50 Hz 15 mm 6 3
15

Brush

STATOR ELECTRICAL- CHARACTERISTICS:

Apparent Power Rated Power Voltage Current Power Factor Frequency Air Gap No. of terminals No. of Phases

Pulsing short circuit Torque at 50 Hz On constant direction Magnetic pull for 1mm Eccentricity Resistance in colds state

2612.5 knm 213.8 knm 67 KN 0.0215 Ohm 3350 mm 2790 mm 850 mm 189 16 Class F Class F 20 0 to 11 Y-connection
16

MAGNETIC CIRCUIT- CHARACTERISTICS:

Outer Diameter Bore Diameter Total Length No. of slots No. of cooling vents

STATOR WINDING CHARACTERISTICS:

Insulation Temperature increase No. of Conductors per slot Winding pitch Type of Winding

ROTOR MECHANICAL CHARACTERISTICS

14 428 rpm 514 rpm 2 36 21.8 m3 / sec 15 mm 2760 mm 910 mm 41420 Kg

No. of Poles Rotation Speed Over Speed No. of Fans No. of Blades per fan Internal Air Flow rate Air Gap Poles Outer Diameter Total Length Total weight including Exciter rotor

17

EXCITER RK 110-20:
Its installation inside the Generator ensures a very small volume of space and allows to have full benefit of an efficient cooling. The advantages of Rotating diodes inverter generator excitation system are.

Elimination of Rings and Brushes, Elimination of Brush Dust Low excitation power.

18

OUTDOOR

YARD

The Outdoor Yard consists of 7 Nos of 25 MVA, 11/66 KV transformers one each per DG set and one Standby. The Voltage generated in the alternator at 11KV is stepped up by 25 MVA transformer to 66KV and fed into the 66KV double bus. From the bus the power is evacuated through 6 transmission lines of 66KV viz Peenya-1 &2, WAP 1&2, DBP 1&2. 1No of 6.3 MVA &1 no of 8MVA station auxiliary transformers to step down the voltage from 66KV to 11KV and 2 Nos of 2.5MVA, 11/0.4 KV station auxiliary Transformers to further step down the voltage to 400V. Each unit is provided with 1MVA capacity 11/0.4KV unit auxiliary transformer to feed power supply to the unit auxiliaries.
19

SINGLE LINE DIAGRAM OF SWITCHYARD[ODY] AT 120MW DIESEL POWER PLANT VVNL, YELAHANKA, BANGALORE-64
COMMON AUXILIARIES

INDEX

WAP-1 LA CVT 29E C.T LCB 29C

WAP-2 LA

PNY-1 LA CVT

PNY-2 LA CVT

DBP-1 LA

DBP-2 LA

2.5MVA 11KV/415V

TC-1
CB

TC-2
CB

2.5MVA 11KV/415V

TO COLONY FEEDER
CB 0.2S-EM

29E 29L
0.2S-EM

29L
0.2S-EM

29E C.T LCB

29L
0.2S-EM

29E 29T C.T LCB

29L
0.2S-EM

29E 29T C.T LCB

29L
0.2S-EM

29E 29L C.T LCB 29C

0.2S-EM

CB TA-1

CB PT-1 TA -2 LA C.T CB
0.2S-EM
8MVA 66KV/11KV

PT-2 LA

C.T LCB

29T

29T 29C

29T 29C

29T

6.3MVA 66KV/11KV

29C

29C

29A 66kV BUS-A 66kV BUS-B 29A PT-1

29B

29A

29B

29A

29B

29A

29B

29A

29B

29A

29B

29A

29B

BUS-A BUS-B

29B

29A

29B

29A

29B

29A PT-2

29B

29A

29B

29A

29B
NCT

29B

29A B/C C.T C.T GTCB LA

29B

29A

GTCB

GTCB

GTCB C.T 0.2 TM LA

NCT

GTCB C.T 0.2 TM LA

NCT

GTCB C.T 0.2 TM 29C GT5

NCT

GTCB C.T 0.2 TM LA

NCT

29C GT1

C.T C.T 0.2 TM 0.2 TM LA 29C LA 29C

NCT

29C GT4

LA

29C GT6

29C GT7

GT2 SNCB AXCB

NCT

GT3 SNCB AXCB

NCT

SPARE SNCB
1.0 EM

AXCB
1.0 EM

SNCB
1.0 EM

SNCB AXCB
1.0 EM 1.0 EM

AXCB

SNCB

AXCB
1.0 EM

1.0 EM

1.0 EM 1.0 EM

1.0 EM 1.0 EM

DRG-Z

1.0 EM

ALT1

ALT2 UAT
MCBs

UAT

ALT3

UAT

ALT4
To Common Auxiliaries

UAT ALT5
MCBs

UAT

ALT6
MCBs

UAT
To Common Auxiliaries MCBs

MCBs

MCBs

TBAT

TBAT

TBAT

TBAT

TBAT

TBAT

20

PRESENT STATUS OF DG PLANT

Plant status

: All Units are available for Generation. : Generation will be as per Load Despatch direction.

