Certified ISO 14001 : 1996 standard

IB THERMAL POWER STATION

The Company
Orissa Power Generation Corporation conceived on 14th November-1984, owns Ib Thermal Power Station with a capacity of 420 MW at Ib valley area of Jharsuguda district in the State of Orissa.

The Company
Prior to 1999 it was the Govt. Of Orissa Under Taking. During December 1998 ,Orissa Govt. entered into a joint venture with AES thereby giving operational control to AES. The transaction resulted in AES acquiring 49% equity in OPGC share.

The Company
OPGC It It

is committed to provide clean,low cost and reliable power to the state. has also highest commitment towards safety and clean environment. has obtained a number of awards both from state and center for its remarkable achievement in different fields.

Award Winning Performance of OPGC

Recipient of meritorious performance award from MOP, GOI for the year 00-01,03-04. Certificate of merit from MOP,GOI for low sp oil 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 20022003. Green tech safety gold award for 2004-2005.

Energy Conservation Programme

at

Ib Thermal Power Station

Efficiency Department

ACTION PLANS For Aux. Power Reduction.

Operation & Maintenance
Duct Repair using castable ceramite coating during annual outage

Installation of Soft touch seal in AirPreheater

PA duct & Expansion Joint Repair Condenser cleaning for improvement of vacuum Repair & Replacement of BFP R/C valves

ACTION PLANS For Aux. Power Reduction.

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

ACTION PLANS For Aux. Power Reduction.

CAPITAL INVESTMENT
Using FRP blades for CT fans in Cooling Tower

100 % dry ash modification

Installation of capacitor banks in HT motors
Efficiency Department

Installation of VVF drive in selected auxiliaries

Energy conservation by Heat Rate Improvement.

OPERATING PRACTICE
Continuous Blow down operation is being regulated as per requirement

Intelligent Soot blowing operation

Startup & stabilization optimization

Trip analysis & recommendation for rectification

Efficiency Department

Energy conservation by Heat Rate Improvement.

Combustion Optimization
Dirty Pitot tube test for setting fuel/Air Ratio and velocity deviation

Automatic Ash Sampling is to be installed for LOI optimization

Hot Foil LOI Analyser procurement for smart LOI analysis FG gas analysis for Co trimming in Furnace
Efficiency Department

Energy conservation by Heat Rate Improvement.

Performance Testing
Condenser Air-ingress test by Helium detection

Condenser performance testing

Heater performance testing

BFP performance testing

Efficiency Department

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

DUCT

MODIFICATION

Before unit 2 annual overhauling, the ID fans were drawing 155 amp (at full load). In overhauling the ducts were opened & found there were holes in the bends and corners of ducts. The holes were formed due to flue gas erosion especially where the direction of velocity changes.
Efficiency Department

 In the overhauling, the castable refractory was applied on the bends & corners of duct.
After undertaking the modification work in ducts, the current drawn by the ID fans was reduced to 15 amp (at same load) So by applying castable refractory and welding work in ducts, there is a saving of 15 amp / ID fan.
Efficiency Department

Ceramite coating in the bend

Efficiency Department

castable refractory in the corner

Efficiency Department

Repair of Ducts
Recurring problem Increases load on ID fan Expected expenditure for repair Rs.10 lacs Payback period < 6 months Long term Modify the ducts to reduce friction leading to saving in Aux Consumption and life Gas Distribution test

PRDS system
Both pressure reducing and spray valve have passing.
Old design- OEM, IEL not able to solve the problem Modifying to proven design of CCI Expected cost Rs.50 lacs Savings 8~10 Kcal Pay back period two years

HP Bypass system
HP bypass control valve and spray valves are passing
For HP bypass valve improved seat is sourced from OEM CCI Sulzer Spray valve is being replaced with new proven design of CCI

Expected cost Rs 60 lacs

Saving 14 kcal Payback three years

Smart Soot Blowing System

Approx cost 1.2 Crores per unit Pay back period ~3 years

Soot blowing only when required, saving in heat rate and reduce chances tube failure, increase overall heat transfer Final decision yet to taken
Feasible only in 2006 annual shutdown
Efficiency Department

Condenser Cleaning Bullets

Clean the condenser during annual outage
Introduce the bullet cleaning cost involvement - Rs 2 lacs Improve HR and CF Payback less ~10 months

Efficiency Department

CT FANS
CT fans of both the units were installed
by M/s Paharpur Cooling Towers Ltd. With blades made of glass wool filled solid blades. Power consumption per fan was 48 Kw with normal flow rate of 929023 CFM. It was proposed to replace the solid blades with hollow ones for economic power consumption.

Efficiency Department

Fan Motor CW IN
F low C V Open Hot water Distribution basin

Louvers

Drft Elim inator Splash fill O r Splash Bar Air Flow Basin

CW OUT

CROSS FLOW INDUCED DRAFT COOLING TOWER

Efficiency Department

 Accordingly FRP hollow blades from M/s Encon Ltd have been replaced in 12 no of CT fans. By installing FRP blades the energy consumption reduced to 30 Kw, with improvement of flow rate to 1774899 CFM. Energy saving over the old solid blades is around 30 to 35%.
Efficiency Department

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 0.145 MU. The cost of energy saving will be Rs. 1.5 lacs / year. Cost of one FRP fan is Rs 2.6 lacs(approx).

Efficiency Department

Dry Ash Collection System

Erection of Dry Ash Collection System by dense 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 Handling system

Efficiency Department

Efficiency Department

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 in stead of 2 series One of the Recycle pump can be stopped out of 2 running pumps

Efficiency Department

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

Arresting BFP Recirculation Valve Passing By replacing the BPF Re-circulation valve from 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

Efficiency Department