2 November, 2013 REPORT ON STUDY AND RECOMMENDATIONS FOR EVAPORATION RATIO IMPROVEMENT IN 80 TPH AND 125 TPH AFBC

BOILERS By Venus energy audit system The study was undertaken to review the present evaporation ratio in 80 TPH and 125 TPH AFBC boilers. Our engineers and undersigned collected lot of operational data to analyse the present evaporation ratio. The study lasted for duration of 12 days. Further 5 days were spent in analysis and preparation of the report and necessary drawings. REVIEW OF EVAPORATION RATIO Evaporation ratio terminology At present the evaporation ratio is used to measure the performance of the boilers. The quantity of steam produced and the quantity of fuel fed are used to calculate the performance. This number can be used for review provided the fuel is same and the GCV variance is minimum. The fuel with lower GCV will produce less evaporation ratio. Instead it is necessary to compare the expected evaporation ratio and actual ratio achieved. The expected evaporation ratio is the steam that can be produced based on the representative GCV. The representative GCV has to be arrived at the fuel mix and their GCV at the time of feeding in to the raw coal hopper. Standard GCV / receipt GCV cannot be used for this. Expected evaporation ratio- FUEL GCV Expected evaporation ratio needs the steam flow, enthalpy of steam, enthalpy of water, normal efficiency for the fuel mix and the mix fuel GCV. Steam flow is taken from flowmeter readings. Enthalpy of steam and water can be taken from steam tables for the average steam / water pressure and average temperature. Expected efficiency of the FBC boiler is in general above 80% for Indian coal / imported coal, provided the load is steady and there are no disturbances in boiler operation. The efficiency for saw dust will be 75% for a moisture of 35%. Fuel GCV in a fired fuel is to be based on a fuel sample. It is seen that the fuel combination keeps varying due to various reasons. Hence the GCV itself varies in 24 hours period. It becomes necessary to check the fuel GCV for more samples in a day. At present one sample is taken for 24 hours. In fact at least one sample is to be taken for shift. For each shift the expected steam to fuel rate has to be calculated. It can be then compared with actual steam to fuel ratio. Fuel mix GCV has to be analysed for the feeder sample each shift. Fuel mix GCV has to match with that of the calculated GCV based on the GCV of each fuel and its ratio as fed at the raw coal hopper. The deviation permitted has to be less than 5%. Whichever is minimum should be taken for expected steam to fuel ratio. When a GCV varies instantaneously the feed rate will change, without the steam flow change. Error creeps in if the mixing is not proper at the raw coal hopper. The way the fuels are blended at present is not a proper way. Generally two fuels are stored in two bunkers and metered by

separate feeders. A common drag chain feeder transports the blend to under feeding nozzles. Two independent bunkers are used to store two different fuels. Units with this kind of arrangement do not have much discrepancy on efficiency. CLARITY REQUIRED FOR STEAM FLOW INDICATION Steam flow measurement compensation block not visible The steam produced is measured by steam flow meters. Steam flow indicated is corrected for variations in steam pressure and steam temperature. There is considerable shift in current operating pressure as compared to design pressure. Invariably the steam pressure fluctuation is also more. The compensation logic was not seen in the DCS engineering screen. However the block logic was available for FBC 02. See Photo 1, 3 and 4 in annexure 1. For FBC 03 & FBC 04 this logic could not be found. Steam flow units from transmitters square rooted The engineering unit for local display is % for FBC 03 steam flow indication. This value is already square rooted. See photo 2 in annexure 1. It was not clear whether the square root is being done at DCS again or not. The engineering unit for local display is TPH for FBC 04 steam flow transmitter value. See photo 5. Again it is not clear whether % is used in compensation block or actual field value is used or not. Span of transmitters The steam flow transmitter is calibrated for a range of 180 TPH in FBC 04. This shall be reduced to 150 TPH to improve the accuracy in indication. Again for steam pressure the range is selected as 100 kg/cm2. This shall be made as 75 kg/cm2 for improving the accuracy. The steam temperature range is 600 deg C. This can be revised to 550 deg C. The steam flow transmitter is calibrated for 96 TPH for FBC 03. This is 1.2 times the MCR flow. This is OK. However the steam temperature transmitter and steam pressure transmitter ranges are to be reduced for better accuracy. Average steam pressure and average steam temperature for the day It is necessary to report the average steam temperature and pressure for the day. This may be taken from the trend chart which generally displays the minimum, maximum and average. Or else this needs to be programmed. In some plants, the heat output is calculated based on enthalpy at small time intervals. Thus the steam enthalpy used for heat output calculation will be realistic. Steam flow measurement is not the heat output measurement. Coal feed rate measurement for actual steam to fuel ratio calculation At present the coal is weighed and fed to the raw coal hoppers. This is a good arrangement. In FBC 03, the bunker is levelled and the correction is applied to know the 24 hours consumption. The levelling is not done by going inside the bunker. There is risk if one has to step inside the bunker for levelling. There is an error coming in here in the case of FBC 03. The coal consumption may vary from day to day. However over a month if we look at the consumption, the error will be evened out. When a compartment is not in operation, the level measurement goes wrong. In FBC 04, load cell is available. Hence the reading does not go wrong. The coal measurement in

FBC 04 will be correct. When a compartment is not in operation the load on load cells will be unequal. This can add up error. This may need a check when the bunker is emptied any time. Review of the data- boiler efficiency The entire data on coal consumption for the year 2013 was taken for analysis. The heat input given to boiler and heat output from the boiler are calculated. The direct efficiency of the boiler is arrived at by this method. The data is presented in annexure 2. Efficiency of the boiler is a right way of knowing the performance of the boiler. For solid fuel fired boilers indirect efficiency calculation is recommended by codes for the reasons in measurement accuracy. The reason behind this can be seen in the data reviewed in annexure 2. The day efficiency of the boiler is seen to be as high as 102.3 % and as low as 59.9%. Both are not practically possible. But that is what the data says. This proves the various errors in measurement. The month efficiency of the boiler is however seen to be varying between 73% and 82%. This is for the entire month and hence the error on coal consumption measurement and GCV measurement and steam flow meter are reducing.

By the above we have seen that the data available are not accurate enough to show the consistency in efficiency. On some days the efficiency is too low and on some days the efficiency is too high. Hence the present methods of measurements of coal consumption, GCV, Steam flow, average steam pressure and average steam temperatures have to be improved. The coal consumed during troubled times have to be deducted properly as they introduce error. Extra fuel is consumed when there is a coal flow problem and when there is a cold start up of the boiler. Ash balancing At present the ash disposed is being monitored by stores. It is possible to tally the ash produced versus the coal consumed. As the feed coal is fed known from the hopper feed, we can back calculate the ash that must be produced. This can be compared with the bed ash and fly ash production. The numbers should tally. If the ash actually produced is more, then the ash content in the fed coal is more than what is found in a sample. The bed ash disposal data is compared with actual ash produced for the month between Jan 2013 and Sept 2013. This is about 10 % of the total coal fed. See table 4 in annexure 2. This means about 10% of the ash produced is the bed ash. Balance 90% has to be fly ash. Now fly ash disposal data from stores was compared with calculated ash production (based on the feed coal ash % and the total coal fed). The table 5 in annexure 2, shows the comparison of fly ash calculated from the total coal fed and the ash% found in the day sample. The actual fly ash disposed exceeds calculated ash by 16%. The % fly ash generated is taken as 85 % of the total ash produced. This leads to the conclusion that the actual coal was containing more ash, than useful heat content. Thus there is lot of discrepancy in the samples being considered. More samples are required to eliminate the error in calculating true heat input to boiler. At present only one sample is considered for the whole day. This will be adding error. Bone dry GCV / total moisture / total ash

It may be worth considering the samples taken are immediately analysed after sampling in a shift. Two samples may be oven dried for total moisture, TM. One dried sample can be used for GCV, which will be bone dry GCV bone dry. Another can be used for ASH bone dry. As fired GCV can be found from GCV as fired = (100- TM) * GCV bone dry / 100. In the same manner ASH as fired can be calculated from ASH bone dry. Thus in a day 3 samples of each fuel fed to ground hopper and 3 samples of mix fuel will have to be analysed. If the mix has two fuels, then the number of samples to be analysed would be 9 samples in total. Analysing these samples can be laborious. There are good automatic bomb calorimeters are available now to test 6 samples per hour. Cold start of the boiler A boiler started from cold consumes more energy. This coal used for start up brings down the evaporation ratio. It is advised to estimate the coal consumed during start up. This quantity must be deducted while arriving at evaporation ratio. GCV variance To know the GCV variance the entire data on each coal were analysed. The analysed data are presented in annexure 3. Table 9 shows the receipt coal analysis for the imported coal as reported by plant lab. We have calculated the GCV arb, 100- TM-ash, GCV / (100-TM-ash) and FC/ VM. GCV arb is the actual fuel heat content. The coals were received from various parties. Hence party-wise the GCV variance was checked. The summary is presented in table 10. One can see there is a difference of GCV to an extent of 758 kcal/kg. The GCV difference as a percentage to the average is seen to be as high as 13.8%. If this is taken as a percentage of the best GCV it is about 27.6%. This GCV variance causes wide variance in steam to fuel ratio. Table 7 shows the entire data on GCV and proximate analysis data from lab for the Indian coals. The GCV variance is presented in table 8. The GCV difference can be seen as high as 1077 kcal/kg. Again when this is the variance in receipt coal, it is natural that the steam to fuel ratio will vary to a large extent. Incidentally the FC/ VM ratio for Gujarat NRE coke is around 2. This coal is not suitable for FBC boilers. It does not burn properly. Table 6 is the data from the imported coal analysis reports received from port samples. The reports indicate considerable variation in GCV. Table 2 shows an important finding. Coals are being mixed at the feed hopper at some ratio. The coal analysis receipt GCV data for the lot is taken in arriving at the calculated GCV. The feeder coal which is a mix fuel, is analysed separately. The GCV of the fuel mix is seen to be less as compared to a calculated GCV. This indicates that there is loss of GCV in the storage. Or the mix is not good. The loss in storage needed a check. Some random samples were given to lab for analysis. See table 1 in annexure 3. We can see Chargaon coal and Majri coal have deteriorated in GCV by 10% to 13%. The Gujarat NRE coke is not deteriorated. The reason for this is that the coke does not burn easily due to less VM.

From the above analysis, it is important to note that there is deterioration of coal in the yard. Yard management is becoming an important subject so that the heat is not lost. In addition a coal GCV has to be analysed at the ground hopper inlet. Counter checking the fuel feeder GCV and the hopper fuel GCV The TM is being analysed once in a day. The GCV sample is taken in all shifts and collective sample is given to lab. This is OK when there was only one coal. It is advisable to take the sample of each fuel before feeding the hopper. Based on the tonnage break up, weighted ash and weighted total moisture, the mix GCV can be calculated. This can be compared with the feeder fuel GCV which is the mix GCV. The variation in GCV should be 5%. This should be brought out in MIS report as explained already. What can be done to reduce the error in the MIS report? 1. Avoid mixing of different lots. 2. Sample each coal that is mixed and analyse for its GCV. GCV of the mix can be calculated based on the mix ratio. After the mix is received at feeder analyse for the mix fuel GCV and tally with calculated GCV. 3. Instead of taking a cumulative sample for the 24 hours, shift wise samples must be taken to arrive at the GCV. This will help to arrive at an equivalent GCV value close to actually used. In addition the variance can be found. This is different from mixing the samples for the day and analysing the mix sample. 4. Instead of mixing all coals for all boilers, the mix should be avoided for one boiler. Indian coal of say 100% can be burnt in one boiler. Imported coal with some minimum percentage of Indian coal can be added to another boiler. Large GCV variance must be avoided. As the GCV varies the coal consumption will vary. 5. Instead of basing the daily analysis on steam to fuel ratio, it should be based on the heat utilisation. That is the steam generation / heat input should be used as a measure of daily performance. If the steam to fuel ratio should be used for MIS then the expected and actual evaporation ratio should be used. 6. The report should contain data on bed ash disposed and fly ash disposed. A tally must be shown with calculated ash production. Even if the daily data does not tally at least monthly data should tally. Recommended MIS report It is possible to modify the present MIS report as discussed above. A sample report is attached in MS excel for use by power plant engineers. See annexure 12 for details. The MS excel sheet is sent separately as a soft copy. Deterioration of GCV in yard Spontaneous combustion is an important aspect to be addressed. The present stacking and reclaiming method does not suit to avoid this. Receipt coal must be unloaded using a truck tippler and stacked in the yard date wise. The fuel stock should be provided with tags showing the dates. The earliest coal arrived should be consumed first. Nowadays yards are designed with light weight roof to store coal indoor. This helps to avoid

moisture pick up problems and loss in handling as well. See annexure 4. It is seen that the deterioration is more if the coal is stocked for more than 5 days even in closed storage. Considering loss in fuel it is necessary to invest on stacker and reclaimer to avoid loss of GCV at yard. Losses in fuel handing system There are losses in coal that is fed in the raw coal hoppers. Conveyor misalignment is seen to cause spillage. However the weight booked for a day includes the spillage. It is learnt that the spilled coals are fed back to hopper instead of dumping back to fuel yard. That is good. But the weight booked for a day goes wrong. Screen blinding and overflowing is another cause for spillage. Indonesian coals have high moisture content. Currently the flip flop screen is found to be the best screen which avoids the problem of blinding and thus overflowing of screen is avoided. See annexure 5. There are dust collection systems deployed to reduce losses in transfer points. This loss also adds up to reduction in steam generation from the heat input. Losses due to fuel flow problems in bunker When moisture coals are handled the flow problems begin. In plants using 100% imported coal fly ash blending is done to avoid flow problems. Rat hole formation in bunker is prevalent in bunkers. The rat holes cause more problems. Regular cleaning of bunkers by air blasters are recommended to ensure the bunker is free from accumulations. When lumps descend to rotary feeders, flow problems are experienced. When experienced, there is disturbance in combustion conditions in furnace. The fuel feed rate raised in another feeder does not burn well as the combustor size increases. An excess coal fed in 1st / 2nd / 3rd compartments will not completely burn for a problem encountered in 5th compartment. This because the air flow is not increased or not available for burning. A coal feed rise in adjacent compartments will help to some extent. However the fines do escape unburnt thus causing the variance in LOI. It can be seen that there is large variance in unburnt in ash. The root cause of the coal flow problem boils down to moisture. Moisture can be removed by air driers in the system. Depending on relative humidity the drying of coal by means of low temperature drying system is possible. There are systems being used in some countries. Heat available in flue gas is used for this. Lumps formed at bunker travel down to feeders. At these times lot of coal is wasted out. This coal travels with bed ash to disposal. It is necessary to separate the lumps from entering in to the feeder. See annexure 5. Photos show the arrangements made in another boiler to trap the lumps formed in bunker due to high surface moisture coals, such as lignites. Please see our suggestion in drawing provided with this report in annexure 5. This can be the arrangement to trap lumps. This arrangement allows the use of one labour only to take care of all feeders. Whenever a feeder or a line is jammed due to lumps, more casual labours are required. Apart from this the boiler is disturbed.

Reasons for extra fuel consumption- boiler operation When there is a disturbance there is going to be extra fuel consumption. There are several factors

that disturb the combustion conditions in the boiler. The factors are hereby reviewed and recommendations are given. Excess air operation anticipating the load change & fuel dumping The oxygen levels are never optimised at present since any time there will be load change. The operators do not know when there is going to be load change. Hence the operators tend to keep a higher Oxygen level expecting the load change any time. It is advised to provide a CCTV to show the load centres. If the loads are known, low pressure operation will be avoided. This will avoid the excess fuel required due to sudden load increase. Also venting losses can be minimised. This sort of exercise was done by undersigned at a paper mill long back. This helps the operator to reduce the pressure swings. Thus the turbine would operate at optimum specific steam consumption. This will result in fuel savings. Sudden fuel dumping in case of low pressure will not allow the coal to burn. Thus the LOI keeps varying. The increment rpm rise for recovering the pressure varies from person to person. Thus more savings can be expected from this measure. See photo 6 in annexure 6. The effect of excess air for various fuels is shown in annexure 6. At present excess air operation cannot be avoided by operators, since the load change takes the operators by surprise. This can be minimised once the operators are accustomed to observe the load centre visuals. Wide feeder rpm limits In the combustion control loop, the upper limit of the feeder rpm is made use of. For a boiler running at say 20 rpm, without changing the fuel GCV, the rpm is seen to go up to upper limit when there is a pressure signal error. A demand may go up momentarily or there may be a fuel flow problem in the feeder. At that time the entire range is made use of by the combustion control loop. This leads to dumping of the fuel. It is a normal practice to set motor rpm on display. Then the operator does not set wide limits. For example if the feeder operates at 600 rpm, he may choose to keep 650 rpm as the upper limit. This is about 8% rise. When it is a percentage, for example for the case in photo 1 in annexure 6, the rise is 32/20 = 1.6. That is, the rpm is increased up to 60% more. The fuel dumped to this level, will not burn fully. Operators must always set the limit to narrow range. There are situations of sudden demands. At that time the feeders rpm should rise proportional to load. Very high limits are not advised. See other photographs in annexure 6. Photo 3 shows the feeder rpm using the full range in boiler 3. When the load centre is known, operators would know what should be the rpm and the air limits. There are cases, where the range is set narrow. Some feeders are set to manual mode. The rpm on manual mode is raised disproportionately. See photo 4 in annexure 6. Some operators argued that the fuel quality keeps changing every now and then. But this is not the case always. By choosing standardised fuel mix, this can be avoided. Or choose to mix the fuels only in one boiler. One single reason for this pattern of operation is that the load is not known. The recommendation on CCTV on load centres can help to a large extent.