Status of Maintenance : 60000 Hrs. major maintenance Works have been completed on 3 Units. Plan of Action proposed: 2008-09 a) 6000 Hrs. maintenance works on unit-1,3 & 5. b) Procurement of spares for 6000 hrs Scheduled maintenance works of unit 1 and 3 under progress.
21

SEMT Guidelines for Scheduled Maintenance Works

a)

Major maintenance works to be carried-out at: 12000 Hrs. 24000 Hrs. 36000 Hrs.

48000 Hrs. & 60000 Hrs and so on. b) Minor maintenance works to be carried-out at 6000 Hrs. 18000 Hrs. 30000 Hrs. 42000 Hrs. 54000 Hrs. and so on.

22

SEMT GUIDELINES FOR SCHEDULE MAINTENANCE WORKS SL. NO. COMPULSORY REPLACEMENT OF PARTS EVERY EVERY
6 000 HRS. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. EXHAUST SEALING RINGS ROCKER ARM SHAFTS & BUSHES BIG END BEARING SHELL BIG END TIE BOLTS & NUTS PISTON RINGS LINER ORings GASKETS OF INSPECTION DOOR & SAFETY VALVES LIP SEAL OF SHAFT OIL SEAL EXTERNAL BEARING SHELL REPLACE AUTOMISERS INSPECT THE ROTATING DEVICES, CRANK CASE, BEARINGS INSPECTION OF TIMING GEARS, FILTERS, AIR VALVES INSPECTION OF GOVERNOR REPLACEMENT OF STATIC O RINGS NO NO NO NO NO NO NO NO NO YES YES YES YES YES 12, 000 HRS. YES NO YES NO YES NO YES NO NO YES YES YES YES YES

EVERY 24, 000 HRS. YES YES YES YES YES YES YES YES YES YES YES YES YES YES

NOTE: REPLACEMENT OF MAJOR PARTS LIKE EXHAUST VALVES, INLET VALVES, CYLINDER HEADS, LINERS ETC., DEPEND ON THE MEASUREMENTS& CLEARANCES TAKENOUT AFTER DISMANTLING 23

Cost of Major Maintenance Works Carried-out at DG Plant

Amount in Rs. lakhs

Type of Maintenance Works

12,000 Hrs. 24,000 Hrs. 36,000 Hrs. 48,000 Hrs. 54,000 Hrs. 60,000 Hrs.

Unit-1
175.77 469.47 154.65 254.36 -

Unit-2
48.48 337.38 159.45 292.04 31.89 230.00

Unit-3
48.97 299.73 190.28 260.83 32.99 244.00

Unit-4
331.25 290.67 139.19 315.67 -

Unit-5
68.12 331.83 222.68 -

Average Unit-6 Cost of Maintenance

17.64 330.19 124.65 265.00 23.61 230.00 115 343 165 283 30 235.00
24

YEARS IN WHICH SCHEDULED MAINTENANCE CARRIED-OUT

YEAR 1996-97 1997-98 1998-99 1999-00 TYPE OF MAINTENANCE 12000 hrs 12000 hrs 24000 hrs 24000 hrs 30000 hrs 30000 hrs 36000 hrs 36000 hrs 42000 hrs 42000 hrs 2002-03 48000 hrs 54000 hrs 2003-04 48000 hrs 54000 hrs 48000 hrs 2004-05 54000 hrs 60000 hrs 2005-06 2006-07 Nil 60,000 hrs. nil UNITS 2,3,5 & 6 1&4 2, 3 & 6 1, 4 & 5 2&6 4&5 3, 4 & 6 1, 2 & 5 3, 4 & 6 1, 2 & 5 2, 3 & 6 3 4 2&6 5 2,3 & 6 3 2&6

