Efficiency Enhancement Projects Sabarmati Thermal Power...

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Efficiency Enhancement Projects Sabarmati Thermal Power Station, AMGEN

Torrent Power Limited

Index

Si No. Description Page

01 Note on Efficiency Enhancement Projects 02

02 Note on ESP retrofit work 09

03 Past Performance data 11

04 GPCB Measurement data 24

05 Consent for Operation‐‐ 1986 27

06 NOC for F and C unit 32

07 Consent for Operation‐2013 36

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Note on Efficiency Enhancement Projects Sabarmati Thermal Power Station,

AMGEN, Torrent Power Limited

Preamble:

Torrent Power Limited (TPL), a part of the Torrent Group has the license to generate, transmit

and distribute electricity in app 380 sq. km. area covering entire Ahmedabad city and Capital

city of Gujarat state‐Gandhinagar. TPL have Coal Generating Stations in Ahmedabad (known as

AMGEN) comprising of following units with total installed capacity of 422 MW as on date. The

efficiency enhancement is carried out in phase manner in 110 mw units.

Unit Existing Capacity in MW

Date of commissioning

Date of enhancement in

capacity

New capacity in MW

C 60 12‐04‐1997 ‐ 60

D 110 12‐10‐1978 01‐04‐2004 120

E 110 31‐12‐1984 05‐11‐2013 121

F 110 28‐09‐1988 14‐05‐2013 121

AMGEN 390 422

Brief on Power Generation Processes at different Units at AMGEN ‐ Sabarmati:

Sabarmati TPS uses a blend of Indian and Imported coal as fuel. Coal is received at the power

station through rail wagons and is unloaded at site by wagon tippler. Subsequently coal is

crushed in a coal crusher to fine grain as per the required size from where it is transferred to

the station bunkers of Units – C, D, E & F by means of a coal conveyor belts. The coal from the

bunkers is fed to the steam generators after being pulverized in the coal mills.

The steam generators of 110 MW are tangentially fired; balance draught, natural circulation,

radiant reheat type, and dry bottom having bowl mills with direct firing arrangement of

pulverised coal.

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Key parameters of steam generators working are listed below:

Type of Steam Generator BHEL make corner fired type

Steam Generator Parameters (BMCR)

Main Steam ‐ 375T/hr @ 138 Kg/cm2(g) at 540oC

Feed water temp 241oC

Re‐heater inlet ‐ 313.5 T/hr @ 34kg/cm2(g) at 365oC

Re‐heater outlet ‐ 313.5 T/hr @ 32kg/cm2(g) at 540oC

Number of Oil Elevation Three (3)

Number of Coal Levels Six (6)

Re‐heat steam temp. control Burner tilting as a primary

In the steam generator, water is heated by the heat generated while burning coal in the furnace

and is converted into a high pressure steam. This high pressure steam is fed to the steam

turbine. The original steam turbine has the following key parameters.

Electrical output : 110 MW

Nominal speed : 3000 rpm

No. of cylinders : 3, namely High Pressure (HP), Intermediate Pressure (IP) and Low Pressure

(LP)

Live steam pressure at HP Turbine Inlet : 130 atm (g)

Live steam temperature at HP Turbine Inlet : 535°C

Steam temperature at IP Turbine inlet : 535°C

The steam Turbine is coupled with the Alternator to convert Mechanical Power of the Turbine

in to Electrical Power at the Output.

The Electrical Power (electricity) generated in the Alternator is fed to the 132 kV Switchyard via

Step up Transformer which is then transmitted to the grid through 132kV switchyard.

Brief on R&M work at AMGEN – Sabarmati

TPL has undertaking Renovation & Modernization (R&M) activities at 110 MW Units (For all

three units in phase manner) at AMGEN – Sabarmati as a part of its initiative to produce power

in a more environmental friendly and economic manner.

Following are the Major activities included under R&M work for all three 110 MW Units.

Improvement in Turbine Cycle Efficiency & efficient control of Steam Turbines.

o Retrofitting the existing turbine components (turbine internals) with new state of

the art efficient turbine components. The turbine rotors & inner casings shall be

replaced where as the existing outer casings will be retained.