Over-riding the pressure control loop In boiler 4, it is seen that the operators chose to interfere manually with some feeders to respond to pressure signal. It is a good aspect. But rpm limits are to be kept in mind. It is advised to add CO meter in the flue path and provide trend in DCS. We can track the situations under which, the operators had to fault on excess fuel dumping. Low bed temperatures in boiler 3 In boiler 3, the bed temperatures are mostly around 750 deg C. The bed temperatures do vary as per load and as per the fuel fed. The load on the boiler 3 is seen to be a maximum of 70 TPH. Imported coal has higher fuel moisture and VM burns above the bed. The bed coil HTA requirement is less for this. Indian coal needs more bed coil area to restrict the bed temperature to 925 deg C maximum. Very low bed temperatures cause various problems. The problems are listed below. Activation of a compartment will take a long time. It calls for more fuel. The rpm is being set as high as 50% where the normal rpm is 30%. Then also the response is slow. The ignition is slow. Upsets in fuel flow will result in excess fuel for revival of bed temperature. Flame out situation occurs. This has happened sometimes. At the time of visit, there was a coal flow problem. Bed temperatures dropped further. Then the flame out occurred. Dry coal was fed to revive the bed. Indonesian coal had high VM and hence the there is a tendency to have high free board temperature than the bed temperature during such situations. The option is to pressurise the furnace for improving the bed temperature. Such a problem is not experienced in boiler 4. It is because in boiler 4, the bed coils HTA is less than the requirement. The bed coils are widely pitched and less studded too. In addition there is refractory applied over the bed coils above the coal nozzle points. Generally poor combustion due to low bed temperature. Three Ts time, temperature and turbulence decide the combustion completeness. Start up will be a problem. This is because the bed coils cool the charcoal fire.

The design of FBC 03 bed coil HTA was checked for various fuels. It is necessary to cover the bed coils to a length of 1.5 m in each outer coil in FBC 03. See the calculations on bed coil area requirement for a case of 50% Indian coal and 50% imported coal mix at 80 TPH load attached in annexure 7. The recommendation on bed coil refractory covering is given at the end of annexure 7. Every operational disturbance causes extra fuel consumption. That is the reason boiler PG test is done under stable conditions and invariably efficiency to a minimum 82% is proven by boiler makers. Air preheater leakage & CO O2 profile In boiler 3 & 4, the CO levels and O2 levels were checked from APH inlet to ID fan inlet. The readings are attached in annexure 8. FBC 04 airpreheater is in good condition. There is leakage across APH. The oxygen is seen to rise by 3% maximum in FBC 03. The APH tubes need replacement. It is learnt that in boiler 3, the air passes through tubes and gas flows outside the tubes. There is large amount of air leakage in APH due to failure of end column of APH tubes. It is advisable to replace these tubes with thicker tubes and blind them on air side at both ends. The end columns of APH tubes do fail, but there will not be casing failure / flue gas dilution / ID fan loading /

FD fan loading. See photo on annexure 8. In addition there is false air ingress from FBC 03. The oxygen in FBC 3 is around 6.5% to 7%. The efficiency loss or extra fuel consumption on this account is to an extent of 1.5%. The Oxygen in FBC 04 is already at the optimum. The false air ingress in FBC is due to improper sealing arrangement at roof. This can be arrested by going in for POP finish for insulation. At many plants the air ingress is minimised / arrested only by this method. See the photographs at the end of annexure 8. It is estimated that around 15 % of the air directly connects to flue gas side. The air flow leak to flue gas increases the power consumption of ID fan and FD fan. Steam leakages and passing of vent valves Passing & leakages in valves in FBC 3 & FBC 4 were checked using IR camera. IR camera identifies passing but the flow cannot be quantified. However higher temperatures mean more passing. In FBC 03, the following were seen. a. b. c. d. Gland leak in MSSV in boiler 3. Steam drum SV passing in boiler 3 Drum levels gauge drain valve passing Start up vent passing

In FBC 4, following are the passing and leakages noticed. e. f. g. h. Steam drum left side safety valve Gland leaks in two valves SH header Drum pressure transmitter line puncture Drum pressure gauge line puncture

The photographs showing the leakages and passing are summarised. There are some guidelines followed by energy auditors regarding the steam wasted from a hole. Based on this we can have an estimate on the energy loss. The energy loss due to steam loss is presented in annexure 9. Also the passing of valves as identified by an infrared camera is presented in annexure 9. Bed draining practice The heat loss from furnace ash can be reduced by resorting to cold ash draining. The gates should be closed once the hot ash begins to come out from the drain pipe. See photo 7 in annexure 6. The drain gates must be half open to remove the coarse materials from the drains. Reasons for extra fuel consumption- water chemistry The feed water conductivity is 2 S/cm and boiler water conductivity is 45 S/cm. The boiler water silica is <2 ppm. The high silica rise can be due to two reasons. One is the return condensate silica. Other is the colloidal silica. Ultra filtration is used to avoid colloidal silica filtration. The conductivity limit for boiler water is 200 S/cm. Condensate polishing will help to avoid tube failures. SDI shall be tested in condensate return. Drum internal will show foam marks. Tube failures due to deposits can occur. It can be caustic attack or hydrogen damage depending upon the pH of the water. The economiser tube failures at chemical

recovery boiler were seen. Inside of the tubes show Iron carry over from process. See photo 1 in annexure 10. When iron is dissolved from MS shell plates, silica also gets dissolved. This aspect is seen in Air cooled condensers of many power plants. Due to low pH situations during start up, ACC tubes corrode and raise silica in condensate return. In water cooled condensers the tubes are of noncorrosive material. Hence silica does not rise in the condensate. Iron carryover to boiler needs to be prevented by incorporating magnetic screen for condensate polishing. Filtration system may also help. The loss due to blow down can be high when the silica increase in condensate return. The economiser tube failures are experienced in the first pass of chemical recovery boiler, where the dirt is unable get flushed out against gravity. Deposits seemed to hinder the heat transfer creating stress assisted corrosion. The failed tube was not available for checking. Hence some photos are given in annexure 10, showing the steam drum appearance and tube failures on account of condensate contamination. Higher blow down leads to high fuel consumption. See photo 3 & 4. A typical blow down calculation is given in annexure 10. The conductivity used here should be after the subtraction of the volatile chemicals. Compartmental operation In the event of compartment shut down, the leakage air that passes through idle bed, adds up to heat loss. This amounts to excess air and can efficiency to a level of 1%. This leakage air does not contribute much to combustion as it is not fed at active bed. During this period the unburnt in fly ash can go up as all the air is not used for combustion. This is to be checked over specific trials. It is seen that during load variation, the LOI is varying from 6% to 10%. The efficiency loss is more as the ash percent increases. For a 40% ash coal, the additional loss is to an extent of 2.56% for the increase in LOI from 6% to 10%. It is advised to check the compartment dampers during shut down. In boiler 4, there will be seals which need to be replaced. In boiler 3, asbestos pad is provided as seal at the compartment damper flap to seating plate area. Shallow bed operation in FBC 04 In FBC 04, the positive pressure is experienced at venturi in PA lines. When the air box pressure is restricted to 500 mmWC, the suction effect at venturi is OK. This problem is seen in Thermax Units. The throat size was changed at two 125 TPH FBC boilers at another plant. Shallow bed results in fines elutriation from the bed. See photo 8 to 10 in annexure 6 showing the recent replacements made and the visible suction effect improvement. Radiation loss for poorly insulated area / uninsulated area See annexure 11, showing the temperature survey done in FBC 3 & FBC 4. In FBC 4, the insulation is generally good. However in FBC3, there are areas which need to be repaired. There has to be gain in repairing the insulation. Hence the heat loss is expressed in terms of coal loss per day. ACTION PLAN The various aspects discussed above are summarised below as key points for the efficient utilisation of the fuel.

1. Imported coal shall be used within 3 days of arrival at plant. 2. Coke shall not be used as it results in poor combustion. 3. Fuels fed at ground hopper must be sampled in 3 shifts and analysed for Total moisture. Samples shall be further analysed for GCV and ash, which will be on bone dry basis. Based on the mix ratio, equivalent TM, GCVaf and Ashaf shall be found out. 4. Feeder samples shall be collected in 3 shifts and shall be analysed for total moisture and then on bone dry basis for GCV and ash. GCVaf and Ashaf shall be calculated. 5. The feeder sample report and ground hopper report should match. Depending on the consumption the time lag shall be accounted for matching the calculated GCV and the feeder GCV. 6. The coal lot shall be stacked with dates and GCV on receipt and the name. As per point 3, the same coal GCV will be analysed at the time of feeding to CHP. This will help to measure the deterioration of GCV on storage. 7. Coal stacking and reclaiming can be automated based on the point 6. Based on the annual coal consumption and the deterioration level, we can decide on the need for covered storage with stacker and reclaimer. 8. LED screen display of each load centre shall be added at each boiler control room. The location of camera shall be discussed and decided with process persons. 9. The steam flow transmitter at boiler 4 shall be calibrated for a lower range to improve the accuracy. 10. Steam temperature transmitters shall be calculated for 550 deg C or 525 deg C. 11. The steam flow compensation logic screen shall be clarified by the supplier in person. 12. Hourly / shift average steam pressure and steam temperature shall be obtained from DCS. Suitable additional software shall be obtained for generating log sheets. This is required to obtain the steam enthalpy and to calculate the heat output of boilers. 13. Air blasters shall be installed in coal bunkers to facilitate removal of lumps as the bunker goes empty. 14. Bar screens shall be added at feeder inlet chutes to trap the lumps from bunker. 15. Ash generation measurement shall be given importance and the calculated ash generation and the actual ash generation must be tallied at the end of the month. 16. Improve the coal handling system maintenance to reduce / eliminate the loss in handling. 17. Add CO meter to improve the fuel feed regulation by boiler operators. 18. Reduce the effectiveness of bed coils in boiler 3 in order to improve the bed temperatures. This is to be done by applying phoscast refractory on the tubes as per recommended drawing. During replacements studs can be avoided in upper part of the bed coils. 19. Replace the failed APH tubes in FBC 3. Consider the suggestion if the failures are only the end column near the casing. 20. Apply plaster of paris at roof top in boiler 3 as per recommendations to avoid false air ingress. 21. Attend to passing valves and steam leakages in FBC 3 & FBC 4. 22. Implement proper bed draining procedure as advised. 23. Review and incorporate condensate polishing system and ultra filtration system for water treatment. 24. Add high capacity magnetic filters in the condensate return. 25. Attend to compartment dampers both in boiler 3 & boiler 4, to minimise the false air during

compartment slumping. 26. Incorporate rpm indication for fuel feeder instead of %. This is to correct the operators tendency to dump fuel. 27. Procure new mixing nozzles with reduced throat diameter for boiler 4. Resort to increasing the operating height. Ensure the refractory is applied in advance in the newly procured coils. 28. Reduce the radiation losses in FBC 3. 29. Modify the MIS with expected steam to fuel ratio / actual steam to fuel ratio. In addition heat input / heat output ratio shall be computed as it reflects the boiler efficiency trend. The work sheet given may be suitably modified.

K.K.Parthiban

ANNEXURE 1- STEAM FLOW METER CALIBRATION

Photo 01 : The above photo shows the screen shot of steam flow meter compensation block of boiler 3. It is seen that the boiler steam flow is calibrated for 96 TPH. The steam flow transmitter is selected for 1.2 times the MCR flow. The steam pressure is calibrated for 100 kg/cm2. This is on the higher side. This may be calibrated for a range of 75 kg/cm2 for better accuracy. Similarly temperature range shall be checked and reduced for better accuracy.

Photo 02: The local indication at steam flow transmitter at FBC 03 shows the output is already square rooted value. The logic used for indication or compensation was not available in DCS screen. Engineers from the C& I section tried their best to show the logic used for compensation. But this was not available in DCS. It is advised to check that the process value is not square rooted again.

Photo 03: The photo shows the compensation logic seen in FBC 02. Such a screen shot was not available both for boiler 3 & 4.

Photo 04: The photo shows the screen shot available for FBC 04 steam flow compensation. The Steam flow meter is calibrated for a maximum value of 180 TPH. This is on the higher side. It is advised to calibrate for 150 TPH only. The steam temperature range is taken as 0-600 deg C. This shall be calibrated for 550 deg C maximum. The steam pressure range shall be checked and reduced to 75 kg/cm2 for better accuracy.

Photo 05: The above photo shows the steam flow reading which is already square rooted at transmitter itself. This shall be checked in the logic of steam flow compensation. This logic was not available in the DCS engineering screen. It may be checked whether the DCS signal is taken as percentage or the flow itself.

ANNEXURE 2- REVIEW OF THE EVAPORATION RATIO

Steam production FBC 3 TPD 1402 1168 1408 1263 1400 1589 1388 1528 1420 609 0 1501 1339 1402 1475 1286 1345 1166 1286 1281 1147 1075 1104 1270 1258 429 0 285 1270 min max aver FBC 4 TPD 2163 1737 2493 2179 2498 2703 2339 2242 2250 2456 2614 2457 2116 2405 2499 1952 2238 2086 2127 2025 2048 2380 2430 2352 2462 2292 2535 1841 2291

Evapor ratio, kg/kg FBC 3 T/T 3.8 3.8 3.9 3.7 3.5 3.5 3.5 3.8 3.7 3.69 3.55 3.5 3.6 3.5 3.7 3.71 3.7 3.7 3.73 3.6 3.5 3.5 3.4 3.5 3.49 3.52 3.5 3.4 3.9 3.6 FBC 4 T/T 4 4.05 4.05 3.91 3.86 3.9 3.8 3.9 3.9 3.9 3.85 3.83 3.8 3.85 3.8 3.9 3.8 3.91 3.85 3.95 3.8 3.6 3.8 3.5 3.6 3.6 3.7 3.6 3.7 3.5 4.1 3.8

Evap ratio, kg/10^3 Kcal FBC 3 FBC 4 FBC 3 % 7.8 -

Silo LOI FBC 4silo 1 % 8.9 FBC 4silo 2 % 8.9 Av LOI % 8.9 0 5.5 6.25 6.05 5.95 5.3 5.75 5.6 6.4 4.95 6.2 5.05 6.3 6.65 7.05 5.25 5.3 6.3 6.5 6.2 7.05 8.65 5.1 4.6 6.55 5.9 5.25 4.95 7.55 min max aver

Heat loss due to ash / heat input FBC 3 % 4.3 4.49 5.96 4.95 5.4 6.05 3.74 4.29 4.18 3.16 2.88 3.49 3.86 2.88 3.92 4.41 4.11 3.98 4.43 3.43 5.06 3.9 3.26 2.9 6.1 4.2 FBC 4 % 4.06 2.43 4.3 3.86 4.22 3.98 4.25 2.85 3.9 1.89 2.58 2.47 2.8 2.98 3.21 2.48 3.14 4.19 3.11 4.93 3.38 4.39 2.55 2.12 3.99 2.81 2.92 2.7 5.32 1.9 5.3 3.3 199812.5 890392.54 min max aver 1052345.83 938768.2 982937.28 1034117.32 901610.09 942974.78 817478.51 901610.09 898104.6 804157.67 753678.73 774010.52 890392.54 881979.38 300770.39 Shut down 982937.28 818880.7 987143.86 885484.87 981535.08 1114042.32 973121.93 1071275.44 995557.01 426967.76 Shut down Heat output Heat input

Direct Efficiency- July 2013 FBC 3 % 1010480.09 1354022.89 1075656.57 1395703.86 1394537.46 1226638.83 1245140.99 1241055.32 652309.43 1366821.54 1353473.87 1487989.98 1396454.25 1243215.74 1222587.16 1029819.27 1059368.72 1039582.31 1216706.84 1074799.35 1206215.24 1256887.96 1232960.89 97.27 72.9 82.32 70.33 79.89 79.33 86.04 80.22 76.99 69.36 66.06 74.05 72.52 77.13 79.38 85.11 86.39 66.09 70.12 64.17 70.84 71.53 64.2 86.4 75.3 1458070.71 1170905.6 1680522.55 1468856.25 1683893.03 1822082.81 1576711.69 1511324.33 1516717.1 1655580.98 1762088.22 1656255.07 1426388.17 1621202.06 1684567.13 1315836.35 1508627.94 1406165.28 1433803.23 1365045.39 1380549.61 1604349.64 1638054.47 1585474.94 1659625.56 1545029.15 1708834.6 1241011.64 1544355.06 1867269.7 2403056.05 1759291.71 2158908.52 2097682.76 1864271.7 1688922.91 1911120.88 1846906.94 2759187.28 2273721.85 2300302.07 2141448.03 2153835.39 2308095.13 1796384.51 1936241.88 1758495.62 1786999.78 1333800 1920561.38 2408717.19 2260003.04 2326627 2264119.7 2578382.1 2302091.95 1828160.95 2188210.23 min max aver FBC 4 % 78.09 69.93 83.49 78 86.86 84.58 89.48 79.36 89.64 63.86 72 66.61 75.27 72.99 73.25 77.92 79.96 80.24 102.34 71.88 66.61 72.48 68.14 73.3 59.92 74.23 67.88 70.58 59.9 102.3 76.0