2000-01

2001-02

25

SCHEDULE OF GUARANTEES
FUEL SPECIFIC FUEL CONSUMPTION / gms/Kwh 191.9 189.9 196.2 219.2 Lube Oil CONSUMPTION grms/hour 22730 17820 14850 ---

At 100% load At 75% load At 50% load At 25% load

The Specific Fuel Consumption past in is 10 years , varied from 196.23 gms to 216.46 gms/Kwh for base load operation. The lube oil consumption also varied from 1.6grams/kwh to 1.9grams/kwh against the performance test result of 1.4grams/hr(22.490Kg/Hr) at base load .
26

 DIESEL ENGINES

The 6 Diesel Engines each 21.32 MW capacity along with the auxiliary equipments were supplied by M/s SEMT Pielstick, France. These Diesel Engines are medium speed type running at 428 RPM directly coupled (without flywheel) to the alternator and are designed to operate on multifuels viz. heavy fuel oil, LSHS and FO .Thermal efficiency of Diesel Engine is 46.7%. Each Diesel Engine has got 18 cylinders and each cylinder has got 2 inlet valves, 2 exhaust valves and one fuel injector with fuel pump. Each Diesel Engine is equipped with 2 turbo-chargers and a waste heat recovery boiler. The Turbo Charger (TC) supplies air required for ignition at a pressure of 2.5 to 3 bar The TC comprises mainly a compressor coupled to a turbine driven by engine exhaust gas . For starting, and for running at low loads upto 35% of rated capacity, the engines require HSD as secondary fuel.
27

Waste Heat Recovery Boiler

The Exhaust gas at 410C heats the water in Waste recovery boiler to a temperature of 135C and the steam produced is used for heat tracing LSHS lines to reach Engines at appropriate viscosity(13.5 to 16.5 Cst) The exhaust gas escapes to atmosphere at a height of 45 Mtr Stack (Restricted due to Aviation Controls) The Stack releases are monitored as per the norms of Pollution Control Board in considerations of the dew points. SOx & NOx levels of the exhaust contents. Proper Aviation lights are provided at top of Stacks.

28

NUMBER OF RUNNING HOURS AS ON 31.1.2008

Unit

Total No of Running Hours 57852 68679 73211 63356 61598 68156

Previous Major maintenance 52117 66398 66496 61070 57269 65107

After Previous major maintenance 5735 2681 6715 2286 4329 3049

Unit 1 Unit 2 Unit 3 Unit 4 Unit 5 Unit 6

29

STARTING OF DG SETS (FROM COLD CONDITION)

Lube oil main pump to run about 15 Hrs to get Engine Lube oil temperature of 45C. Jacket Water pump to run for 15 Hrs to get Engine Jacket Water temperature of 40C. Two units to be run on HSD for about 24 Hrs to get steam pressure of 2.5 Bar and temperature of 120C. LSHS should attain 80C by Steam tracing to Start Ring Pump. 160 KL of HSD Required for cold starting.
30

BREAK POINT OF FUEL CONSUMPTION (HSD AND LSHS)

(@Net Cal. Values of Std sample) (HSD:10260 & LSHS:9740 Kcal/Kg)

Sl no.

LSHS gm/ kwh

HSD WACV in gm/ KCal/Kg Kwh

Heat rate Kcal/Kg

No.of Units

PLF %

Generation MU/Month

1 2 3 4 5 6 7

175 180 185 190 192 193 193

25 18 12 6 4 2.8 2.5

9805.0 9787.3 9771.7 9755.9 9750.6 9747.4 9746.6

2054.52 2029.02 2014.44 1999.85 1950.38 1942.47 1937.92

2 2&3 3 3&4 4 5&6 6

24 33 41 49 67 72.5 98

18.79 25.92 38.88 45.36 51.84 60.91 69.98

31
VC=FC

POWER PURCHASE AGREEMENT-PPA

DRAFT PPA STIPULATES PAYMENT OF VARIABLE CHARGES LOWER OF THE FOLLOWING: A. VARIABLE CHARGES CALCULATED AS PER THE FORMULA (Rs./KWH) a) VC (due to fuel) =1995 X Wtd.Av. Cost of fuel Wtd.Av.Cal.value (1-AC%) b) VC (due to LO) =1.1 X LO Cost per gram (1-AC%)

B. Actual expenses made on fuel and Lube oils against accounts of a tariff calendar month. Most of the times A < B and there is revenue loss to DG Plant
32

PPA
Heat Rate :Station heat rate is stipulated by KERC is 1995 K Cal/KWH.based on the statistics of the plant during 2001-02,02-03 and LCV of the fuel. The heat rate now reached is more than 2050 K cal/KWH due to reasons: a) Frequent Cold Starts consuming more secondary fuel ie.HSD & Auxiliary consumption.(More than 3.5%) with lower Cal. value of LSHS and viscosity. b) Plant is operated in seasonal peaks from December to beginning of monsoon. c) The life of the plant reaching 15 years influences the fuel consumption. KERC should accept our appeal for Heat rate of 2050 Kcal/KWH & Aux Con. to extent of 4% of gross generation.