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o Replacement of Gland Sealing & Leak OFF System

o Refurbishment / re‐babitting of turbine bearings to suit the requirements of the

retrofitted turbine rotors.

o Replacement of turbine control system with state of the art Electro Hydraulic

Turbine Control system (EHTC) to achieve better control of TG set.

o Replacement of turbine drain system to facilitate Automatic Turbine Run‐up System

(ATRS)

o These activities helped in improvement of turbine efficiency.

o D unit 3rd ESP path installed and commissioned for improving the overall ESP system

performance. While E and F unit ESP system retrofit by increases height of ESP

system results in higher area available for ESP system. Also the old ash collection

mechanism replaced with new and efficient system

Technical Description of the new System: Turbine.

In order to reduce the emission of green house gases, TPL has carry out Renovation &

Modernization (R&M) work at existing 110 MW Units at AMGEN – Sabarmati Power Station as a

proactive step towards protection of environment. Under these projects, TPL changed the

turbine internals. After this retrofit, there is no change in pollution load. Incidentally, the unit

capacity was also enhanced to 121 MW from the existing rating of 110 MW.

The modification of steam turbine consists of replacement of turbine internals (Rotors & inner

casings) with state of the art energy efficient turbine components. The original gland sealing &

leak‐off system has replaced to suit with the new turbine components. The original bearings

have modified & re‐babitted to match with requirements of retrofitted turbines. The turbine

drain system components have replaced to match requirements of new turbine controls & auto

run‐up system.

High Pressure Turbine

The HP turbine is of similar design as the original one. The original design with the Curtis type

control stage and eight impulse stages have replaced by the A‐type control stage and nine other

impulse stages.

The new HP rotor is fitted with improved specific blades. The blades are fixed to the rotor by

"T" clamped roots or fork type pinned roots and bound in bundles by shrouds. These shrouds

bind the blades to increase the dynamic stiffness, and are also used for forming the peripheral

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sealing of the moving blades. The HP rotor is machined from a solid forging including a coupling

flange for its mutual connection to the IP rotor. The connections among the turbine rotors are

made by means of rigid couplings with fitted bolts.

Intermediate Pressure Turbine

The IP turbine is of similar design as the original one with the same number of stages. Some of

the salient features are as below:

a. The new rotor is fitted with improved specific blades. The blades are fixed to the rotor by

"T" clamped roots or fork type pinned roots and they are bound in bundles by shrouds.

These shrouds bind the blades to increase the dynamic stiffness, but they are also used for

forming the peripheral sealing of the moving blades. The rotor is machined from a solid

forging including coupling flanges for its mutual connection to the HP and LP rotors. The

connections among the turbine rotors are made by means of rigid couplings with fitted

bolts.

b. The inner casing including sealing rings for two pipes of steam inlets to casing, carriers,

improved gland casings along with gland rings, the nozzle box of improved design used.

c. The diaphragms have placed in the inner casing and in two new carriers; last two

diaphragms has placed in the original outer casing. All the diaphragms have made of steel

and the nozzle cascades fixed by means of pins in the diaphragms discs and rims. The

diaphragms have mounted in the inner casing and two carriers. New upgraded nozzles 3D

profiles, more perfectly streamlined, optimised from the point of minimization of

aerodynamic losses have used. The new inter stage sealing arrangements (honeycomb type)

has form parts of the diaphragms (guide wheels).

d. All shaft glands are of an axial flow labyrinth type. The labyrinths rings are mounted in the

seal casings or in the diaphragms. Rebounding labyrinth rings made from stainless material

is used. These rings are divided into six parts; they are pressed into their operating position

by springs and by the pressure of the steam. The teeth are turned on the labyrinth rings. On

the individual rings there are alternate higher and lower teeth. A true labyrinth forms the

seal. Inter stage‐sealing arrangements are also provided.

e. The original outer casing has repaired and retained.