Heat output

Heat input

kg/10^3 kcal 1387.46 1039.86 1174.17 1003.08 1139.45 1131.55 1227.17 1144.19 1098.17 989.31 942.21 1056.25 1034.41 1100.13 1132.24 1213.93 1232.23 942.71 1000.19 915.26 1010.43 1020.31 915.3 1232.2 1073.7 1158.38 1037.43 1238.57 1157.07 1288.56 1254.65 1327.47 1177.32 1329.79 947.38 1068.12 988.12 1116.61 1082.71 1086.63 1155.85 1186.24 1190.26 1518.22 1066.35 988.08 1075.22 1010.91 1087.4 888.93 1101.17 1007.02 1046.97 888.9 1518.2 1126.8

9.2 8.2 7.7 7.1 8.1 6.7 8.4 8 5.5 5.7 8.7 7 6.1 7.1 7.6 7.1 7.8 7.7 6.3 9.2 6.5 6.5 6.7 6.3

5.9 6.5 6.2 6.4 5.6 6.2 5.8 6.7 5.2 6.2 5.1 6.4 6.7 7.7 5.6 5.4 7.3 7.2 6.4 7.7 10.1 5.4 4.8 7 6.1 5.5 4.3 8.5

5.1 6 5.9 5.5 5 5.3 5.4 6.1 4.7 6.2 5 6.2 6.6 6.4 4.9 5.2 5.3 5.8 6 6.4 7.2 4.8 4.4 6.1 5.7 5 5.6 6.6

Performance review of FBC 3 and FBC 4 FBC 3 Evap ratio kg/kg Jan-13 Min Max Average Min Max Average Min Max Average Min Max Average Min Max Average Min Max Average Min Max Average Min Max Average Min Max Average 3.8 4.3 4.1 3.9 4.1 4.0 3.8 4.1 4.0 3.7 4.1 4.0 3.9 4.1 4.0 2.7 4.0 3.7 3.4 3.9 3.6 3.5 4.0 3.7 3.6 4.2 3.8 FBC 4 FBC 3 Steam prodn kg/10^3 kcal 902.3 1306.0 1110.5 1098.8 1311.6 1150.0 912.7 1370.3 1122.9 849.1 1567.0 1133.4 920.4 1308.3 1169.1 694.0 1251.9 1014.5 915.3 1232.2 1073.7 864.8 1216.7 1025.6 819.8 1358.7 1031.7 FBC 4 FBC 3 FBC 4 Heat loss due to ash / heat input 2.3 6.9 4.7 2.0 6.2 4.5 1.8 8.0 5.3 4.7 26.1 8.6 0.9 21.1 9.4 1.7 7.7 4.1 2.9 6.1 4.2 1.9 5.3 3.0 0.8 4.6 2.4 2.0 5.6 3.1 1.4 4.3 2.7 1.5 7.2 3.4 2.9 15.0 6.2 2.8 14.8 7.3 1.6 7.0 3.1 1.9 5.3 3.3 1.2 4.9 2.4 0.9 3.7 1.9 FBC 3 Efficiency 63.3 91.6 77.9 77.0 92.0 80.6 64.0 96.1 78.7 59.5 109.9 79.5 64.5 91.7 82.0 48.7 87.8 71.1 64.2 86.4 75.3 60.6 85.3 71.9 57.5 95.3 72.2 61.3 85.7 77.1 73.9 96.9 82.0 69.1 83.9 76.8 60.4 95.9 77.1 70.5 96.7 81.4 60.8 113.3 76.2 59.9 102.3 76.0 60.1 95.4 73.1 60.1 108.2 77.7 FBC 4

Feb-13

Mar-13

Apr-13

May-13

Jun-13

Jul-13

Aug-13

Sep-13

3.8 4.5 4.2 4.0 4.3 4.2 3.9 4.5 4.2 3.9 4.2 4.0 4.1 4.2 4.2 3.6 5.3 4.1 3.5 4.1 3.8 3.5 4.2 3.9 3.8 5.8 4.1

909.7 1271.3 1144.5 1096.1 1436.7 1216.8 1025.1 1244.0 1139.7 895.3 1423.1 1144.1 1045.2 1434.9 1207.5 902.0 1681.3 1131.0 888.9 1518.2 1126.8 891.9 1414.5 1083.7 890.9 1605.7 1152.3

TABLE 4: Waste Bed Material during January 2013 to September 2013

Date 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 total January'13 Trips Nearby Ddl MT February'13 Trips Nearby Dd MT 4 78.32 1 19.88 1 20.07 1 16.24 3 1 3 1 2 1 1 1 1 2 1 1 1 15.2 16.7 15.55 34.38 17.49 18.64 8.8 1 1 3 64.04 19.46 54.04 19.48 36.96 16.59 19.21 18.69 57.02 2 1 3 41.74 18.04 52.20 Mar'13 Trips Nearby Dd MT 1 2 17.98 36.03 1 1 16.33 16.3 Apr'13 Trips Nearby Dd MT 2 33.64 May'13 Trips Nearby Dd MT Jun'13 Trips Nearby Dd MT 7 108.87 6 3 1 1 5 4 5 4 2 7 7 6 3 4 8 6 3 3 4 2 1 1 14.57 5 6 5 3 4 35 79.62 97.31 79.48 46.67 61.42 551.02 92.12 47.18 15.52 16.07 79.61 61.34 79.3 62.90 31.22 120.3 115.04 96.23 48 63.67 129.68 100.22 40.80 47.67 62.74 31.51 16.48 Jul'13 Trips Nearby Dd MT Sep'13 Aug'13 Trips Nearby Dd Trips Nearby Ddl MT MT 1 14.9 6 85.85 3 35.88 1 16.12 2 22.91 3 36.22 5 75.02 4 53.88 1 15.41 2 30.3 1 14.24 2 27.91 2 30.33 1 13.52 1 11.06 1 15.27 1 11.47 6 76.97 1 14.21 6 79.28 3 41.33 3 1 2 11.06 24.29 1 2 1 5 4 3 1 9 4 8 7 2 5 82 12.19 33.48 15.99 63.8 60.56 46.53 15.11 111.12 47.84 110.04 108.3 28.33 66.34 1127.57 2 1 1 2 2 1 2 1 3 25 14.97 43.37 331.69 3 1 41 39.19 33.34 16.83 11.87 34.64 32.13 15.74 33 49.29 16.13 596.30

32.07

16.98

17.57

1 1

16.98 17.36

3 3 1

45.63 44.73 14.27

15.05

2 4

24.05 53.76

2 1 2 16

35.54 14.4 36.19 264.80

3 2 1 1 3 1 3 3 2 2

52.36 35.22 18.52 18.48 58.25 17.99 50.64 52.44 38.84 35.85

2 1 1 6 5 2 3 2 2 3 2 3 1 1 1 1 3 2 50

30.51 14.2 17.72 103.89 82.42 31.48 47.11 29.71 30.69 50.40 32.33 53.06 16.99 15.38 15.78 18.52 47.67 35.56 839.41

1 1

13.32 16.02

1 1 1 15.65 1 1 2 1 35.31 15.81 2 3

15.03 15.21 15.05 15.37

31.00 47.74

2 3 2 1 1

22.96 35.08 26.97 13.04 15.82

44

818.59

16

252.24

92

1466.47

Total disposal of bed ash 6248.1 total coal used in this period 249072.0 total ash production in this period with 25% ash 62268.0 Percentage bed ash disposed 10.03

TABLE 5: FLY ASH BALANCING REPORT - COMPARISON OF FLY ASH AS PER CALCULATION AND AT ACTUALS Only for FBC-03&04 Boilers Running time- sample data 1 Coal used Date 1/9/2013 2/9/2013 3/9/2013 4/9/2013 5/9/2013 6/9/2013 7/9/2013 8/9/2013 9/9/2013 10/9/2013 Total coal FBC 3 IM ASH adb ASH af 10.94 10.51 21.18 11.42 13.39 12.48 8.97 8.04 8.24 6.73 FBC 4 TM IM ASH adb ASH af 10.37 8.43 17.38 14.41 13.37 12.37 7.31 10.16 9.43 13.52 Total Ash Disposal as per calc FBC-03 43.98 37.52 92.77 43.51 50.75 47.17 35.7 31.76 31.64 24.36 FBC-04 62.95 43.16 112.45 82.57 78.35 64.82 43.06 60.66 53.09 75.85 total ash Total 106.93 80.68 205.22 126.08 129.1 111.99 78.76 92.42 84.73 100.21 Fly ash calculated (85%) FBC-03 FBC-04 Total calc 37.38 31.89 78.85 36.98 43.14 40.09 30.35 27 26.89 20.71 90.89 68.58 174.44 107.17 109.74 95.19 66.95 78.56 72.02 85.18 948.72 Fly ash gen as per stores 105.49 93.74 99.19 170.9 204.57 164.05 143.84 171.13 186.3 164.14 1503.35 554.6 58.5

FBC 03 FBC 04 TM 402 357 438 381 379 378 398 395 384 362 3874 607 512 647 573 586 524 589 597 563 561 5759

34 36 32 34 38.5 34 36.5 37.5 37 35

8.3 11.1 5.3 13.9 7.7 5.9 5.8 7.5 8.2 9.2

15.2 14.6 29.5 14.9 20.1 17.8 13.3 11.9 12 9.4

36 34 30.5 30 36.5 37 37.5 38.5 37 37

8.7 10 8.4 10.6 9.3 7.3 5.9 8.6 8.5 8.2

14.8 11.5 22.9 18.4 19.1 18.2 11 15.1 13.7 19.7

Average ash % 11.59

53.51 36.69 95.58 70.18 66.6 55.1 36.6 51.56 45.13 64.47 Total difference 1116.12 Percentage difference

Only for FBC-03&04 Boilers Running time- sample data 2 Coal used Date 1/5/2013 2/5/2013 3/5/2013 4/5/2013 5/5/2013 6/5/2013 7/5/2013 8/5/2013 9/5/2013 10/5/2013 FBC 3 IM 4.7 7 11 4.1 4.5 6 4.5 4.6 6.9 9.7 ASH adb 33.9 33.3 22.1 36.1 27.9 24.2 30.5 30.5 36.1 22.7 ASH af 27.39 24.17 17.63 25.60 19.43 16.86 20.76 21.58 26.37 16.34 FBC 4 TM 21 34 31 33.5 30.5 32.5 35 33 35 29 IM 4.4 6 13 5.6 4.4 5.3 4.4 5.3 5.7 9.9 ASH adb 34 34.6 22.1 32.2 26.7 30.8 32.3 32 36.4 19.9 ASH af 28.10 24.29 17.53 22.68 19.41 21.95 21.96 22.64 25.09 15.68 Total Ash Disposal as per calc FBC-03 97.51 86.05 66.47 97.02 74.42 64.74 82.62 86.1 94.14 59.31 FBC-04 175.34 119.75 100.27 137.21 110.44 126.65 131.32 137.42 140.5 87.65 Total 272.85 205.8 166.74 234.23 184.86 191.39 213.94 223.52 234.64 146.96 Fly ash calculated(85%) FBC-03 FBC-04 Total calc 82.88 73.14 56.5 82.47 63.26 55.03 70.23 73.19 80.02 50.41 149.04 101.79 85.23 116.63 93.87 107.65 111.62 116.81 119.43 74.5 231.92 174.93 141.73 199.1 157.13 162.68 181.85 189.99 199.44 124.92 Fly ash gen as per stores 236.15 232.84 244.36 258.24 96.21 214.23 255.83 209.04 128.08 170.76

FBC 03 FBC 04 TM 356 356 377 379 383 384 398 399 357 363 624 493 572 605 569 577 598 607 560 559 23 32.5 29 32 33.5 34.5 35 32.5 32 35

11/5/2013 12/5/2013 13/5/2013 14/5/2013 15/5/2013 16/5/2013 17/5/2013 18/5/2013 19/5/2013 20/5/2013 21/5/2013 22/5/2013 23/5/2013 24/5/2013 25/5/2013 26/5/2013 27/5/2013 28/5/2013 29/5/2013 30/5/2013 31/5/2013 Total coal

388 388 359 360 365 381 377 364 293 305 355 300 321 307 310 324 330 343 318 320 334 10894

526 471 545 547 545 553 483 498 487 464 516 470 461 555 490 505 521 489 461 482 520 16353

29 31.5 27.5 25.5 22.5 22.5 19.5 24 25 24 25.5 24 17.5 13.5 30 33.5 18 18 16 24 21.5

3.1 7.2 8.5 3.9 3.8 3.3 3.1 3.9 6.9 3.5 5 8.6 3.7 2.7 4.4 7.7 5.8 5.3 7.8 4.7 7.7

32.9 22 27.3 40.3 41.2 2.8 40.9 39.5 29.8 38.4 38 30.8 40.4 43.8 40.5 32.2 25.4 30.2 23 33 32.2

24.11 16.24 21.63 31.24 33.19 2.24 33.98 31.24 24.01 30.24 29.80 25.61 34.61 38.94 29.65 23.20 22.11 26.15 20.95 26.32 27.39

28 29.5 31.5 28 24 23 25 24.5 23 20 29 25 13.5 12.5 29 29 19 20 18 23 20

3.7 7.9 4.9 4.5 3.9 3.3 4.2 4.6 10.4 3 5.1 9.8 3.9 2.9 5.3 7.4 5.4 5.5 7 5.4 5.1

30.9 18.6 40.6 41.6 40 42.3 40.8 41.8 23.5 39.9 32.1 33.1 40.1 43.2 38.4 30.4 31.8 27.4 28.4 30.8 32.1

23.10 14.24 29.24 31.36 31.63 33.68 31.94 33.08 20.20 32.91 24.02 27.52 36.09 38.93 28.79 23.31 27.23 23.20 25.04 25.07 27.06 25.38

93.55 63.01 77.65 112.46 121.14 8.53 128.1 113.71 70.35 92.23 105.79 76.83 111.1 119.55 91.92 75.17 72.96 89.69 66.62 84.22 91.48

121.51 67.07 159.36 171.54 172.38 186.25 154.27 164.74 98.37 152.7 123.94 129.34 166.37 216.06 141.07 117.72 141.87 113.45 115.43 120.84 140.71 total ash

215.06 130.08 237.01 284 293.52 194.78 282.37 278.45 168.72 244.93 229.73 206.17 277.47 335.61 232.99 192.89 214.83 203.14 182.05 205.06 232.19 6915.98

79.52 53.56 66 95.59 102.97 7.25 108.89 96.65 59.8 78.4 89.92 65.31 94.44 101.62 78.13 63.89 62.02 76.24 56.63 71.59 77.76

Average ash %

103.28 57.01 135.46 145.81 146.52 158.31 131.13 140.03 83.61 129.8 105.35 109.94 141.41 183.65 119.91 100.06 120.59 96.43 98.12 102.71 119.6 Total difference

182.8 110.57 201.46 241.4 249.49 165.56 240.01 236.68 143.41 208.19 195.27 175.24 235.85 285.27 198.04 163.96 182.61 172.67 154.74 174.3 197.36 5878.57

113.98 188.83 146.07 172.07 154.65 439.74 228.68 195.25 259.04 159.58 298.21 182.46 144.15 248.57 342.26 391.46 149.43 185.38 190.21 277.77 317.73 6831.26 952.7 16.2

Percentage difference

ANNEXURE 3- REVIEW OF THE HEAT CONTENT IN COAL- THE VARIANCE

TABLE 9: LAB ANALYSIS REPORT FOR IMPORT COAL RECD BY RAIL: 12 - 13- as per central lab report LAB S.n Report country o no I 1 2 3 4 5 6 AGARWAL IMPORTED COAL 2 IMP-INDONESIA 3 IMP-INDONESIA 5 IMP-INDONESIA 6 IMP-INDONESIA 7 IMP-INDONESIA 8 IMP-INDONESIA No of Wagons recd / Date Qty TM% IM Ash on 5% Sulphur Ash moisture GCV adb V.M % adb% arb % GCV arb 100-TMAsh GCV arb/(100TM-Ash) FC adb FC / VM

59 / 10.04.12 59 / 11.04.12 59 / 11.04.12 59 / 27.04.12 59 / 28.04.12 59 / 30.04.12

3370.85 3279.10 3328.95 3277.85 2946.95 3298.10

34.00 34.80 34.50 36.00 36.40 36.60

10.90 7.10 8.60 11.00 10.20 10.20

7.50 6.50 8.40 6.90 7.10 6.90

5660.00 5710.00 5600.00 5630.00 5680.00 5630.00

0.70 0.73 0.71 0.73 0.73 0.72

41.50 41.80 41.50 41.30 41.70 41.80

5.2 4.5 5.8 4.6 4.8 4.6

4192.6 4007.4 4013.1 4048.5 4022.8 3974.9

60.8 60.7 59.7 59.4 58.8 58.8

69 66 67.2 68.2 68.4 67.6

40.10 44.60 41.50 40.80 41.00 41.10

0.97 1.07 1.00 0.99 0.98 0.98

Average 35.38 9.67 II 7 8 9 10 11 12 13 14 15 AGARWAL IMPORTED COAL 27 IMP-INDONESIA 28 IMP-INDONESIA 29 IMP-INDONESIA 31 IMP-INDONESIA 33 IMP-INDONESIA 34 IMP-INDONESIA 37 IMP-INDONESIA 38 IMP-INDONESIA 42 IMP-INDONESIA 58 / 12.06.12 59 / 12.06.12 59 / 13.06.12 57 / 20.06.12 59 / 21.06.12 59 / 22.06.12 Truck 47/ Truck 07/ 59 / 28.08.12 3668.85 3398.30 3342.75 3218.10 3093.00 3204.35 669.42 63.89 3752.70 35.50 36.20 38.20 37.50 37.70 37.60 38.00 38.00 41.80 9.40 9.80 10.20 9.90 8.60 9.20 8.40 8.40 7.50