33

M/s IOCL expressed their inability to supply more than 5TMT of LSHS owing to restricted availability of LSHS due to all refineries tending to become zero residual refinery(ZRR) due to increasing availability of LNG from other sources Hence , requested us to accept LSFO with less than 2% sulphur The IOCLs proposal for supply of LSFO with (< 2 % sulphur) has been apprised to KSPCB and SPPCC for necessary consent and concurrence for use in place of LSHS (<1 % sulphur). The consent and concurrence from KSPCB & SPPCC is awaited. M/s IOCL were requested to explore the possibility for supply of LSFO(<1%sulphur). M/s IOCL offered to supply the LSFO (<1 % sulphur) by importing the same on high sea sales basis unloaded from the harbour and transported through tankers by road from Mangalore to Yelahanka for which KPCLs firm commitment was requested with price on back to back basis.
34

The infra structure for unloading LSHS at yelahanka terminal by IOCL is about one rake / day(1400MT). To operate all the six units 11 to 12 rakes are to be unloaded per month . The turn around time taken by each rake for a long haul ( Koyali to Yelahanka) is 15 to 20 days per trip. Only about 21 rakes are available in railway for transportation of LSHS . Hence M/s IOCL are facing difficulty in getting rakes for loading to DG plant , Yelahanka. M/s IOCL were unable to get more than 3 to4 rakes from the railways. IOCL informed that railways are placing restriction at Koyali refinery for loading rakes to yelahanka and hence requested KPCL to address a letter to railways for releasing empty rakes for DG plant requirement of LSHS. Accordingly a draft letter addressed to Member traffic railway ministry has been sent to HO for further transmission to Railway department.
35

M/s IOCL have taken action to supply LSHS , Ex Narimanam from their refinery at Narimanam through tankers by road due to non availability of railway facility at Narimanam. The existing infra structure at IOCL depot is sufficient to unload about 15 to 20 (200 MT) trucks per day. In order to operate 5 units rake receipts with IOCL utility of tanks (1000 KL) have to be made use. If other vendors are explored for supply of LSHS, maximum10 trucks can be directly unloaded to plant tanks. In this case only one unit can be run depending on truck unloading capacity and constraints due to available storage tank.

36

LSFO has not been used in DG Plant so far. At present only one HFO ring pump circuit is available. Which may not be capable to handle two residual oils (LSHS & LSFO) simultaneously due to variation in fire points and pour points. Pipe lines carrying the fuel may choke due to variations in viscosity. The centrifuges require modifications to handle LSFO for separation of water and sludge content and also the annunciation panels and settings in the control room requires modification. There is no separate storage facility for this fuel. If at all it requires to be used, the existing tanks and pipe lines are to be cleaned thoroughly for using LSFO. To unload the fuel supplied by trucks additional crew is required and also it has to be done only during day light. Only two units can be operated if both the fuels have to be used one after other depending upon its availability.
37

ALTERNATE FUEL PROPOSAL

Due to CNG becoming more available from new sources , all refineries are switching over to CNG production and proceeding towards becoming ZRR( Zero residual refineries) i.e LSHS may become redundant shortly. IOCL have intimated that Karnataka State is also expected to become complete user of CNG by 2011.
38

Alternate fuel

HPCL have also opined the same .Hence LSFO(Low sulphur Furnace oil) with less sulphur content has been proposed for use in DG Plant yelahanka until switching over to gas. As DG Plant units are designed to operate on multi fuels, proposal to use LSFO has been put up to KSPCB for issuing the consent. The HO has also been apprised about this issue.