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Low Pressure Turbine

The LP turbine is of similar design as the original one. The original number of stages 2 x 4 is

retained. Some of the salient features are as below:

a. The original front and rear exhaust casings and the middle casing is used and retained. The

solid forging rotor including coupling flanges, moving blades, diaphragms including labyrinth

rings and the modified gland casings for both front and rear outer glands along with gland

rings used are new ones.

b. The new rotor is fitted with improved specific blades. Moving blades of all stages are fixed

to the rotor by fork type pinned roots. Moving blades are bound in bundles by shrouds.

These shrouds bind the blades to increase the dynamic stiffness, but they are also used for

forming the peripheral sealing of the moving blades. The moving blades of the last two

stages are designed with twisted transonic profiles, which enable to achieve higher

efficiency. Last two moving blades are very rigid, free standing, without any lacing wire and

it gives the possibility to operate continuously in range 47.5 to 51.5 Hz. Erosion protection

of the moving blades fitted to the last stage is achieved by using a surface hardening

process during manufacture. The rotor is machined from a solid forging including coupling

flanges for its mutual connection to the IP rotor and generator rotor. The connections

among these rotors are made by means of rigid couplings with fitted bolts.

c. First two diaphragms are made of steel, and the nozzle cascades are fixed by means of pins

in the diaphragms discs and rims. Other two diaphragms are made of steel, and the nozzle

cascades are welded to the diaphragms discs and rims. The diaphragms are divided in the

horizontal axis to form upper and lower halves. They are mounted in the middle casing,

centre‐line supported, to maintain precise inter‐stage sealing clearances.

d. All shaft glands are of an axial flow labyrinth type. The labyrinths rings are mounted in the

seal casings or in the diaphragms. Rebounding labyrinth rings made from stainless material

are used. These rings are divided into six parts; they are pressed into their operating

position by springs and by the pressure of the steam. Teeth of the same height are used

against a smooth rotor ‐ untrue labyrinth. Inter stage‐sealing arrangements are also

provided.

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The Turbine rotor blade profile and advanced seals which improves the efficiency.

Indicative assembly of a 3 casing turbine in the existing outer casings is given below:

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Top view of final assembly work of new Turbine rotor.

Final Assembled Turbine after up rating work.

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Note on ESP retrofit work done during the Turbine R & M work.

ESP Up‐gradation at D STN

• Additional ESP Path containing 5 fields added in parallel to existing two paths

• Original ESP had 4 fields per path i.e. total 8 fields, after up‐gradation total field 13

Major work carried out

• Construction of new path in parallel to existing paths

• Construction of new ESP control room

• Replacement of Power & control panels with cabling

• New EPIC‐III controllers for all the 13 fields

• Extension of ash handling system for new ESP path

• Overhauling of Existing ESP paths including replacement of warn out internals.

New ESP 3rd Path. ESP control room with latest controls.

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ESP Up‐gradation at E and F STN

Major works.

• Replacement of all internals of existing ESP paths

• Filling of Dummy Fields

• Total fields after dummy field filling – 14

• Increase in height of Existing ESP by @ 1.6 mtr.

• Replacement of ESP controllers with EPIC‐III controllers

• Replacement of power & control panels with cabling.

E and F unit ESP Retrofitting work photograph.

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Past Performance data

As explained above Torrent Power Limited‐Sabarmati plant capacity increases from 390 MW to

422 MW without increase in the input parameters for the turbine. Also there is no change in

the pollution load by improving the Turbine efficiency. The environment parameters like Stack

emission, Air quality etc. remains well within the approved limit and no major upward change

observed in the emission parameters after retrofitting work. The emission parameters for the

last five years as measured and submitted by schedule‐1 auditor in the Annual Audit report is

tabulated as under for ready reference.

Emission.

Year 2011 (Auditor—ATIRA)

Stack Emission

ROUND – 1 Date: 28‐29/04/2011

Stack Side SPM NOx

GPCB Limit 100 mg/Nm3 50 ppm

C Stack Left 88 0.59

Right 52 0.65

D Stack Left 56 0.46

Right 48 0.45

E Stack Left 38 0.17

Right 52 0.24

F Stack Left 42 0.26

Right 46 0.21

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ROUND – 2 Date: 06/07/2011

Stack Side SPM NOx


C Stack Left 31.11 1.2

Right 69.24 0.85

D Stack Left 69.45 1.36

Right 51.81 0.67

E Stack Left 23.08 0.89

Right 52.18 1.3

F Stack Left 66.98 2.34

Right 45.95 0.80

ROUND – 3 Date: 21/11/2011

Stack Side SPM NOx


C Stack Left 72.35 3.8

Right 23.83 2.6

D Stack Left 77.77 3.4

Right 48.35 0.6

E Stack Left 31.11 0.4

Right 42.35 1.2

F Stack Left 60.39 2.8

Right 42.14 3.2

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Ambient Air Quality.

