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IB THERMAL POWER STATION

CertifiedISO 14001 : 1996 standard

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The Company

Orissa Power Generation Corporation

conceived on 14th

November-1984,owns Ib Thermal Power Station witha capacity of 420 MW at Ib valleyarea of Jharsuguda district in theState of Orissa.

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The Company

OPGC is committed to provide clean,lowcost and reliable power to the state.

It has also highest commitmenttowards safety and clean environment.

It has obtained a number of awardsboth from state and center for itsremarkable achievement in different

fields.

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Award Winning Performance of

OPGC

Recipient of meritorious performance awardfrom MOP, GOI for the year 00-01,03-04.

Certificate of merit from MOP,GOI for low spoil consumption for the year 2001,2002 &2003.

Green tech environment Gold award for 03-04. Best environment management award from

Directorate of Factories for the year 2002-2003.

Green tech safety gold award for 2004-2005.

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Energy ConservationProgrammeat

Ib Thermal Power Station

Efficiency Department

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ACTION PLANS For Aux. PowerReduction.Operation & Maintenance

Duct Repair using castable ceramite coating

during annual outageInstallation of Soft touch seal in Air-Preheater

PA duct & Expansion Joint Repair

Condenser cleaning for improvement ofvacuum

Repair & Replacement of BFP R/C valves

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ACTION PLANS For Aux. PowerReduction.MODIFICATIONS

PRDS modification

HP bypass spray system modification

BFP re-circulation valve modification

Air pre-heater baskets replacement

Flue gas duct repairs / modification

Efficiency Department

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ACTION PLANS For Aux. PowerReduction.CAPITAL INVESTMENT

Using FRP blades for CT fans in Cooling Tower

100 % dry ash modification

Installation of VVF drive in selected auxiliarie

Installation of capacitor banks in HT motors

Efficiency Department

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Energy conservation by Heat RateImprovement.OPERATING PRACTICE

Continuous Blow down operation is beingregulated as per requirement

Intelligent Soot blowing operation

Startup & stabilization optimizationTrip analysis & recommendation forrectification

Efficiency Department

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Energy conservation by Heat RateImprovement.Combustion Optimization

Dirty Pitot tube test for setting fuel/Air Ratioand velocity deviation

Automatic Ash Sampling is to be installed forLOI optimization

Hot Foil LOI Analyser procurement for smartLOI analysis

FG gas analysis for Co trimming in Furnace

Efficiency Department

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Energy conservation by Heat RateImprovement.Performance Testing

Condenser Air-ingress test by Heliumdetection

Condenser performance testing

Heater performance testingBFP performance testing

Efficiency Department

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OUR ONGOING IMPORTANT PROJECTS

.

Duct Modification

PRDS modification

HP Bypass System Modification Smart Soot blowing

Condenser Cleaning

FRP blades in CT fans

Dry Ash Evacuation system

BFP Re-Circulation Valve Replacement

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DUCT MODIFICATION

Before unit 2 annual overhauling, the IDfans were drawing 155 amp (at full load).

In overhauling the ducts were opened &found there were holes in the bends andcorners of ducts. The holes were formed

due to flue gas erosion especially wherethe direction of velocity changes.

Efficiency Department

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In the overhauling, the castablerefractory was applied on the bends &

corners of duct.

After undertaking the modification workin ducts, the current drawn by the IDfans was reduced to 15 amp (at sameload)

So by applying castable refractory andwelding work in ducts, there is a saving of15 amp / ID fan.

Efficiency Department

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Ceramite coating

in the bend

Efficiency Department

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castable

refractory in the

corner

Efficiency Department

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Repair of Ducts

Recurring problem

Increases load on ID fan

Expected expenditure for repair Rs.10lacs

Payback period < 6 months

Long term Modify the ducts to reducefriction leading to saving in Aux Consumptionand life

Gas Distribution test

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PRDS system

Both pressure reducing and spray valvehave passing.

Old design- OEM, IEL not able to solvethe problem

Modifying to proven design of CCI

Expected cost Rs.50 lacs

Savings 8~10 Kcal

Pay back period

two years

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HP Bypass system

HP bypass control valve and spray valves arepassing

For HP bypass valve improved seat is sourcedfrom OEM CCI Sulzer

Spray valve is being replaced with new proven

design of CCIExpected cost Rs 60 lacs

Saving 14 kcal

Pa back three ears

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Smart Soot Blowing

System

Approx cost 1.2 Crores per unit

Pay back period ~3 yearsSoot blowing only when required, saving inheat rate and reduce chances tube failure,

increase overall heat transferFinal decision yet to taken

Feasible only in 2006 annual shutdownEfficiency Department

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CT FANSCT fans of both the units were installedby M/s Paharpur Cooling Towers Ltd. Withblades made of glass wool filled solid blades.

Power consumption per fan was 48 Kw withnormal flow rate of 929023 CFM.

It was proposed to replace the solid bladeswith hollow ones for economic power

consumption.

Efficiency Department

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Fan

Motor

CW IN Flow CV

Open Hot w ater Distribution basin

Louvers

Drft Eliminator

Splash fill

Or Splash Bar Air Flow

Basin CW OUT

CROSS FLOW INDUCED DRAFT COOLING TOWEREfficiency Department

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Accordingly FRP hollow blades from M/sEncon Ltd have been replaced in 12 no of CT

fans. By installing FRP blades the energy

consumption reduced to 30 Kw, withimprovement of flow rate to 1774899 CFM.

Energy saving over the old solid blades isaround 30 to 35%.

Efficiency Department

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Energy Saving

Around 18 KW is being saved per fan.

Assuming 335 days/year of operation of a

fan, the total energy saving will be 0.145MU.

The cost of energy saving will be Rs. 1.5lacs / year.

Cost of one FRP fan is Rs 2.6 lacs(approx).

Efficiency Department

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Dry Ash Collection System

Erection of Dry Ash Collection System bydense phase evacuation is started by M/s

Ultratech & M/s OPGC The Fly Ash from 2nd Field onwards will be

supplied to M/s Ultratech

Energy saving from wet Ash Handlingsystem

Efficiency Department

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Efficiency Department

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Energy Saving

One LP pump will run in stead of 2

One HP pump will run in stead of 2

One series of Ash slurry pump will run instead of 2 series

One of the Recycle pump can be stoppedout of 2 running pumps

Efficiency Department

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Energy Savings

Additional 2 nos compressors are required

Additional 2 nos of blowers

Additional 2 nos Silo fluidizing Blowers

Net saving in Energy 900 kw

Efficiency Department

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Arresting BFP Recirculation ValvePassing

By replacing the BPF Re-circulation valvefrom M/s IEL make to M/s MIL around 15

Amps saving is achieved per BFP This saving is achieved after arresting the

Recirculation valve passing

Around 145 Kw saving is achieved

Efficiency Department

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Efficiency Department