39

ENERGY GENERATED, FUEL CONSUMED FROM THE DATE OF COMMISSIONING TILL DATE AT DG PLANT (YEAR WISE GENERATION AT DG PLANT YELAHANKA)

Year 92-93 93-94 94-95 95-96 96-97 97-98 98-99

Gross units generated in MUs 0.012 148.46 364.65 542.54 536.73 665.45 625.01

Aux. cons. in MU 0.003 9.055 15.396 20.619 19.881 22.625 22.079

Aux. cons. in % 25 6.1 4.22 3.8 3.7 3.4 3.53

Net Units in MUs 0.009 139.41 349.25 521.92 560.65 642.83 602.93

HSD in KL 36.97 36407.4 12288.9 16664.8 6585.0 8406.75 8482.28

F.O. in KL -1149.63 61996.1 6237.71 4785.78 ---

LSHS in MT -716.735 3901.67 87703.4 95868.7 123898.3 117793.4

L.O. in KL 45.74 668.1 823.3 911.3 896.9 1033.6 1013.5

Hours Run 2 15176.1 25754.3 31140.6 29130.7 36798.1 36716

%PLF 108 MW --15.69 38.54 57.35 56.73 70.34 66.06

40

ENERGY GENERATED, FUEL CONSUMED FROM THE DATE OF COMMISSIONING TILL DATE AT DG PLANT (YEAR WISE GENERATION AT DG PLANT YELAHANKA)
Gross units genera ted in MUs 707.49 658.40 768.73 706.82 397.91 271.46 96.69 139.55 96.44

Year 99-00 00-01 01-02 02-03 03-04 04-05 05-06 06-07 07-08*

Aux. cons. in MU 21.32 19.51 22.75 21.82 13.90 9.50 3.38 4.89 3.41

Aux. cons. in % 3.01 2.96 2.96 3.09 3.49 3.50 3.50 3.50 3.54

Net Units in MUs 686.17 632.50 738.52 685.01 384.01 261.96 91.57 134.65 93.01

HSD in KL 3339.04 2970.63 2861.3 2814.99 3050.12 2224.26 825.82 1515.44 642.48

F.O . in KL

LSHS in MT 136130.1 128219.3 149129.9 136712.6 94419.12 52914.6 18951.08 26848.36 18679.15

L.O. in KL 1138 1012.16 1141.5 1181.44 726.33 477.77 171.74 167.387 170.38

Hours Run 38547.9 35530.5 42637.2 38878.6 22412.1 15674.35 5367.2 8187.7 5465.4

PLF % on 108 MW 74.78 69.59 81.25 74.71 42.06 28.69 10.22 14.75 10.19

41

FUELOIL SPECIFICATIONS
SPECIFICATIONS Sp gravity Ash content ( max) Pour point Kinematic CST viscosity LSHS 0.91 0.10 % by weight 72 deg C 700 @ 50 C max
0

HSD 0.83% -0.85 % @ 15 Deg cent 0.02 % by weight 12 deg 18deg C 2.5-15.7 @ 38 deg C

LUBE OIL ---13.515.3 @100 deg C -----96 29.5 36.5 42

Sediment % by wt ( max) Total sulphur content ( max) Water content % by volume Gross calorific value ( Kcal/Kg) Net calorific value Viscosity index TBN (Total base number)

0.25 0.75 % by wt 1.00 10000 -n.a. --

0.10 1.80 % 0.25 (Max) 10900 10230 n.a ---

TREND OF PRICE RISE OF FUEL OILS WITH TARIFF

AVERAGE PRICE OF LSHS/Kg (in Rs.) 12.36 10.83 13.49 13.53 15.05 20.34* 24.76* 25.90* AVERAGE PRICE OF HSD/Ltr. (in Rs.) 15.48 17.16 17.14 21.11 25.99 31.76 35.16 41.98 AVERAGE PRICE OF LO/Ltr. (in Rs.) 46.80 53.14 56.74 51.47 52.72 51.48 75.05 92.40 TREND TARIFF

YEAR

LSHS BASE -13% +9% +9% +21% +64% +200% +209%

HSD BASE +10.8% +10.7% +37% +68% +200% +227% +271%

2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 2007-08

2.671 2.344 2.944 2.950 (PPA) 3.030 4.980 5.640 5.744 43

*EXICE DUTY AFFFECTED FROM SEPT 2005 ON LSHS

TREND OF PRICE RISE OF FUEL OILS

180 160 140 120 100 80 60 40 20 0 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 2007-08 AVERAGE PRICE OF LSHS/Kg (in Rs.) AVERAGE PRICE OF LO/Ltr. (in Rs.) AVERAGE PRICE OF HSD/Ltr. (in Rs.)