ROUND – 1 Date: 28/04/2011

Sr.

No. Location PM 10 PM 2.5 SO2 NOx

GPCB Limit 100 µg/m3 60 µg/m3 80 µg/m3 80 µg/m3

1 On Terrace of Lab 82.2 22.18 21.73 8.72

ROUND – 2 Date: 06/07/2011

Sr.



1 On Terrace of Lab 59.70 3.9 12.40 4.10

ROUND – 3 Date: 21/11/2011

Sr.



1 On Terrace of Lab 48.5 26.59 14.30 3.48

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Year 2012 (Auditor—GITCO)

Stack Emission

Round‐1 Date: 14/3/2012

Stack Side SPM NOx


C Stack River Side 49.9 7.1

Road Side 53.4 7.6

D Stack River Side 68.9 6.7

Road Side 76.4 8.0

E Stack River Side 52.7 7.9

Road Side 48.6 8.0

F Stack River Side 43.9 7.5

Road Side 60.1 6.8

Round‐2 Date: 06/09/2012

Stack Side SPM NOx



Road Side 64.9 9.4


Road Side 68.7 11.0


Road Side 54.3 11.7


Road Side 52.5 11.6

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Round‐3 Date: 27/11/2012 & 28/12/2012

Stack Side SPM NOx



Road Side 69.7 11.0


Road Side 59.7 11.8


Road Side 63.9 11.5


Road Side 41.7 11.6

Ambient Air quality

ROUND – 1 Date: 14/03/2012

Sr.

No. Location PM 10 PM 2.5 SO2 NOx SPM

GPCB Limit 100 µg/m3 60 µg/m3 80 µg/m3 80 µg/m3 200 µg/m3

1 On Terrace of Lab 86.9 ‐ 32.7 16.3 178.2

ROUND – 2 Date: 06/09/2012

Sr.



1 On Terrace of Lab 92.8 ‐ 26.5 18.1 189.9

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ROUND – 3 Date: 27/11/2012

Sr.



1 On Terrace of Lab 91.3 54.7 24.1 22.0 ‐


Stack Emission

Round‐1 Date: 17/05/2013

Stack Side SPM NOx



Road Side 61.2 7.3


Road Side 68.7 8.1


Road Side 57.8 8.6


Road Side 52.6 8.5

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Round‐2 Date: 21/08/2013

Stack Side SPM NOx



Road Side 57.2 9.1


Road Side 60.9 6.7

E Stack River Side Unit

Shutdown Unit

Shutdown Road Side


Road Side 55.2 8.4

Round‐3 Date: 22/11/2013

Stack Side SPM NOx



Road Side 66.7 11.3


Road Side 57.8 8.7


Road Side 59.5 8.4


Road Side 59.1 10.7

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Ambient Air Quality

ROUND – 1 Date: 17/05/2013

Sr.



1 On Terrace of Lab 94.1 55.8 20.2 16.8

ROUND – 2 Date: 21/08/2013

Sr.



1 On Terrace of Lab 90.3 54.1 19.8 18.5

ROUND – 3 Date: 22/11/2013

Sr.



1 On Terrace of Lab 92.2 57.8 16.2 14.8

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Stack Emission

Round‐1 Date: 04/04/2014

Stack Side SPM NOx



Road Side 56.7 6.5


Road Side 52.1 7.4


Road Side 52.5 8.0


Road Side 58.7 7.7

Round‐2 Date: 20/08/2014

Stack Side SPM NOx



Road Side 53.5 10.2


Road Side 58.1 7.4


Road Side 40.7 11.2


Road Side 50.8 8.0

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Round‐3 Date: 22/12/2014

Stack Side SPM NOx



Road Side 52.8 11.6

D Stack River Side Unit under

Shut down Unit under Shut down Road Side


Road Side 55.2 9.0


Road Side 62.4 7.7

Ambient Air Quality

ROUND – 1 Date: 04/04/2014

Sr.