7.22 6.40 7.10 6.60 6.70 6.20 6.70 6.40 6.40 9.00

5651.67 5720.00 5730.00 5750.00 5710.00 5790.00 5720.00 5775.00 5775.00 5610.00

0.72 0.70 0.71 0.73 0.71 0.72 0.72 0.76 0.76 0.70

Min GCV Max GCV 41.60 4.92 42.00 41.90 42.00 42.00 42.00 41.80 42.70 42.70 42.00 4.3 4.8 4.3 4.4 4.1 4.4 4.2 4.2 5.5

3974.9 Difference between 4192.6 max & min 4043.22 59.70 67.73 4072.2 4052.9 3957.1 3960.9 3946.6 3930.9 3908.8 3908.8 3529.8 60.2 59 57.5 58.1 58.2 58 57.8 57.8 52.7 67.6 68.7 68.8 68.2 67.8 67.8 67.6 67.6 67

217.70 5.38 41.52 42.20 41.20 41.20 41.40 43.20 42.30 42.50 42.50 41.50 1.00 1.00 0.98 0.98 0.99 1.03 1.01 1.00 1.00 0.99

Average 37.83 9.04 1 2 3 4 5 6 7 MAHESHWARI IMPORTED COAL 11 IMP-INDONESIA 59 / 09.05.12 12 IMP-INDONESIA 59 / 10.05.12 13 IMP-INDONESIA 59 / 15.05.12 14 IMP-INDONESIA 59 / 13..05.12 15 IMP-INDONESIA 59 / 14.05.12 18 IMP-INDONESIA 59 / 12.05.12 43 IMP-INDONESIA 57 / 03.09.12 3227.10 3252.65 3335.65 3294.00 3234.70 3482.78 3522.30 30.00 29.80 29.20 29.00 28.20 28.50 32.30 8.00 8.50 8.10 11.30 10.90 9.20 8.20

6.83 8.10 8.00 8.30 6.40 6.90 7.40 9.00

5731.11 5760.00 5780.00 5780.00 5760.00 5850.00 5820.00 5570.00

0.72 0.73 0.74 0.72 0.73 0.74 0.73 0.72

Min GCV Max GCV 42.12 4.47 42.00 41.60 41.80 40.80 41.80 41.40 42.00 6 5.9 6.2 4.8 5.2 5.6 6.4

3529.8 Difference between 4072.2 max & min 3918.67 57.70 67.90 4382.6 4434.5 4452.9 4610.6 4714.1 4582.9 4107.7 64 64.3 64.6 66.2 66.6 65.9 61.3 68.5 69 68.9 69.6 70.8 69.5 67

542.40 13.84 42.00 41.90 41.90 41.80 41.50 40.40 42.00 40.80 1.00 1.00 1.01 1.00 1.02 0.97 1.01 0.97

8 9 10 11 12 13 14 15 16 17 18 19 20 21

44 48 52 56 57 58 61 62 64 66 67 71 73 88

IMP-INDONESIA IMP-INDONESIA IMP-INDONESIA IMP-INDONESIA IMP-INDONESIA ( PKP IMP-INDONESIA IMP-INDONESIA IMP-INDONESIA IMP-INDONESIA IMP-INDONESIA IMP-INDONESIA IMP-INDONESIA IMP-INDONESIA IMP-INDONESIA

59 / 11.09.12 59 / 18.09.12 59 / 10.10.12 59 / 24.10.12 59 / 24.10.12 59 / 27.10.12 59 / 02.11.12 59 / 03.11.12 59 / 11.11.12 59 / 14.11.12 59 / 20.10.12 to 59 / 30.11.12 59 / 05.12.12 59 / 20.02.13

3609.30 3504.10 3475.55 3002.50 3242.70 3005.30 3016.69 3141.79 3364.25 3406.40 461.38 3411.00 3442.05 3457.15

31.50 30.10 34.80 32.20 35.50 33.00 32.50 32.60 32.40 32.20 35.60 32.10 32.00 32.60

10.50 11.40 11.50 11.70 12.20 13.40 12.80 12.60 11.80 12.50 11.80 12.10 11.80 12.90

8.20 8.50 10.70 8.00 8.50 8.00 8.30 8.60 8.80 8.40 8.70 8.00 9.70 7.10

5650.00 5560.00 5370.00 5585.00 5510.00 5605.00 5630.00 5655.00 5630.00 5630.00 5580.00 5630.00 5620.00 5620.00

0.71 0.76 0.77 0.73 0.76 0.70 0.74 0.77 0.75 0.75 0.77 0.76 0.73 0.75

41.80 40.80 41.50 41.20 41.00 40.50 42.60 41.30 42.20 41.50 45.10 42.70 41.80 42.70

5.9 6.3 7.3 5.7 5.8 5.6 5.9 6.1 6.3 6 5.9 5.7 6.9 5

4324.3 4386.5 3956.2 4288.4 4047.8 4336.4 4358.1 4360.9 4315.1 4362.4 4074.3 4349 4332.9 4348.9

62.6 63.6 57.9 62.1 58.7 61.4 61.6 61.3 61.3 61.8 58.5 62.2 61.1 62.4

69.1 69 68.3 69.1 69 70.6 70.7 71.1 70.4 70.6 69.6 69.9 70.9 69.7

39.50 39.30 36.30 39.10 38.30 38.10 36.30 37.50 37.20 37.60 34.40 37.20 36.70 37.30

0.94 0.96 0.87 0.95 0.93 0.94 0.85 0.91 0.88 0.91 0.76 0.87 0.88 0.87

Average 31.72 11.10 1 2 3 4 5 6 7 8 GIMPEX IMPORTED COAL 17 IMP-INDONESIA 19 IMP-INDONESIA 20 IMP-INDONESIA 22 IMP-INDONESIA 23 IMP-INDONESIA 24 IMP-INDONESIA 26 IMP-INDONESIA 40 IMP-INDONESIA 59 / 18.05.12 59 / 19.05.12 59 / 21.05.12 59 / 28.05.12 59 / 29.05.12 59 / 30.05.12 59 / 05.06.12 By Truck. 3276.70 3051.40 3382.15 3320.75 3375.05 3326.80 3394.05 1475.55 32.70 33.50 32.40 32.40 32.00 32.80 32.50 34.20 10.40 10.70 8.70 8.40 9.40 10.00 10.80 10.10

8.27 8.50 8.10 7.80 9.50 6.70 7.60 7.80 6.70

5647.38 5620.00 5600.00 5655.00 5625.00 5750.00 5665.00 5600.00 5650.00

0.74 0.74 0.74 0.74 0.71 0.70 0.73 0.73 0.73

Min GCV Max GCV 41.81 5.93 41.20 41.50 41.50 41.30 42.40 41.90 41.80 41.80 6 5.7 5.6 6.8 4.8 5.4 5.5 4.6

3956.2 Difference between 4714.1 max & min 4339.36 62.35 69.59 4221.3 4170.2 4187.1 4151.2 4315.7 4229.9 4237.7 4135.4 61.3 60.8 62 60.8 63.2 61.8 62 61.2 68.9 68.6 67.5 68.3 68.3 68.4 68.4 67.6

757.90 17.47 38.81 39.90 39.70 42.00 40.80 41.50 40.50 39.60 41.40 0.93 0.97 0.96 1.01 0.99 0.98 0.97 0.95 0.99

1 1 1

Average 32.81 9.81 Australian Imported Coal : ( By Truck ) M/s Rohan Entp - Hospet 53 IMP-Australian 05 / 16.10.12 122.53 16.50 4.50 BHATIA IMPORTED COAL 54 IMP-INDONESIA 59 / 19.10.2012 3559.51 29.20 12.30 Gupta IMPORTED COAL IMP-INDONESIA ( 60 58 / 1.11.2012 3529.25 32.50 11.70

7.84 43.70 7.30 8.40

5645.63 4015.00 5700.00 5650.00

0.73 0.69 0.72 17.80

Min GCV Max GCV 41.68 5.55 18.70 40.50 40.80 38.4 5.4 6

4135.4 Difference between 4315.7 max & min 4206.06 61.64 68.25 3510.5 4601.6 4319.1 45.1 65.4 61.5 77.8 70.4 70.2

180.30 4.29 40.68 33.10 39.90 39.10 0.98 1.77 0.99 0.96

2 3 4 5 6

65 75 77 81 83

IMP-INDONESIA IMP-INDONESIA IMP-INDONESIA IMP-INDONESIA IMP-INDONESIA

( ( ( ( (

58 / 11.11.2012 59 / 15.12.2012 59 / 23.12.2012 59 / 08.01.2013 58 / 24.01.2013

3530.60 3428.40 3523.55 3463.50 3502.10

33.00 33.00 33.20 35.80 33.00

11.40 12.00 12.40 12.30 12.60

11.40 7.40 9.30 9.40 8.90

5610.00 5620.00 5510.00 5505.00 5470.00

16.20 16.20 14.70 16.20 15.60

41.30 42.00 42.60 42.30 41.40

8 5.2 6.5 6.4 6.3

4242.3 4278.9 4201.7 4029.9 4193.2

59 61.8 60.3 57.8 60.7

71.9 69.2 69.7 69.7 69.1

35.90 38.60 35.70 36.00 37.10

0.87 0.92 0.84 0.85 0.90

Average 33.42 12.07 1 2 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 GANDHAR IMPORTED COAL IMP-INDONESIA 89 IMP-INDONESIA 93 IMP-INDONESIA 94 Gandhar Imported Coal 2 Indonesia 3 Indonesia 4 Indonesia 9 Indonesia 14 Indonesia 15 Indonesia 17 Indonesia 20 Indonesia 23 Indonesia 30 Indonesia 31 Indonesia 32 Indonesia 33 Indonesia 34 Indonesia 43 Indonesia (viz) 49 Indonesia (viz) 51 Indonesia (viz) 53 Indonesia (viz) 56 Indonesia 58 Indonesia 58 / 26.02.2013 3256.90 33.50 12.80 57 / 11.03.2013 3313.90 34.00 13.20 58 / 20.03.2013 3439.20 32.00 12.70 59 / 02.04.13 59 / 06.04.13 59 / 08.04.13 59 / 24.04.13 59 / 01.05.13 59 / 04.05.13 59 / 06.05.13 59 / 06.05.13 59 / 23.05.13 59 / 01.06.13 59 / 02.06.13 59 / 06.06.13 59 / 07.06.13 59 / 08.06.13 59 / 13.08.13 58/ 28.08.13 58/ 01.09.13 58 / 04.09.13 56 / 20.09.13 58 / 28.09.13 3482.1 3406.7 3401.6 3346 3382.4 3364 3470.3 3370.9 3623.7 3305.8 3855.2 3305 3467.2 3605.7 3442.7 3457 3535.7 3448.8 3531.8 3464.9 33.7 33 33.1 33 33.8 33.5 33.5 33.4 34 43.1 39.8 39.7 38.5 38.8 37 35.1 34.1 35.6 39.2 37.2 13 13.3 13.2 13.5 13.1 13.2 13 13.8 13 19.1 20.2 20.2 19.6 20.8 15.9 15.6 15.4 15.9 17.9 18

9.13 7.50 8.10 9.80 9.4 9.8 7.9 6.3 7.5 6.4 9.7 9.1 9.5 7.1 6.5 7.5 6.5 6.1 9.6 7.3 7.5 9.5 9.1 11.6

5560.83 5540.00 5545.00 5480.00 5480 5470 5525 5545 5520 5535 5510 5485 5520 5420 5530 5555 5520 5500 5575 5440 5460 5440 5540 5520

16.12 16.30 0.75 0.74 0.61 0.69 0.73 0.72 0.7 0.72 0.7 0.65 0.68 0.67 0.62 0.65 0.61 0.63 0.57 0.58 0.52 0.5 0.52 0.49

Min GCV Max GCV 41.73 6.40 41.50 41.50 41.90 42.1 41.6 42.4 41.7 41.8 43.7 41.5 41.2 39.7 38.1 40 42.3 43.5 41.9 40.4 41.5 40.9 40.1 40.7 39.5 5.3 5.6 7 6.6 6.9 5.6 4.4 5.2 4.5 6.8 6.4 6.6 4.3 4.1 4.8 4.2 3.9 6.4 5 5.2 6.4 5.8 7.7

4029.9 Difference between 4319.1 max & min 4210.85 60.18 69.97 4224.9 4216.2 4268.5 4176.1 4227.1 4258.3 4295 4205.1 4240.5 4211.7 4237.8 4187.6 3812.1 4171.8 4197.6 4222.4 4250 4176.3 4183.1 4253.1 4165.7 4102.7 4227.5 3812.1 4295 61.2 60.4 61 59.7 60.1 61.3 62.6 61 62 59.7 60.2 59.4 52.6 56.1 55.5 57.3 57.3 56.6 59.9 60.7 58 55 55.1 69 69.8 70 70 70.3 69.5 68.6 68.9 68.4 70.5 70.4 70.5 72.5 74.4 75.6 73.7 74.2 73.8 69.8 70.1 71.8 74.6 76.7

289.20 6.87 37.07 38.20 37.20 35.60 35.50 35.30 36.50 38.50 37.60 36.70 35.80 35.90 37.80 35.70 33.30 30.00 30.40 31.20 34.10 35.60 36.20 34.50 32.30 30.90 0.89 0.92 0.90 0.85 0.84 0.85 0.86 0.92 0.90 0.84 0.86 0.87 0.95 0.94 0.83 0.71 0.70 0.74 0.84 0.86 0.89 0.86 0.79 0.78

Min GCV Max GCV

Difference between max & min

482.90 11.52

Average 35.96 15.89 1 2 3 4 5 Gupta Imported Coal 39 Indonesia 42 Indonesia 45 Indonesia 46 Indonesia 48 Indonesia 59 / 29.07.13 59 / 10.08.13 59 / 16.08.13 59 / 20.08.13 59 / 23.08.13 3699.2 3598.4 3735.9 3805.4 3796.6 40.1 35.1 34.8 36.5 38.3 19.9 16.8 16.3 16.8 18.6

8.20 10.9 7.7 9.7 10.7 8.6

5504.50 5550 5430 5470 5440 5480

0.63 0.5 0.62 0.57 0.59 0.55

41.23 39.6 41.3 40.8 42 40.3

5.54 6.9 5.3 6.7 7.2 5.6

4190.08 58.51 4150.4 4235.7 4261 4151.9 4153.8 53 59.6 58.5 56.3 56.1

71.72 78.3 71.1 72.8 73.7 74

34.69 29.60 34.20 33.20 30.50 32.50

0.84 0.75 0.83 0.81 0.73 0.81

Average 36.96 17.68 1 2 3 4 Maheshwari Imported Coal 40 Indonesia 41 Indonesia 47 South America 50 Indonesia 58 / 02.08.13 59 / 07.08.13 59 / 24.08.13 57 / 28.08.13 3634 3700 3584.3 3534.3 18.5 18.3 18.8 18.8 7.6 9.5 9.7 8.7

9.52 19 18.1 21.2 18.3

5474.00 5140 5160 5170 5120

0.57 20.2 0.4 0.47 0.43

Min GCV Max GCV 40.80 6.34 33 33.5 32.8 35 16.3 15.6 18.1 15.6

4150.4 Difference between 4261 max & min 4190.56 56.70 73.98 4533.7 4658.3 4649 4553.6 65.2 66.1 63.1 65.6 69.5 70.5 73.7 69.4

110.60 2.64 32.00 40.40 38.90 36.30 38.00 0.78 1.22 1.16 1.11 1.09

TABLE 10- IMPORTED COAL FC/VM RATIO- range of GCV - from receipt coal analysis reports from LAB VM Agarwal lot 1 Agarwal lot 2 Maheswari 1 Gimpex Gupta 1 Gandhar 1 Gupta 2 41.60 42.12 41.81 32.81 41.73 41.23 40.80 GCV arb / (100-TMAsh) 67.7 67.9 69.6 68.3 70.0 71.7 74.0 FC/VM 1.00 1.00 0.93 0.98 0.89 0.84 0.78 TM 35.4 37.8 31.7 32.8 33.4 36.0 37.0 ASH arb 4.92 4.47 5.93 5.55 6.40 5.54 6.34 Min GCV 3794.9 3529.8 3956.2 4135.4 4029.9 3812.1 4150.4 Max GCV 4192.6 4072.2 4714.1 4315.7 4319.1 4295.0 4261.0 GCV arb average 4043.2 3918.7 4339.4 4206.1 4210.9 4190.1 4190.6 GCV diff bet min & max 397.7 542.4 757.9 180.3 289.2 482.9 110.6 GCV diff in % 9.8 13.8 17.5 4.3 6.9 11.5 2.6 Comment

In all coals, the GCV range is very high. It is rather difficult to base the steam to fuel ratio as the measure of plant performance