44

KARNATAKA POWER CORPORTION LIMITED DG PLANT, YELAHANKA PARTICULARS OF GENERATION, FUEL COST, HEAT RATE, SFC & VARIABLE COST YEAR GROSS GEN (in MU) AUX. CONS. (in MU) AUX. CONS. (in %) NET GEN (in MU) (SALE OF ENERGY) TAR HSD GETD. CONSUMED GEN (in (in KL) MU) LSHS CONSUMED (in MT) LUBE OIL WTD. AVG GROSS CONS. CALORIFI HEAT (in KL) C VALUE RATE (Kcal/Kg) Kcal/Kwh % PLF on 108 MW

2000-01 652.02

19.52

2.99

632.500

689

2970.630

128219.299 1012.160 9832.00

1952.00

68.92

2001-02 768.73

30.21

3.93

738.520

689

2861.300

149129.995 1141.480 9805.00

1933.00

81.25

2002-03 706.82

21.81

3.09

685.010

689

2814.990

136712.557 1181.440 9751.00

1919.00

74.71

2003-04 397.91

13.90

3.49

384.010

689

3050.120

94419.120

726.330

9778.18

1934.70

42.06

2004-05 271.46

9.50

3.50

261.961

689

2224.260

52914.601

477.770

9932.38

2007.50

28.69

2005-06

96.69

5.12

5.29

91.570

240

825.820

18951.080

171.740

9831.86

1963.50

10.22

2006-07 139.55

4.90

3.51

134.650

240

1515.436

26848.360

167.387

9862.83

1994.50

14.75

2007-08* 96.44

3.44

3.56

93.005

240

642.482

18679.145

170.380

9725.21

1999.33

10.19

As per KERC Norms the % Aux iliary Consumption is stipulated 3.5% of Gross Generation and Station He at Rate is 1995 Kcal/Kw h * Gene ra tion up to October-2007 Tariff Month

45

YEAR

AV. PRICE COST OF AV. PRICE OF OF LSHS / HSD HSD / KL MT (in UTILISED (in Rs.) Rs.) (in Lakhs)

COST OF AV. PRICE OF WTD. WTD. SPECIFIC FUEL VAR. VAR. TOTAL VAR. LUBE OIL LO / KL AVG AVG CONSUM- PTION COST COST COST UTILISED (in Rs.) COST OF COST OF (gm/KWH) DUE TO DUE TO (in Lakhs) FUEL LUBE OIL FUEL LUBE (Rs/Kg) (Rs/Kg) OIL LSHS+ HSD LO

2000-01 12366.03

459.930

15482.57

473.670

46797.94

12.46

52.17

190.41

1.47

2.61

0.059

2.671

2001-02 10831.61

491.230

17168.07

606.530

53135.40

10.82

59.73

220.60

1.66

2.28

0.068

2.344

2002-03 13498.07

502.700

17857.97

606.890

51368.67

13.63

56.74

202.51

1.71

2.88

0.064

2.944

2003-04 10807.98

635.840

20846.39

377.840

52020.43

13.64

51.81

253.82

1.83

2.89

0.060

2.950

2004-05 13497.50

604.080

27158.70

236.600

49521.74

14.27

56.34

210.48

1.76

2.97

0.060

3.030

2005-06 20344.28

262.490

31785.38

81.010

47170.14

23.38

48.42

215.98

1.78

4.92

0.060

4.980

2006-07 24764.08

531.370

35063.84

122.620

73255.39

26.44

78.45

210.65

1.20

5.55

0.090

5.640

2007-08* 25909.06

269.747

41985.15

157.414

92389.95

26.47

91.91

207.75

1.77

5.64

0.105

5.744 46

Requirement of fuel (LSHS) for operation of units on peak load of 18 MW

Fuel required per day (MT) / KL MT One unit Two units Three units Four units Five units Six units Monthly requirement for all units The rate of fuel is taken as on 29-02-08 Rs.31602 per MT 90 180 270 360 450 540 16200 KL 100 200 300 400 500 600 18000

Fuel Cost In Lakhs

Remarks

28.44 56.88 85.33 113.77 142.21 170.65 511.95

47

Fuel receipts for last three years

Name of the fuel 2005-06 2006-07 2007-08

HSD

735.407 KL

1598.220 KL

1505.896 KL

LSHS

166617.28 MT

27675.56 MT

35739.43 MT

LUBE OIL

95.141 KL

193.439 KL

461.092 KL

48

 uqxSx q u xS q x q m UhN .d. UhN m.d.

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