1 On Terrace of Lab 96.3 57.6 18.5 12.1

ROUND – 2 Date: 20/08/2014

Sr.



1 On Terrace of Lab 95.1 55.8 16.2 14.6

ROUND – 3 Date: 22/12/2014

Sr.



1 On Terrace of Lab 98.4 57.9 15.7 13.2

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Year 2015‐16 (Auditor—GITCO)

Stack Emission

Round‐1 Date: 26/11/2015

Stack Side SPM NOx


C Stack River Side Unit under

shut down Unit under shut down Road Side


Road Side 57.9 12.4


Road Side 59.3 15.1


Road Side 72.4 14.6

Round‐2 Date: 18/01/2016

Stack Side SPM NOx





Road Side 50.1 11.4


Road Side 56.7 11.4


Road Side 70.1 12.6

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Round‐3 Date: 05/03/2016

Stack Side SPM NOx





Road Side 46.8 13.3


Road Side 53.1 13.4


Road Side 72.4 12.2

Ambient Air Quality

ROUND – 1 Date: 26/11/2015

Sr.



1 On Terrace of Lab 96.8 59.4 28.7 16.4

ROUND – 2 Date: 18/01/2016

Sr.



1 On Terrace of Lab 95.3 56.7 24.1 12.8

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ROUND – 3 Date: 05/03/2016

Sr.



1 On Terrace of Lab 90.7 51.9 19.4 16.1

Water Consumption.

Water Consumption: Torrent Power Ahmadabad Thermal Power plant has track record of

optimum water utilization. We get discount in the water cess payment as we have not

discharging water to Sabarmati River from our ash pond. The last five years water consumption

data is as under.

Water Consumption in M3

2011 2012 2013 2014 2015‐16

Yearly Total 12694368 12700521 11717812 12706696 10217841

Average per day 34779 34700.88 32104 34813 27918

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GPCB Measurement data

Yearly stack emission measurement at regular time interval done by GPCB, and its results are as

under.

Stack emission as per GPCB 2013‐14

Date Station Path SPM

mg/NM3 Nox ppm

16/04/2013 C A 49 0.06

C B 48 0.06

D A 36 0.06

D B 40 0.05

E A 47 0.06

E B 46 0.05

22/10/2013 C A 11 0.06

C B 34 0.06

D A 6 0.07

D B 20 0.07

E A 9 0.07

E B 38 0.06

F A 17 0.07

F B 12 0.06

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mg/NM3 Nox ppm

23/04/2014 C A 32 0.09

" C B 63 0.07

" D A 37 0.08

" D B 30 0.08

" E A 29 0.08

" E B 50 0.07

" F A 12 0.09

" F B 12 0.18

22/08/2014 C A 38 0.11

" C B 42 0.13

" D A 57 0.15

" D B 57 0.19

" E A 69 0.20

" E B 72 0.19

" F A 13 0.05

" F B 21 0.07

25/02/2015 C A 13 0.06

" C B 12 0.10

" D A 10 0.07

" D B 16 0.04

" E A 12 0.04

" E B 38 0.07

" F A 11 0.06

" F B 12 0.04

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mg/NM3 Nox ppm

09/04/2015 D A 47 0.10

" E A 59 0.11

" F A 57 0.14

04/08/2015 D B 54 0.90

" E B 35 0.49

" F B 39 1.12

06/11/2015 D A 71 0.08

" E A 71 0.03

" F A 65 0.07

22/03/2016 D B 38 0.67

" E B 55 0.67

" F B 48 0.72

Following documents are reproduce hear for reference.

The copy of Consent to operate is first time issued by GPCB in the year 1986.

The copy of No objection certificate (NOC) for our F unit and C unit as issued by GPCB in

the year 1985 and 1993 respectively is also reproduce hear for ready reference.

The copy of latest Consent to operate issued by GPCB in the year 2013.

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