TABLE 7: LAB ANALYSIS REPORT FOR INDIAN COAL RECD BY RAIL: 12 - 13 - 14- central lab report Sl no LAB Report Colliery no WCL : 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 4 9 10 16 21 25 30 32 35 36 38 41 45 47 49 50 51 52 59 63 68 69 72 74 78 79 84 85 86 MAJRI MAJRI MAJRI MAJRI MAJRI MAJRI MAJRI MAJRI MAJRI MAJRI MAJRI MAJRI MAJRI MAJRI MAJRI MAJRI MAJRI MAJRI MAJRI MAJRI MAJRI MAJRI MAJRI MAJRI MAJRI MAJRI MAJRI MAJRI MAJRI MAJRI 3644.33 to 06.05.12 1048.87 59 / 05.05.12 3822.55 57 / 13.05.12 3643.10 59 / 05.05.12 3823.80 59 / 03.06.12 3879.60 59 / 05.06.12 3850.95 879.30 58 / 27.06.12 3752.55 59 / 01.07.12 3825.30 59 / 26.07.12 3921.45 7 Trucks 236.25 59 / 11.09.12 4162.60 59 / 17.09.12 3828.10 59 / 24.09.12 4074.05 59 / 26.09.12 3823.00 59 / 30.09.12 3875.10 58 / 23.10.12 3976.30 58 / 23.10.12 4201.00 58 / 05.11.12 3950.45 59 / 16.11.12 3774.65 59 / 16.11.12 3870.45 59 / 03.12.12 4044.85 59 / 10.12.12 3852.00 59 / 28.12.12 3889.15 59 / 04.01.13 3774.30 59 / 27.01.13 3785.15 59 / 29.01.20133819.60 59 / 10.02.20133737.20 59 / 09.04.12 59 / 21.04.12 3818.40 13.70 11.80 11.50 12.10 12.00 13.00 11.70 12.20 11.20 14.60 13.50 14.40 12.80 14.60 15.80 14.60 16.60 15.00 12.00 11.00 14.80 14.20 13.80 12.10 14.00 12.70 11.60 12.10 11.60 11.10 7.50 5.90 6.40 5.90 6.90 6.40 7.90 9.00 6.90 7.60 8.00 7.10 6.20 5.60 7.50 6.50 7.40 7.40 6.40 6.50 6.80 6.10 7.20 7.60 7.00 6.40 5.10 4.70 4.80 5.20 29.40 29.50 29.80 29.10 30.00 29.90 29.60 29.80 29.70 28.90 30.50 30.80 30.00 38.60 33.50 30.20 32.50 30.90 31.80 32.20 31.80 39.50 30.70 30.20 29.10 31.20 32.00 33.00 32.10 32.20 4550.00 4590.00 4520.00 4510.00 4460.00 4510.00 4655.00 4650.00 4560.00 4630.00 4500.00 4540.00 4385.00 3930.00 4300.00 4390.00 4340.00 4405.00 4450.00 4390.00 4440.00 4220.00 4640.00 4585.00 4600.00 4440.00 4485.00 4410.00 4680.00 4560.00 0.62 0.62 0.60 0.60 0.60 0.60 0.62 0.66 0.65 0.66 0.63 0.66 0.64 0.68 0.63 0.64 0.64 0.66 0.65 0.67 0.64 0.62 0.66 0.68 0.63 0.62 0.66 0.64 0.64 0.66 28.30 28.70 28.20 28.10 28.20 28.00 28.40 28.20 28.40 28.80 28.10 28.20 27.50 23.90 25.70 26.70 26.90 27.10 28.20 27.70 27.30 25.30 29.50 29.00 28.70 29.10 28.90 28.60 26.20 27.20 26.7 27.4 27.8 26.9 27.8 27.4 27.5 27.5 27.8 26 27.8 27.8 27.5 34.7 29.7 27.1 28.5 27.6 29.5 30.2 28.5 35.7 27.9 27.9 26.3 28.7 29.8 30.5 29.9 30.1 4245 4302.2 4273.7 4212.8 4215.7 4192 4462.9 4486.5 4349.4 4279.2 4231 4183.3 4076.5 3555.3 3914.2 4009.7 3908.8 4043.5 4183.8 4178.7 4058.9 3856 4310 4361.7 4253.8 4141.2 4177.8 4067.6 4345.7 4276.2 59.6 60.8 60.7 61 60.2 59.6 60.8 60.3 61 59.4 58.7 57.8 59.7 50.7 54.5 58.3 54.9 57.4 58.5 58.8 56.7 50.1 58.3 60 59.7 58.6 58.6 57.4 58.5 58.8 71.2 70.8 70.4 69.1 70 70.3 73.4 74.4 71.3 72 72.1 72.4 68.3 70.1 71.8 68.8 71.2 70.4 71.5 71.1 71.6 77 73.9 72.7 71.3 70.7 71.3 70.9 74.3 72.7 34.80 35.90 35.60 36.90 34.90 35.70 34.10 33.00 35.00 34.70 33.40 33.90 36.30 31.90 33.30 36.60 33.20 34.60 33.60 33.60 34.10 29.10 32.60 33.20 35.20 33.30 34.00 33.70 36.90 35.40 1.23 1.25 1.26 1.31 1.24 1.28 1.20 1.17 1.23 1.20 1.19 1.20 1.32 1.33 1.30 1.37 1.23 1.28 1.19 1.21 1.25 1.15 1.11 1.14 1.23 1.14 1.18 1.18 1.41 1.30 No of Wagons Qty recd / Date Moisture Moisture Ash on 5% as recd in test moisture % sample % GCV adb Sulphur V.M % Ash adb % adb arb GCV arb GCV 100-TM-Ash arb/(100- FC adb FC / VM TM-Ash)

31 32 33 34

87 90 91 95

MAJRI MAJRI MAJRI MAJRI

59 / 18.02.20133777.65 59 / 1.03.2013 3765.10 1150.70 3839.70 59 / 18.03.2013

12.60 11.50 11.70 12.40

4.80 4.10 6.90 5.40

28.40 35.10 29.00 30.90

4590.00 4350.00 4350.00 4480.00

0.62 0.64 0.62 0.51

Average Median SCCL 1 2 3 4 5 6 46 70 76 80 82 96 SCCL SCCL SCCL SCCL SCCL SCCL 59 / 15.09.20123970.90 59 / 28.11.20123743.70 59 / 23.12.20123876.55 58 / 05.01.20133809.50 58 / 13.01.20133961.45 58 / 19.03.2013

12.95 12.60 17.80 19.40 11.60 12.30 13.60 11.20

6.50 6.50 7.50 8.70 6.70 5.50 4.80 4.50

31.23 30.70 40.90 28.00 29.60 27.50 30.70 37.00

4473.38 4485.00 3500.00 4520.00 4420.00 4250.00 4560.00 4375.00

0.63 0.64 0.68 0.65 0.62 0.65 0.63 0.56

26.1 32.7 27 28.5 Min GCV Max GCV 27.76 28.61 28.10 27.80 24.60 35.4 30.00 23.8 27.30 27.5 27.50 25.4 29.40 27.9 26.50 34.6 Min GCV Max GCV 27.55 29.10 19.70 25.10 37.9

30.70 27.30 26.10 26.70

4213.9 4014.3 4125.7 4148.5 3555.3 4486.5 4158.3 4183.8 3110.3 3990.3 4187.9 3944.2 4138.5 4068.1 3110.3 4187.9 3906.55 3607 3903.2 3974.6 4146.2 4289.4 3898.7 4363.5 3988 4009 4180.4 4031.4 4225.3 4179.1 4416.8 3898.7 4416.8

61.3 55.8 61.3 59.1

68.7 71.9 67.3 70.2

36.10 33.50 38.00 37.00

1.18 1.23 1.46 1.39

Difference between max 931.20 22.39 & min 58.44 71.33 34.50 1.25 58.80 71.30 34.55 1.23 46.8 56.8 60.9 62.3 58.5 54.2 66.5 70.3 68.8 63.3 70.7 75.1 27.00 33.30 36.40 39.50 35.10 32.00 1.10 1.11 1.33 1.44 1.19 1.21

Average GUJRAT NRE 1 1 2 3 4 5 6 7 8 9 10 11 12 13 92 GUJRAT N32 Trucks WCL : 1 MAJRI 59 / 09.04.13 MAJRI 5 By Truck MAJRI 59 / 18.04.13 10 MAJRI 59 / 18.04.13 12 MAJRI 59 / 28.04.13 16 MAJRI 59 / 17.05.13 19 MAJRI 59 / 23.05.13 21 MAJRI 24 By Truck MAJRI 59 / 26.05.13 28 MAJRI 59 / 30.05.13 29 MAJRI 59 / 12.06.13 35 MAJRI 59 / 28.06.13 36 MAJRI 37 By Truck 442.85 3835.10 987.79 3850.70 3756.30 3736.35 3813.85 3830.4 1346.52 3866.8 3959.65 3989.4 3884.2 750.70

14.32 10.10 12.20 11.80 12.80 12.90 12 10.1 12.6 10 10.7 10.2 12 14.3 10.5

6.28 1.80 04.40 04.80 06.20 07.00 5.2 7.7 6.2 5.6 6.5 6 6.8 6.9 7.8

32.28 40.00 40.80 38.90 32.90 30.30 42.7 32.5 39.4 40.1 34.5 40.4 32.2 31.6 31.7

4270.83 3940.00 4250.00 4290.00 4460.00 4580.00 4200 4480 4280 4205 4377 4220 4475 4540 4550

0.63 0.50 00.45 00.63 00.60 00.54 0.62 0.58 0.6 0.52 0.55 0.52 0.58 0.59 0.59

Difference between max 1077.6 27.58 & min 56.58 69.12 33.88 1.23 52 50.3 52.2 56.6 58.7 48.4 58.2 50.7 51.8 56.3 51.2 57.6 56.6 58.7 69.4 77.6 76.1 73.3 73.1 80.6 75 78.7 77.4 74.3 78.7 73.4 73.8 75.2 38.50 29.70 31.10 32.30 34.20 30.70 31.90 30.50 30.80 35.40 31.20 33.60 35.50 34.30 1.95 1.18 1.23 1.13 1.20 1.43 1.14 1.28 1.31 1.50 1.39 1.23 1.37 1.31

37.5 25.20 36 28.60 30.6 28.50 28.4 21.4 39.6 27.9 31.7 23.9 36.7 23.5 38.2 23.6 33 22.4 38.6 27.4 30.4 26 29.1 26.2 30.8 Min GCV Max GCV

Difference between max 518.10 12.56 & min

Average 14 15 52 54 GHUGUS 59 / 02.09.13 GHUGUS 59 / 14.09.13 3914.70 4028.10

11.70 15.7 16.6

6.24 8.2 7.2

36.00 29.9 34.4

4377.46 4520 4410

0.57 0.41 0.38

25.36

33.89 4123.51 4150.7 3963.3 3963.3 4150.7 4057.00 4138.6 4216.8 4138.6 4216.8 4177.70 4124.2

54.41 56.8 52.5

75.94 73.1 75.5

Average 16 17 55 56 CHARGAO59 / 20.09.13 CHARGAO58 / 25.09.13 3831.50 3683.40

16.15 15.5 15.2

7.70 7.1 8.5

32.15 30.7 28.1

4465.00 4550 4550

0.40 0.37 0.38

26.4 27.5 25.1 30.9 Min GCV Max GCV 25.75 29.20 25.8 27.9 29 26 Min GCV Max GCV 27.40 26.95 25.8 29.3

32.40 35.50 33.30

1.29 1.34 1.33

Difference between max 187.40 4.62 & min 54.65 74.30 34.40 1.34 36.40 1.41 56.6 73.1 34.40 1.19 58.8 71.7 Difference between max 78.20 & min 57.70 72.40 35.40 35.50 56.9 72.5 1.87 1.30 1.38

Average 18 1 2 3 4 5 6 7 8 9 BY Truck 6 truck 58 Gujarat NRE COKE : BY Truck 6 7 8 11 13 22 25 26 27 4 66 66 61 55 55 72 58 52 31.03.2013 10.04.2013 16.04.2013 22.04.2013 27.04.2013 04.05.2013 14.05.2013 21.05.2013 29.05.2013 211.88 Qty 1088.41 1150.52 1161.5 1023.28 1071.93 1319.45 1136.18 1032.8

15.35 13.8 e as 12.80 12.60 10.2 9.7 8.4 9.1 8.6 10.2

7.80 7.2 2.40 1.70 1.80 1.9 2 1.7 1.8 2.2 2

29.40 31.5 40.70 38.40 38.00 40 40.6 41.4 41 41.9 41.9

4550.00 4440 4080.00 4380.00 4480.00 4530 4480 4625 4640 4564 4563

0.38 0.34 0.50 0.48 0.42 0.38 0.37 0.35 0.37 0.32 0.31

Average SCCL S.noReport 1 18 2 38 3 44 4 60 the SCRM SCRM CXSG Wagons recd Qty 57 / 11.05.20133723.8 59 / 17.07.20133854.3 59 / 11.08.20133938.1 58 / 30.09.20133956.83

10.20 e as 10.6 14.1 15.1 11

1.89 in test 6.8 5.9 6.1 5.9

40.40 ( on 5% 39.9 38.2 40.3 24.5

4532.75 c Value 4315 4320 4250 4140

0.38 p

20.00 19.10 34.1 20.00 33.8 18.8 36.6 19 37.4 18.5 38.6 18.2 38 18.6 39.2 17.3 38.4 Min GCV Max GCV 18.69 37.01

3885.4 3987.3 4146.7 4128 4309.8 4295.1 4265.3 4181.2 3885.4 4309.8 4149.85

53.1 53.6 53.2 52.9 53 52.9 52.2 51.4

73.2 74.4 77.9 78 81.3 81.2 81.7 81.3

40.80 40.20 39.30 38.40 38.40 39.00 37.30 38.80

2.14 2.01 2.09 2.02 2.08 2.14 2.01 2.24

Difference between max 424.40 10.23 & min 52.79 78.63 39.03 2.09

Average

12.70

6.18

35.73

4256.25

r ( V.M % 0.53 25.5 38.3 0.55 24.2 34.9 0.33 25.1 36.4 0.32 24.5 23.2 Min GCV Max GCV 0.43 24.83 33.20

4139.1 3943.5 3842.7 3915.6 3842.7 4139.1 3960.23

51.1 51 48.5 65.8

81 77.3 79.2 59.5

27.80 31.70 28.50 45.10

1.09 1.31 1.14 1.84

Difference between max 296.40 7.48 & min 54.10 74.25 33.28 1.34

TABLE 8- INDIAN COAL FC/VM RATIO- range of GCV - from receipt coal analysis reports from LAB GCV arb / (100-TMFC/VM Ash) 71.3 69.1 69.4 75.2 74.3 72.4 78.6 74.3 1.2 1.2 2.0 1.3 1.3 1.3 2.1 1.3 GCV arb average 4158.3 3906.6 4123.5 GCV diff bet min & max 931.2 1077.6 518.1 GCV diff in % 22.4 27.6 12.6

VM Majri SCCL Gujrat NRE coke Majri Chugus Chargaon Gujrat NRE coke SCCL 27.8 27.6 19.7 25.4 25.8 27.4 18.7 24.8

TM 13.0 14.3 10.1 11.7 16.2 15.4 10.2 12.7

ASH arb Min GCV 28.6 29.1 37.9 33.9 29.2 27.0 37.0 33.2 3555.3 3110.3 3898.7

Max GCV 4486.5 4187.9 4416.8

Comment Wide range of GCV Ash reported is less Difficult to burn

Only one report is available Only two reports available Only two reports available 3885.4 3842.7 4309.8 4139.1 4149.9 3960.2 424.4 296.4 10.2 7.5

Difficult to burn Ash reported is less

In all coals, the GCV range is very high. It is rather difficult to base the steam to fuel ratio as the measure of plant performance

TABLE6IMPORTEDCOALANALYSISREPORTSAMPLEDATDESPATCHPOINT Analysisby Port geochem pt.TCRC TCRC TCRC Griffith Griffith Griffith Griffith Griffith Ship PTOorja Krishnapatnam ih Mangalore Dharamtar Goa Mangalore Mangalore Mangalore Mangalore Mangalore Mangalore Mangalore Mangalore Mangalore Mangalore Mangalore Mangalore Mangalore Dateof placement reportdate qty,tons 55 3405 3954 3481 3990 3903 3450 3422 3522 3488 3473 3452 3460 3502 3469 3350 3515 3522 3365 3518 3499 3494 3589 3575 3666 3693 3701 TM 26.87 29.79 30.98 35.12 29.8 31.84 32.11 33.2 34 48 34.48 34.4 32.65 32.2 33.6 34.2 33.8 33.7 33.2 33.8 42.8 39.22 38.9 37.7 38.2 35.38 35.1 35.5 35.58 35.6 IM 15.81 13.45 12.45 12.02 14.28 13.95 14.77 14 14 5 14.5 15.97 13.92 13.53 14.4 14.73 13.95 13.65 13.35 13.73 19.46 19.93 19.86 19.27 20.1 11.12 15.58 13.56 11.98 12.47 VMadb 41.09 38.31 37.8 42.31 40.14 39.33 37.04 41.77 42 65 42.65 39.52 42.03 43.01 42.67 37.07 24.38 43.09 24.19 43.9 43.41 43 44.57 44.08 42.42 40.76 38.39 39.62 41.25 40.65 Ashadb 6.45 5.14 6.11 6.63 6.83 8.57 8.13 7.72 6 72 6.72 6.97 8.61 6.33 6.73 7.73 5.92 8.18 7.41 6.75 6.04 6.04 6.35 6.29 6.56 9.66 6.01 6.73 6.02 6.34 FCadb 36.65 43.64 39.04 38.75 38.15 40.06 36.51 36 13 36.13 37.54 35.44 37.13 36.2 40.47 37.75 35.08 37.05 35.62 31.09 31.03 29.22 30.36 30.92 38.46 40.02 40.09 40.75 40.54 GCVadb 5763 5650 5535 5466 5633 5490 5466 5420 5495 5424 5430 5450 5435 5450 5485 5475 5452 5489 5455 5535 5520 5460 5475 5565 5530 5652 5815 5775 E=100FC GCVadb VM /E 77.74 74.1 81.41 69.4 81.44 68 81.35 67.2 78.89 71.4 77.48 70.9 77.1 70.9 78.28 69.2 78 78 78.78 69 8 69.8 77.06 70.4 77.47 70.1 80.14 68 78.87 68.9 77.54 70.3 80.13 68.5 78.17 70 79.24 68.8 79.52 69 74.5 73.2 74.03 74.8 73.79 74.8 74.44 73.3 73.34 74.7 79.22 70.2 78.41 70.5 79.71 70.9 82 70.9 81.19 71.1 Sadb 0.63 0.23 0.52 0.48 0.76 0.95 0.78 0.68 0 76 0.76 0.49 0.45 0.5 0.49 0.25 0.63 0.68 0.48 0.26 0.78 0.76 0.57 0.55 0.73 0.61 0.72 0.77 0.75 0.62 GCVarb 5005.9 4583.3 4363.5 4030.8 4613.1 4348.6 4353.9 4210 4210 9 4210.9 4234.4 4248.5 4273.3 4215.9 4205.6 4219.7 4203.7 4203 4212 3874.2 4201.5 4208.5 4213.5 4234.7 4046 4251.3 4217.4 4255.9 4248.9 Asharb 5.6 4.2 4.8 4.9 5.6 6.8 6.5 6 51 5.1 5.4 6.7 5 5.2 6 4.6 6.3 5.7 5.2 4.3 4.6 4.8 4.9 5.1 7 4.6 5 4.4 4.7

Dubai Gandharoil Gandharoil Patriot Patriot Patriot Patriot Patriot Patriot Patriot Patriot Patriot Patriot Patriot Xing gMinda

Griffith Griffith

Griffith

Griffith

Griffith

Guptacoal Guptacoal Guptacoal Guptacoal Guptacoal

Fontai Fontai Fontai Fontai Fontai

19/4/2012 1/8/2012 26/8/2012 / / 31/8/2012 / / 15/10/2012 23/10/2012 15/10/2012 1/11/2012 2/12/2012 26/12/2012 29/11/2012 26/12/2012 12/3/2013 30/3/2013 8/3/2013 3/4/2013 31/3/2013 18/4/2013 4/4/2013 18/4/2013 6/4/2013 18/4/2013 22/4/2013 15/5/2013 29/4/2013 15/5/2013 2/5/2013 27/5/2013 4/5/2013 27/5/2013 15/5/2013 27/5/2013 21/5/2013 3/7/2013 30/5/2013 3/7/2013 30/5/2013 3/7/2013 2/6/2013 3/7/2013 / / / / 3/6/2013 3/7/2013 4/6/2013 3/7/2013 27/7/2013 3/10/2013 8/8/2013 14/8/2013 18/8/2013 21/8/2013

TRENDANALYSISOFIMPORTEDCOAL

Asharbtrend
8 7 5000 6 5 4 3 2 1 0 1 3 5 7 9 11 13 15 17 19 21 23 25 27 1000 0 1 3 5 7 4000 3000 2000 6000

GCVarbtrend
45 40 35 30 25 20 15 10 5 0 9 11 13 15 17 19 21 23 25 27 1 3

Totalmoisturetrend

11 13 15 17 19 21 23 25 27

TABLE 2: Comparison of calculated GCV based on receipt analysis and actual GCV in the fuel mix fed to the boiler
S.No Feeder Coal Parameter 1 2 3 4 5 6 Total moisture Res.Moisture Ash on AD V.M on AD G.C.Value on AD G.C.Value on ARB Unit % % % % Cals/gm Cals/gm Unit % % % % Cals/gm Cals/gm % Unit % % % % Cals/gm Cals/gm % 12.10.2013 20 4.1 41.4 25.9 3790 3162 18.10.2013 18.5 7.4 34.9 27.3 4140 3644 0.64 18.10.2013 20.5 7.2 33.9 29 4270 3658 0.51 Coal combination , receipt GCV & % mix Chargoan Gandhar Singareni GCV % GCV % GCV % 4216.8 50 4131 25 4026 25 Calculated GCV Loss in GCV, % 986 4147.65 23.77

S.No Feeder Coal Parameter 1 2 3 4 5 6 7 Total moisture Res.Moisture Ash on AD V.M on AD G.C.Value on AD G.C.Value on ARB Sulphur

Coal combination , receipt GCV & % mix Chargaon Maheswari Singareni GCV % GCV % GCV % 4216.8 40 4173.7 40 4026 20

Calculated GCV

Loss in GCV, % 518

4161.4 12.44

S.No Feeder Coal Parameter 1 2 3 4 5 6 7 Total moisture Res.Moisture Ash on AD V.M on AD G.C.Value on AD G.C.Value on ARB Sulphur

Coal combination , receipt GCV & % mix Chargaon Maheswari Gandhar GCV % GCV % GCV % 4216.8 25 4173.7 50 4131.6 25

Calculated GCV

Loss in GCV, % 516

4173.95 12.36

TABLE 1: Yard coal analysis report and receipt coal analysis compared

Name of the coal Chargaon Majri Gandhar (imp-Indo) Gujarat NRE coke ltd Gupta (imp-Indo) Agarwal (imp-Indo) Bhatia Maheshwari (imp-Indo) Singrani Mahavir

As per suppplier report / as per receipt report Coal GCV Coal GCV IM TM (adb) (afb) 4550 8.5 15.2 4216.83 4480 5.4 12.4 4148.5 5480 3940 5505 5700 5725 5700 4550 4555 9.8 1.8 12.3 10.2 12.4 8.5 8.8 9.6 32 10.1 35.8 32.8 32 33 19.3 10.6 4131.26 3606.99 4029.89 4265.48 4444.06 4173.77 4026.15 4504.61

WCPM lab reports for the yard samples Coal GCV (adb) 4125 4000 5400 5420 IM 7.8 7.2 18.9 17.5 TM 15.2 16.5 39 37.8 Coal GCV (afb) 3793.93 3599.14 4061.65 4086.35

Loss of GCV %

Comment

10.03 13.24 1.7 1.1

Taken from Outdoor Taken from Indoor

The loss of GCV is the function of many parameters. The no of days in stock / exposure to sunlight, exposure to wind: spontaneous combustion can cause deterioration in GCV

ANNEXURE 4- COAL STORAGE AND RECLAIMING & SPONTANEOUS COMBUSTION

Photo 1 & 2 : Covered shed with light roof construction for coal yards to reduce the GCV variance. The coal is swept clean from storage. The properly stocked coal is consumed date wise easily.

Photos 3- 8: The above photos show the burning of coal in yard due to haphazard storage as taken by IR camera. Most of the coals are stored in ship yard are prone for combustion. Coals which are directly unloaded from ship and transported to plant do not suffer losses. Coal consumed with 3 days do not lose GCV.

ABOUT SPONTANEOUS COMBUSTION

Spontaneous combustion is an oxidation reaction that

occurs without an external heat source. The process changes the internal heat profile of the material leading to a rise in temperature. This can eventually lead to open flame and burning of the coal. Coal fires require three basic elements to exist as shown in figure. The process leading to spontaneous combustion can be summarised as follows: Oxidation occurs when oxygen reacts with the fuel, i.e. coal The oxidation process produces heat If the heat is dissipated, the temperature of the coal will not increase If the heat is not dissipated then the temperature of the coal will increase At higher temperatures the oxidation reaction proceeds at a higher rate Eventually a temperature is reached at which ignition of the coal occurs.

Combustible matter can interact with the oxygen in the air at ambient temperature releasing heat. Favourable conditions for spontaneous heating would be the accumulation of heat caused by a rise in temperature and hence an increase in the reaction rate. Although, at ambient temperature, the reaction can be so slow that it is unnoticed, when heat accumulates the temperature is raised and, according to the Arrhenius law, the reaction rate increases exponentially. The following are the factors affecting spontaneous combustion Factors inherent to coal: Size of the coal particles and surface area Moisture content Coal composition, quality and rank of coal Heat conductivity of the particles Coal friability, particle size and surface area Moisture content & ash content The presence of iron pyrites.

Extrinsic conditions: Degree of compaction Temperature Barometric pressure Oxygen concentration Dimensions and Shape of stockpile

Ash content can take away the heat in high ash coal, without causing much fire. Detecting spontaneous combustion Spontaneous combustion fires can be detected fairly early in their development, i.e. before any obvious smoke and/or flame. Any of the following may assist in early detection, depending upon the

particular circumstances. Temperature difference Heat haze and steam plumes may be observed on cold mornings and in times of high humidity. Hot spots may also be detected by infrared monitoring instruments. Routine surveying of stockpiles using infrared scanning devices is an excellent precaution in situations where spontaneous combustion may be likely to occur.

Some characteristics of spontaneous combustion as well as guidelines for minimising the probability of a fire are listed below. The higher the inherent moisture, the higher the heating tendency The lower the ash-free calorific value, the higher the heating tendency The higher the oxygen content in the coal, the higher the heating tendency Sulphur, once considered a major factor, is now thought to be a minor factor in the spontaneous heating of coal. The finer the size of the coal, the more surface is exposed per unit of weight and the greater the oxidising potential, all other factors being equal. Segregation of the coal particle sizes is often a major cause of heating. Coarse sizes allow air to enter the pile at one location and react with the high surface area fines at another location. Coals with a large top size (>100mm) will segregate more in handling than those of smaller size (<50mm) It is believed that the rate of reaction doubles for every 8oC to 11oC increase in temperature Freshly mined coal has the greatest oxidising characteristics, but a hot spot in a pile may not appear for the first one or two month. There is a critical amount of airflow through a portion of a coal pile that maximises the oxidation or heating tendencies of coal.

Stock pile management Proper selection of particle size distribution. If the stockpile is of mainly medium to fine particle then making it finer or adding fines will help. If the pile consists of coarse particles of relatively low reactivity then removing the finer material will help. Avoiding segregation. Improper stacking might result in segregation of stockpiles and hence

increased propensity to oxidation. Higher size particles roll down to bottom causing voidage. This helps air to penetrate. Proper attention must be given to the preparation and maintenance of the stockpile. Pile maintenance might be crucial in avoiding channels where air can easily creep into the dump. Haphazard storage must be avoided. Proper compaction. Air circulating within the stockpile should be restricted by proper compacting and dozing off. Or else the coal piles must be covered at the bottom ends of say up to 1 m height. Moisture contributes the spontaneous combustion as it aids in the oxidation process. Moisture content should be limited to about 3 percent to avoid enhanced oxidation. Measures must be taken to keep stored coal from being exposed to moisture. This is not practical in Imported coal. But addition of moisture by water spray aids combustion. Only burning coal must be separated. Dimensions of stockpile. Size and area of stockpile should be based not only on estimated tonnage but also on design principles of stockpile management. Proper dimensioning of stockpiles helps negate weathering of coal. Just dumping the coal in a big pile might lead to problems. Rather coal should be packed in horizontal layers of about 1.3 to 3 feet high followed by leveling and compaction by dozers. It helps in evenly distribution of coal thus avoiding segregation of fine coal. Pile unlayered, uncompacted high grade coal should be limited to about 15 feet and while layered and packed coal pile height should be limited to about 26 feet. Use of protective covering. Inert covering material such as tarpaulin sheets with sufficient heat resistivity can be used to cover the openly kept stockpile to reduce the loss of calorific value and further oxidation of coal. It helps in cutting off oxygen to come in contact with coal. Regular use of IR camera for identification of the hot zones will help to identify the hot spots and removal of burning zones from the main pile must be attempted.

ANNEXURE 5 FLOW PROBLEMS IN BUNKER AND FUEL FEED SYSTEM DUE TO WET COAL

Photo 1 : Misalignment in conveyor is seen in a conveyor. The spilled coal may be transported back to yard or to bunker. Yet it causes a reduction of evaporation ratio or it increases the specific coal consumption.

Photos 2 & 3: Photographs show the flip flop screen used nowadays to handle high moisture coal. Blinding of screen is minimum in these screens. These screens are now available in India.

Photo 4: Coal spillage due to lumps coming from bunker. Bunker generates lumps due to powder and moist coals at the corners. Conical bunkers are not causing this problem.

Photo 5: bar screens used in a lignite fired bunker to filter the lumps coming from the bunker.

Photo 6: Photo shows the air blaster used in a bunker for clearing rat holes and arches. This device can be used in raw coal hopper to remove the accumulated coal due to moisture. There are electrically operated vibrators, but they tend to compact the coal. These air blasters are to be operated when the coal level is less so that the bunker is kept free of big lumps.

ANNEXURE 6 BOILER OPERATIONAL ASPECTS

Photo 1: The present for the coal is 20 and 32. For an error signal, the coal flow had touched 32 and returned back old value of 20. It implies that there was no load change. There was a pressure disturbance due to GCV variance. There was 60% extra fuel dumping during which time there was no increase in air flow.

Photos 2: Photograph on the right show the fuel feeder rpm percent ( boiler no 3) in a narrow range 38% - 40% corrected by one operator when discussed. The variance in boiler 4 on left side is seen from 15% to 35%. This happens due to load variance which made the operator to operate the boiler in different styles.

Photo 3: This photo shows the trend in boiler 03 taken when the operator had set wide rpm limits. The pressure signals made use of the entire rpm range and dumped fuel. This can be the reason for inconsistent ash LOI.

Photo 4: Some feeder rpm is as low as 15. Some are as high as 30. Several reasons are there. Coal flow issues also make the operators do it. If coal flow problems are addressed then these situations would not arise. Also when the loads are known, this would be automatically stop.

Photo 5: The bed temperatures are low most of the time in boiler 3. This affects the smooth boiler operation and the efficiency. The bed coil HTA has to be reduced to improve the bed temperature.

Photo 6: The above is the loss table for various fuels when the oxygen is excess.

Photo 7: It is advisable to avoid the draining of hot ash from the bed. The drain must be closed, once the hot ash begins to pour out. The drains should be partly opened to enable drain out only coarse particles. Presence of coarse particles affects the fluidization quality.

Photo 8 to 10: The photo shows the recent replacement of mixing nozzles at another plant by Thermax with reduced throat. The new throat size is 42 mm. The old throat size is 48-50 mm. By reducing the throat higher back pressure can be handled.

ANNEXURE 7: BED COIL SIZING FOR FBC 03

EWS 604

PROJECT : WCPM SCCL coal 80 TPH- designing bed coil HTA INPUTS FOR COMBUSTION CALCULATIONS AIR & GAS CALCULATIONS Ta P1 Ma E Te El P Moisture 10 Ambient temperature 40 Deg C Relative humidity 60 % Moisture in dry air ( from tables) 0.02825 kg/kg Excess air 20 % Boiler outlet gas temperature 135 Deg C Site elevation 200 Metres Flue gas pressure 5 mmwc

34

12

10

36

Indian coal- SCCL Imported coal- des Indian coal Majiri Rice husk Saw dust Std As fired Std As fired Std As fired Std As fired Std As fired 42.65 41.97 54.95 44.32 49.29 48.13 36.67 36.67 38.32 31.44 2.65 2.61 4.75 3.83 3.06 2.99 3.00 3.00 4.54 3.73 7.23 7.12 12.43 10.03 8.35 8.15 31.02 31.02 32.64 26.78 0.41 0.40 0.81 0.65 0.47 0.46 0.08 0.08 0.00 0.00 0.51 0.50 0.87 0.70 0.59 0.58 0.40 0.40 0.23 0.22 8.55 10.00 18.17 34.00 9.88 12.00 10.00 10.00 22.00 36.00 38 37.40 8.02 6.47 28.35 27.68 18.83 18.83 2.27 2.22 100 100 100 4060 3995.63 5598.00 4515.07 4690.00 4579.67 3150.00 3150.00 3350.00 2748.72 91.45 90 81.83 66 90.12 88 90 90 78 64 Weight percentage 0 50 50 0 0 actual weight 0 7566 7566 0 0 heat input ratio 0.00 54.41 45.59 0.00 0.00 Constituents of fuel C H O S N M A GCV FUEL Carbon Hydrogen Oxygen Sulphur Nitrogen Moisture Ash Gross GCV of fuel Fuel Mix 46.23 3.41 9.09 0.56 0.64 23.00 17.08 100.01 4547.37 % % % % % % % by wt by wt by wt by wt by wt by wt by wt

Kcal /kg

INPUTS FOR EFFICIENCY CALCULATIONS HLS6 HLS7 Radiation loss ( assumed ) Manufacturer margin (assumed 0.5 % 0%

EWS 604 A1 A2 A3 A4 A5 A6 % Ash collection at location 1 % Ash collection at location 2 % Ash collection at location 3 % Ash collection at location 4 % Ash collection at location 5 % Ash collection at location 6 Locations Bed Bank Economiser Airheater Dust collector Wet bottom 900 300 250 140 140 140 Deg C Deg C Deg C Deg C Deg C Deg C 20 10 5 5 55 5 100 % % % % % %

T1 Temperature of ash at location1 T2 Temperature of ash at location2 T3 Temperature of ash at location3 T4 Temperature of ash at location4 T5 Temperature of ash at location5 T6 Temperature of ash at location6 INPUTS FOR BOILER DUTY CALCULATIONS **Adjusted for heat duty

Steam generation rate Nett Main steam pressure Main steam temperature Feed water inlet temperature Superheater Pressure drop Saturated steam flow from drum Boiler efficiency Calculated Actual boiler efficiency

80000 63 485 108 3.5 0 84.37 81.37

Kg/h kg/cm2 g Deg C Deg C kg/cm2 g kg/h %

INPUTS FOR FLUIDISED BED SIZING CALCULATIONS Design bed temperature = 900 Fluidisation velocity = 2.6 Deg C m/s

EWS 604 COMBUSTION CALCULATIONS FOR FUEL PER KG BASIS PROJECT : WCPM SCCL coal 80 TPH- designing bed coil HTA INPUTS FOR AIR & GAS CALCULATIONS Ta, Ambient temperature P1, Relative humidity Ma, Moisture in dry air E, Excess air Constituents of fuel ( % by weight ) C, Carbon Carbon lost in ash carbon burnt H, Hydrogen O, Oxygen S, Sulphur N, Nitrogen M, Moisture A, Ash Air requirement calculations O2 reqd, kg/kg of Carbon in fuel O2 reqd, kg/kg of Hydrogen in fuel O2 reqd, kg/kg of Sulphur in fuel Solid crbon unburnt from Efficiency calc, O2 reqd, for the Carbon in fuel O2 reqd, for the Hydrogen in fuel O2 reqd, for the Sulphur in fuel Stochiometric O2 reqd / kg of fuel Stochiometric O2 reqd / kg of fuel Excess O2 required / kg of fuel = 2.644 kg/kg = 7.937 kg/kg = 0.998 kg/kg = 0.0092 kg/kg =( 0.4623 - 0.0092)x2.644 /100) kg/kg = 1.198 kg/kg =( 7.937x3.41 /100) kg/kg = 0.271 kg/kg =( 0.998x0.56 /100) kg/kg = 0.006 kg/kg = O2 reqd for C,H,S in fuel - O2 in fuel) kg/kg = ( 1.198+0.271+0.006) -(9.09 / 100) kg/kg = 1.3841 kg /kg of fuel = ( 1.3841x / 100 ) kg /kg of fuel = ( 1.3841x 20 / 100 ) kg /kg of fuel = 0.27682 kg/kg = ( 1.3841+ 0.27682) kg/kg = 1.66092 kg/kg = 0.23 kg/kg =( 1.66092/ 0.23) kg/kg = 7.221 kg/kg =( 1 + 0.02825) x 7.221) kg/kg = 7.425 kg/kg = 7.221 kg/kg = 46.23 % = 0.92 % = 45.31 % = 3.41 % = 9.09 % = 0.56 % = 0.64 % = 23 % = 17.08 % Fuel Mix = 40 deg C = 60 % = 0.02825 kg / kg = 20 % Date & time: 10/31/13 5:31 AM

Total O2 required / kg of fuel Weight fraction of O2 in atmospheric air Dry air required for Combustion, kg/kg of fuel Due to relative Humidity, wet air reqd, kg/kg of fuel Wet air required, kg /kg of fuel fired Dry air required, kg /kg of fuel fired

EWS 604 Gas weight constituents calculations CO2 produced, kg/kg of Carbon in fuel = 3.644 kg/kg H2O produced, kg/kg of Hydrogen in fuel = 8.937 kg/kg SO2 produced, kg/kg of Sulphur in fuel = 1.998 kg/kg CO2 produced, for the Carbon in fuel =( 3.644x45.31 /100) kg/kg = 1.651 kg/kg H2O produced, for the Hydrogen in fuel =( 8.937x3.41 /100) kg/kg = 0.305 kg/kg H2O in combustion air = 0.02825x7.221 kg/kg = 0.204 kg/kg H2O due to moisture in fuel = 23/100 kg/kg = 0.23 kg/kg H2O due to air & H2 combustion& fuel moisture =( 0.204+0.305+0.23) kg/kg = 0.739 kg/kg SO2 produced, for the Sulphur in fuel =( 1.998x0.56 /100) kg/kg = 0.011 kg/kg O2 in flue gas ( Excess O2 added ) = 0.27682 kg/kg N21,Nitrogen due to fuel = N kg/kg = 0.0064 kg/kg Weight fraction of Nitrogen in Dry Air = 0.77 kg/kg N22 due to Air, kg per kg of fuel = 0.77 x 7.221 kg/kg = 5.560 kg/kg Total N2 in flue gas , kg/kg of fuel fired = N21+N22 kg/kg = ( 0.0064+5.560) kg/kg = 5.5664 kg/kg of fuel Qfgw, Total wet flue gas produced per kg of fuel fired = 1.651+0.739+0.011+0.27682+5.5664 = 8.24422 kg/kg Wet flue gas produced, kg /kg of fuel fired = 8.244 kg/kg Qfgd, Total dry flue gas produced per kg of fuel fired = 1.651+0.011+0.27682+5.5664 = 7.505 kg/kg Dry flue gas produced, kg /kg of fuel fired = 7.505 kg/kg Composition of Flue gas wet gas Flue gas ( wet ) composition kg / kg of by % wt fuel CO2 1.651 100x1.651/8.24422=20.026 H2O 0.74 100x0.739/8.24422=8.964 SO2 0.011 100x0.011/8.24422=0.133 O2 0.28 100x0.27682/8.24422=3.358 N2 5.57 100x5.5664/8.24422=67.519 Total 8.244

Mol. No of moles / kg of weight fuel 44.04 18.02 64.06 32.00 28.01 1.651/44.04 = 0.037 0.739/18.02 = 0.041 0.011/64.06 = 0.000 0.27682/32 = 0.009 5.5664/28.01 = 0.199

Flue gas ( wet ) composition by % vol 100x0.037/0.286=12.94 100x0.041/0.286=14.34 100x0.000/0.286=0.00 100x0.009/0.286=3.15 100x0.199/0.286=69.58

Total moles = 0.037+0.041+0.000+0.009+0.199=0.286

Mole.wt of flue gas = ((12.94x 44.01)+(14.34x 18.02)+(0.00x64.06)+(3.15x32)+(69.58x28.01)) / 100 Mole.wt of flue gas = 28.78

EWS 604 Results Summary Dry air required, kg /kg of fuel fired Wet air required, kg /kg of fuel fired Dry Flue gas produced, kg /kg of fuel fired Flue gas produced, kg /kg of fuel fired Flue gas composition summary Carbon di oxide Water vapour Sulfur di oxide Oxygen Nitrogen Wet by vol % = 12.94 % = 14.34 % = 0.00 % = 3.15 % = 69.58 % Dry by vol% = 15.11 % =0% = 0.00 % = 3.68 % = 81.23 % = 7.221 = 7.425 = 7.505 = 8.244 kg/kg kg/kg kg/kg kg/kg

EWS 604 DESIGN EFFICIENCY CALCULATIONS PROJECT : WCPM SCCL coal 80 TPH- designing bed coil HTA INPUTS FOR EFFICIENCY CALCULATIONS HLS1, assumed unburnt carbon loss HLS6, Assumed radiation loss HLS7, Manufacturer margin Ta, Ambient temperature Rh, Relative humidity Ma, Moisture in dry air E, Excess air Te, Boiler outlet gas temperature A1, % Ash collection at location 1 A2, % Ash collection at location 2 A3, % Ash collection at location 3 A4, % Ash collection at location 4 A5, % Ash collection at location 5 A6, % Ash collection at location 6 T1, Temperature of ash at location1 T2, Temperature of ash at location2 T3, Temperature of ash at location3 T4, Temperature of ash at location4 T5, Temperature of ash at location5 T6, Temperature of ash at location6 Constituents of fuel H, Hydrgen M, Moisture A, Ash GCV, Gross calorific value of fuel = 3.41 % = 23 % = 17.08 % = 4547.37 kcal /kg Date & time : 10/31/13 5:31 AM

=3% = 0.5 % =0 % = 40 deg C = 60 % = 0.02825 kg / kg = 20 % = 135 Deg C = 20 % = 10 % =5% =5% = 55 % =5% Bed Bank Economiser Airheater Dust collector Wet bottom

= 900 deg C = 300 deg C = 250 deg C = 140 deg C = 140 deg C = 140 deg C

DESIGN EFFICENCY CALCULATIONS Assumed heat loss through unburnt carbon in ash Heat loss through unburnt carbon in furnace ash A, Ash content in fuel = 0.1708 kg/kg M1, % ash collection in furnace hopper = 20 % LOI in ash = 1.5 % Calorific value of carbon = 8050 kcal/kg Fuel GCV = 4547.37 kcal/kg Carbon Loss =M1x A x LOI x 8050 / ((100-LOI) x 4547.37) % =20 x 0.1708 x 1.5 x 8050 /( (100-1.5 ) x 4547.37) % HLS1-1, Unburnt carbon loss in furnace ash = 0.0921 % Heat loss through unburnt carbon in fly ash A, Ash content in fuel = 0.1708 kg/kg M1, % ash collection in fly ash hopper = 80 %

EWS 604 LOI in ash = 6 % Calorific value of carbon = 8050 kcal/kg Fuel GCV = 4547.37 kcal/kg Carbon Loss =M1x A x LOI x 8050 / ((100-LOI) x 4547.37) % =80 x 0.1708 x 6 x 8050 /( (100-6 ) x 4547.37) % HLS1-1, Unburnt carbon loss in fly ash = 1.5440 % HLS1, Total unburnt carbon loss = 1.6361 % Solid carbon loss = 1.6361x4547.37 / 8050 % = 0.92 % HLS1, Unburnt carbon loss = 1.6361 % Calculations for Heat loss though ash A, Ash content in fuel = 0.1708 kg/kg C, Specific heat of ash = 0.22 kcal/kg Deg C HLn, % Heat lost through ash at n'th location = A x (An /100 ) x C x (Tn-Ta) x 100 / GCV HL1, % Heat lost through ash at a location 1 = 0.1708x (20 / 100 ) x0.22x (900-40) x 100 / 4547.37 % HL1, % Heat lost through ash at a location 1 = 0.14 % HL2, % Heat lost through ash at a location 2 = 0.1708x (10 / 100 ) x0.22x (300-40) x 100 / 4547.37 % HL2, % Heat lost through ash at a location 2 = 0.02 % HL3, % Heat lost through ash at a location 3 = 0.1708x (5 / 100 ) x0.22x (250-40) x 100 / 4547.37 % HL3, % Heat lost through ash at a location 3 = 0.01 % HL4, % Heat lost through ash at a location 4 = 0.1708x (5 / 100 ) x0.22x (140-40) x 100 / 4547.37 % HL4, % Heat lost through ash at a location 4 = 0.00 % HL5, % Heat lost through ash at a location 5 = 0.1708x (55 / 100 ) x0.22x (140-40) x 100 / 4547.37 % HL5, % Heat lost through ash at a location 5 = 0.05 % HL6, % Heat lost through ash at a location 6 = 0.1708x (5 / 100 ) x0.22x (140-40) x 100 / 4547.37 % HL6, % Heat lost through ash at a location 6 = 0.00 % HLS2, Total Heat loss through the ash = HL1+HL2+HL3+HL4+HL5+HL6 = ( 0.14+0.02+0.01+ 0.00+0.05+0.00 )% HLS2, Total Heat loss through the ash = 0.22 % Calculations for Heat loss through moisture in air Ww, wieght of water in air Wd, Dry air required per kg of fuel Cp1, specific heat of water vapor at boiler exit temp Cp2, specific heat of water vapor at ambient temp Ta, Ambient temperature Te, Boiler exit temperature = 0.02825 kg/kg = 7.221 kg/kg from combustion calc = 0.4967 kcal/kg C = 1 kcal/kg C = 40 deg C = 135 deg C

EWS 604 HLS3, % Heat lost through moisture in air = Ww x Wd x{(Cp1x Te)-(Cp2 x Ta)}x100/(GCV) = 0.02825x7.221x[(0.4967x135)-(1x40]x100 /(4547.37) HLS3, % Heat lost through moisture in air = 0.12 % Calculations for Heat loss through moisture & hydrogen in fuel H, hydrogen in fuel M, moisture in fuel Cp1, Specific heat of water vapor at boiler exit temp L, latent heat of water Ta, Ambient temperature Te, Boiler exit temperature HLS4, % Heat lost through moisture & H2 in fuel HLS4, % Heat lost through moisture & H2 in fuel = 0.0341 kg/kg = 0.23 kg/kg = 0.4967 kcal/kg = 595.4 kcal/kg = 40 deg C = 135 deg C ={M+(8.94 x H)} x [595.4+(Cp1 x Te) -Ta] x 100 / (GCV) ={ 0.23+ (8.94 x 0.0341)}x [ 595.4+(0.4967x 135) 40]x100/(4547.37) %

HLS4, % Heat lost through moisture & H2 in fuel = 7.32 %

Calculations for Heat loss through dry flue gas Qfgd, Dry flue gas produced per kg of fuel Cp3, specfic heat of flue gas at boiler exit temp Cp4, specfic heat of flue gas at ambient temp Ta, Ambient temperature Te, Boiler exit temperature HLS5, % Heat lost through dry flue gas = 7.505 kg/kg = 0.242 kcal/kg deg C = 0.236 kcal/kg deg C = 40 deg C = 135 deg C =Qfgd x{ (Cp3 x Te) - (Cp4 x Ta)} x100/(GCV) =7.505x { ( 0.242 x 135) - (0.236x40)} x 100/(4547.37) %

HLS5, % Heat lost through dry flue gas = 3.83 % Assumed heat loss through radiation HLS6, Radiation loss = 0.5 % Manufacturer margin HLS7, blow down & vent loss = 2 % Total efficiency break up HLS1, Unburnt carbon loss = 1.64 % HLS2, Total Heat loss through the ash = 0.22 % HLS3, Heat lost through moisture in air = 0.12 % HLS4, Heat lost through moisture & H2 in fuel = 7.32 % HLS5, Heat lost through dry flue gas = 3.83 % HLS6, Radiation loss = 0.5 % HLS7, blow down & vent loss = 2 % Total losses = 1.64+0.22+0.12+7.32+3.83+0.5+2 = 15.63 % Therefore, Boiler efficiency, = 100 - 15.63 % Boiler Efficiency = 84.37 %

EWS 604 BOILER HEAT DUTY CALCULATIONS PROJECT : WCPM SCCL coal 80 TPH- designing bed coil HTA Date & time: 10/31/13 5:31 AM

INPUTS FOR BOILER DUTY CALCULATIONS Steam generation rate Nett = 80000 Main steam pressure = 63 Main steam temperature = 485 Feed water inlet temperature = 108 Superheater Pressure drop = 3.5 Saturated steam flow from drum = 0 Selected boiler efficiency = 81.37 BOILER HEAT DUTY CALCULATIONS Msup, Steam generation rate = 80000 kg / h P1, Main steam pressure = 63 kg/cm2 g Ts, Main steam temperature = 485 deg C Tw, Feed water inlet temperature = 108 deg C Hw, Feed water inlet enthalphy = 108 kcal / kg Hs, Main steam enthalpy = 807.91 kcal / kg H, Heat added per kg of water = ( Hs - Hw ) = ( 807.91 - 108) kcal / kg H, Heat added per kg of water = 699.91 kcal / kg Heat output of the boiler ( SH steam) = ( Msup x H) kcal / hr = ( 80000 x 699.91) kcal / hr Qo Msat Heat output of the boiler ( SH steam) Saturated steam flow from drum Saturated steam enthalpy Heat output thorugh the sat. steam Qs Qt Qt Total heat output of the boiler Total heat output of the boiler = 55992800 kcal / h = 0 kg / h = 663.57 kcal/kg = 0x( 663.57-108) kcal/kg = Qo+Qs kcal/hr = ( 55992800 + 0 )kcal/hr = 55992800 kcal/hr Fuel GCV = 4547.37 kcal /kg Fuel firing rate = Qt x 100 / ( Eff x GCV ) = 55992800 x 100 / ( 81.37 x 4547.37 ) % = 15,132 kg / hr Results Total heat output of the boiler = 55992800 kcal / hr Calculated boiler efficiency = 81.37 % Fuel firing rate = 15,132 kg / hr Steam fuel ratio = 5.29 kg / kg Selected Boiler efficiency = 81.37 % Kg/h kg/cm2 g Deg C Deg C kg/cm2 g kg/h %

heat output of the boiler ( saturated steam) = 0 kcal/hr

EWS 604 UNDER FED FLUIDISED BED SIZING PROJECT : WCPM SCCL coal 80 TPH- designing bed coil HTA INPUTS FOR FLUIDISED BED SIZING Vf, Fluidisation velocity = 2.6 m/s Tb, Design bed temperature = 900 Deg C Steam generated nett Main steam temperature Main steam pressure Fuel burnt rate Wet air required, kg /kg of fuel fired Flue gas produced, kg /kg of fuel fired Flue gas molecular weight Te, Boiler exit temperature Tca, Combustion air temperature Ta, Ambient temperature Assumed carbon loss Ts, Saturation temperature Constituents of fuel H, Hydrgen M, Moisture A, Ash GCV, Gross calorific value of fuel UNDERBED FLUIDISED BED SIZING Calculations for bed cross sectional area Wet flue gas produced per kg of fuel = 8.244 kg/kg Fuel firing rate = 15,132 kg/h Wet flue gas flow rate = 8.244 x 15,132 kg/h = 124748.208 kg/h Molecular wt of flue gas = 28.78 from air & gas calc K, altitude correction factor = 0.977 Flue Gas volume flow rate at 0 deg C = 124748.208 x 22.4 / 28.78 x 0.977 = 99,379.54 Nm3 /hr Flue Gas volume flow rate at 0 deg C = 27.61 Nm3 / sec Design bed temperature = 900 Deg C Gas flow at bed temperature = ( 27.61x ( 273 + 900 ) / 273 )m3 /sec = 118.63 m3 /sec Vf, Fluidisation velocity = 2.6 m/s Therefore, bed cross sectional area = 118.63 / 2.6 Bed cross sectional area required = 45.63 m2 bed width 9015 mm bed length 4725 mm Bed cross sectional area available = 42.6 m2 = 3.41 % = 23 % = 17.08 % = 4547.37 kcal /kg = 80000 kg/h = 485 Deg C = 63 kg/cm2 a = 15,132 kg/h = 7.425 kg/kg = 8.244 kg/kg = 28.78 = 135 Deg C = 150 Deg C = 40 Deg C =4% = 283.4 deg C Date & time : 10/31/13 5:31 AM

EWS 604 Calculations for bed heat transfer area Unburnt carbon loss HL1, % design Unburnt carbon loss = 4 % Calculations for Heat loss though ash A, Ash content in fuel C, Specific heat of ash Ta, Ambient temperature Tb, Design bed temperature HL2, % Heat lost through ash

= 0.1708 kg/kg = 0.22 kcal/kg Deg C = 40 deg C = 900 deg C = A x C x (Tb-Ta) x 100 / GCV = 0.1708x 0.22x (900-40) x 100 / 4547.37 % HL2, % Heat lost through ash = 0.71 %

Calculations for Heat loss through moisture in air Ww, weight of water in air = 0.02825 kg/kg Wd, Dry air required per kg of fuel = 7.221 kg/kg from combustion calc Cp1, specific heat of water vapor at bed temp = 0.577 kcal/kg C Cp2, specific heat of water vapor at ambient temp = 0.3592 kcal/kg C Tca, Combustion air temperature = 150 deg C Tb, Design bed temperature = 900 deg C HL3, % Heat lost through moisture in air = Ww x Wd x {(Cp1 x Tb) -(Cp2 x Tca)}x 100 / GCV = 0.02825x7.221x[(0.577x900)-(0.3592x150]x100 /4547 HL3, % Heat lost through moisture in air = 2.09 % Calculations for Heat loss through moisture & hydrogen in fuel H, hydrogen in fuel = 0.0341 kg/kg M, moisture in fuel = 0.23 kg/kg Cpb, Specific heat of water vapor at bed temp = 0.577 kcal/kg L, latent heat of water = 595.4 kcal/kg Ta, Ambient temperature = 40 deg C Tb, Design bed temperature = 900 deg C HL4, % Heat lost through moisture & H2 in fuel ={M+(8.94 x H)} x [595.4+(Cpb x Tb) -Ta] x 100 / GCV HL4, % Heat lost through moisture & H2 in fuel ={ 0.23+ (8.94 x 0.0341)}x [ 595.4+(0.577x 900) 40]x100/4547.37 % HL4, % Heat lost through moisture & H2 in fuel = 12.64 % Calculations for Heat loss through dry flue gas Qfgd, Dry flue gas produced per kg of fuel = 7.505 kg/kg Cpb, specific heat of flue gas at bed temp = 0.287641446781092 kcal/kg deg C Cpa, specific heat of flue gas at Tca = 0.242735283090913 kcal/kg deg C Tb, Design bed temperature = 900 deg C Tca, Combustion air temperature = 150 deg C HL5, % Heat lost through dry flue gas =Qfgd x{ (Cp1 x Tb) - (Cp2 x Tca)} x 100 / GCV =7.505x { ( 0.287641446781092 x 900) -

EWS 604 HL5, % Heat lost through dry flue gas = 36.72 % Calculation for Heat loss through radiation to waterwall Ab, Bed cross sectional area = 45.63 m2 e, Emissivity of waterwall surface = 0.9 S, Steafan boltzmann constant = 4.9 x 10 ^ -8 Tb, bed temperature = 900 Deg C Ts, saturation temperature = 283.4 Deg C Radiation heat loss to waterwall =Ab x e x S x {( Tb + 273 )^4 - ( Ts + 273 )^4} = 45.63x0.9x4.9 x 10^-8x{( 900+273)^4-(283.4+273)^4} = 3,616,757 kcal/h Fuel heat input in the bed = 15,132x 4547.37= 68810802.84 kcal/h HL6, % Radiation loss to waterwall = 100x 3,616,757/ 68810802.84 HL6, % Radiation loss to waterwall = 5.26 % Bed heat balance & HTA required HL1, Unburnt carbon loss = 4 % HL2, Total Heat loss through the ash = 0.71 % HL3, Heat lost through moisture in air = 2.09 % HL4, Heat lost through moisture & H2 in fuel = 12.64 % HL5, Heat lost through dry flue gas = 36.72 % HL6, % Radiation loss to waterwall = 5.26 % Total losses = 4+0.71+2.09+12.64+36.72+5.26 = 61.42 % Therefore, % heat to be transferred to Bed coil = 100 - 61.42 % % Heat transferred to Bed coil = 38.58 % Fuel heat input in the bed = 68810802.84 kcal/h Actual heat to be transferred to Bed coil = 38.58 x 68810802.84/ 100 = 26,547,208 kcal/h Tb, bed temperature = 900 Deg C Ts, Saturation temperature = 283.4 Deg C Temperature difference = (900 - 283.4)= 616.6 deg C Heat transfer coeff = 220 kcal / kg m2 Deg C Bed coil area required = 26,547,208/ ( 220 x 616.6) Bed Coil HT area required, if plain = 195.70 m2 free board combustion = 0 % Bed Coil HTA reqd a/c free board combustion = 195.7 m2 Bed Coil length required = 1221.44 m Checking the available bed HT area Bed coil length per coil- type 1- studded length = 4182 mm No off bed coils- type 1 = 166 No Bed coil length per coil- type 2- studded length = 2943 mm No off bed coils- type 2 = 166 No Total eff length of bed coil = 1537.58 m

EWS 604 Summary of results Bed cross sectional area required Bed cross sectional area available Bed Coil length required Bed Coil length available Bed coil eff length to be covered by refractory Actual length to be covered by refractory Bed coil length to be covered by refractory Bed coil length to be covered by refractory Bed coil length to be covered by refractory Selected length to be covered by refractory Per coil length to be covered on outer coil Per coil length to be covered on inner coil = 45.63 m2 = 42.6 m2 = 1221.44 m = 1537.58 m = 316.14 m = 243.2 m = 223.8 m = 246.4 m = 368.1 m = 250 m = 1.51 m = nil For SCCL For Majiri For Imp coal

ANNEXURE 8: AIRPREHEATER LEAKAGE REPORT- CO & O2 PROFILE

AIRPREHEATER LEAKAGE REPORT- FBC 3

Photo 1: Oxygen measurement upstream and downstream of the boiler is seen to rise by nearly 3%. The air indicated by the air flow meter includes the air mixing to the flue gas.

OXYGEN CO PROFILE FROM APH INLET TO ID FAN FBC 3

VENUS ENERGY AUDIT SYSTEM Log Sheet-1 Flue gas analysis for FBC-3 Customer name: West Coast Paper Mills Ltd,.
DATE: 06.10.13 O2 (Field %) 6.5 6.4 6.3 10.2 10.7 10.4 10.4 10.8 10.8 TIME: CO (PPM) 205 226 214 150 159 155 160 166 157 TIME: O2 (Field %) 6.7 6.6 6.3 11 10.8 10.9 10.9 10.6 CO (PPM) 220 227 206 140 144 160 167 170 11.15am FUEL COMBINATION: 100% coal

FLUE GAS ANALYSIS (TRIAL - 1)

S.No LOCATION COAL FEEDER RPM O2 Feeder Feeder Feeder Feeder Feeder Feeder Feeder Feeder Feeder Feeder (DCS %) 1 2 3 4 5 6 7 8 9 10 4.54 4.52 4.52 FD Flow (TPH ) MainSteam Flow (TPH)

APH I/L

APH O/L

45

45

45

45

45

45

45

45

78 to 79

52.7 to 53.5

ID FAN I/L

DATE:

06.10.13

12.30am

FUEL COMBINATION: 100% coal

FLUE GAS ANALYSIS (TRIAL - 2)

S.No LOCATION COAL FEEDER RPM O2 Feeder Feeder Feeder Feeder Feeder Feeder Feeder Feeder Feeder Feeder (DCS %) 1 2 3 4 5 6 7 8 9 10 4.7 4.3 4.4 FD Flow (TPH ) MainSteam Flow (TPH)

APH I/L

APH O/L

48

48

48

48

48

48

48

48

79 to 80

53 to 54

ID FAN I/L

DATE:

06.10.13 O2 (Field %) 6.1 6.3 6.2 9.8 10.2 9.9 10 10.2 10

TIME: CO (PPM) 240 266 253 179 165 169 157 155 163 TIME: O2 (Field %) 6.9 6 9 6.7 6.7 10.5 10.7 9.9 10.1 10.2 10.2 CO (PPM) 217 229 243 160 157 163 162 159 163

02.30pm

FUEL COMBINATION: 100% coal

FLUE GAS ANALYSIS (TRIAL - 3)

S.No LOCATION COAL FEEDER RPM O2 Feeder Feeder Feeder Feeder Feeder Feeder Feeder Feeder Feeder Feeder (DCS %) 1 2 3 4 5 6 7 8 9 10 4.54 4.52 4.52 FD Flow (TPH ) MainSteam Flow (TPH)

APH I/L

APH O/L

45

45

45

45

45

45

45

45

78 to 79

52 to 53

ID FAN I/L

DATE:

06.10.13

4.15pm

FUEL COMBINATION: 100% coal

FLUE GAS ANALYSIS (TRIAL - 4)

S.No LOCATION COAL FEEDER RPM O2 Feeder Feeder Feeder Feeder Feeder Feeder Feeder Feeder Feeder Feeder (DCS %) 1 2 3 4 5 6 7 8 9 10 4 92 4.92 4.71 4.52 FD Flow (TPH ) MainSteam Flow (TPH)

APH I/L

APH O/L

50

50

45

45

45

45

45

45

80 to 81

52 to 53

ID FAN I/L

AIRPREHEATER LEAKGE REPORT- FBC 04

Photo 1: Oxygen measurement upstream and downstream of the boiler is seen above. The O2 level of 4% seems optimum here since CO level is below 200 ppm. The APH is OK. There is no leak.

OXYGEN CO PROFILE FROM APH INLET TO ID FAN FBC 4

VENUS ENERGY AUDIT SYSTEM Log Sheet-1 Flue gas analysis for FBC-4 Customer name: West Coast Paper Mills Ltd,.
DATE: 07.10.13 O2 (Field %) 3.4 3.4 3.3 3.4 3.3 3.4 4.1 3.9 4.1 TIME: CO (PPM) 221 211 230 190 201 205 155 179 158 TIME: O2 (Field %) 3.9 3.9 4 4.2 4.3 4.2 4.3 4.4 4.7 CO (PPM) 220 216 207 194 198 192 201 199 178 12.15pm FUEL COMBINATION: 100% coal

FLUE GAS ANALYSIS (TRIAL - 1)

S.No LOCATION COAL FEEDER RPM O2 FDR FDR FDR FDR FDR FDR FDR FDR FDR FDR FDR FDR FDR FDR FDR (DCS %) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 3.88 3.79 3.74 FD Flow (TPH ) MainSteam Flow (TPH)

APH I/L

APH O/L

36

36

36

36

36

36

36

36

36

36

36

36

36

36

36

180 TO 181 118 TO 120

ID FAN I/L

DATE:

07.10.13

1.40pm

FUEL COMBINATION: 100% coal

FLUE GAS ANALYSIS (TRIAL - 2)

S.No LOCATION COAL FEEDER RPM O2 FDR FDR FDR FDR FDR FDR FDR FDR FDR FDR FDR FDR FDR FDR FDR (DCS %) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 4.19 4.06 4.15 FD Flow (TPH ) MainSteam Flow (TPH)

APH I/L

APH O/L

38

38

38

38

38

38

38

38

38

38

38

38

38

38

38

182 TO 183 122 TO 123

ID FAN I/L

DATE:

07.10.13 O2 (Field %) 3.3 3.5 3.4 3.3 3.3 3.5 4.2 4 4.3

TIME:

03.15pm

FUELCOMBINATION:100%coal FLUE GAS ANALYSIS (TRIAL - 3)

FD Flow (TPH ) MainSteam Flow (TPH)

S.No LOCATION

CO (PPM) 217 203 210 219 209 202 195 199 182 TIME:

APH I/L

COAL FEEDER RPM O2 FDR FDR FDR FDR FDR FDR FDR FDR FDR FDR FDR FDR FDR FDR FDR (DCS %) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 3.9 3.89 3.9

APH O/L

36

36

36

36

36

36

36

36

36

36

36

36

36

36

36

181 TO 182 122 TO 123

ID FAN I/L

DATE:

07.10.13 O2 (Field %) 3.6 3 6 3.8 3.9 3.9 4.1 4.2 4 4.3 4.3

5.20pm

FUELCOMBINATION:100%coal FLUE GAS ANALYSIS (TRIAL - 4)

FD Flow (TPH ) MainSteam Flow (TPH)

S.No LOCATION

CO (PPM) 218 200 194 179 170 169 163 156 163

APH I/L

COAL FEEDER RPM O2 FDR FDR FDR FDR FDR FDR FDR FDR FDR FDR FDR FDR FDR FDR FDR (DCS %) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 3.99 3 99 4.02 4.1

APH O/L

42

42

42

42

42

42

42

42

42

42

42

42

42

42

42

184 TO 185 115 TO 116

ID FAN I/L

ASH LEAKAGES / AIR INGRESS IN BOILER 03 ROOF

Photo 1 & 2: Ash leakages observed in FBC 03.

Photo 3 & 4: Boiler roof sealed with Plaster of paris over the insulation mattress. The SH headers, side waterwall and steam drum are full covered by POP. The cloth layer with bitumen coating is applied for two layer. This sort of insulation cover is provided for turbine.

Photo 5 & 7: Boiler roof sealed with Plaster of paris over the insulation mattress in a CVL boiler at Birla white cements. The dust nuisance is avoided by choosing plaster of paris. Outside air ingress and false indication is avoided by this.

Photo 8 & 9: Flame test confirms the air ingress around the SH headers. There are some damaged portions in boiler outlet expansion joints. These shall be repaired.

AIR PREHEATER LEAKAGE ANALYSIS CALCULATION REPORT- FBC 03 Flue gas analysis for 40% EA - 50% majiri coal + 50% imp coal kg/kg fuel %wt MW Vol CO2 17.41 44.34 0.39 1.651 H2O 8.15 18.02 0.45 0.773 SO2 0.12 64.06 0.00 0.011 O2 5.84 32 0.18 0.55364 N2 68.48 28.01 2.44 6.4934 total 9.48 total 3.47 Air analysis H2O O2 N2 Total %wt 2.77 26.25 70.98 100.00 % wet vol 11.30 13.02 0.05 5.25 70.37

Flue gas + Air mixing at APH outlet by weight Flue gas Air % wt % wt 85.28 14.72 Input

Air to furnace FG production Air direct to flue gas Ratio of air leak to air supplied to furnace Flue gas + air mix gas analysis % mix wt Vol CO2 14.85 0.33 H2O 7.36 0.41 SO2 0.10 0.00 O2 8.84 0.28 N2 68.85 2.46 total 3.48

kg/kg of fuel kg/kg of fuel kg/kg of fuel % % wet mix vol dry mix vol 9.63 10.91 11.74 0.00 0.04 0.05 7.94 9.00 70.65 80.04 100.00

8.663 9.482 1.396 13.9

Actual measured

Photo 10: APH is seen leaking heavily. End columns of APH tubes do fail due to gas laning along the casing. This can be prevented by adding gas baffle. Or else the end column of tubes can be left plugged.

Photo 11: Plugging done by CVL after failure at a 90 TPH installation.

ANNEXURE 9 STEAM LEAKS

Above is an empirical formula used to estimate the steam wasted in small holes. Holes can be passing valves or leaky glands or punctures in impulse piping. The heat loss as a % of the heat input to a 80 TPH boiler is shown here. About 0.38% of the heat is lost due to steam leakage in a 5 mm hole.

Photo 1 to 5: The above photos show the steam leaks in 125 TPH boiler. Sample cooler lets out considerable heat. It can be opened only when the sample is to be taken.

Photo 6: The photo at the left shows the leak from gland of MSSV in boiler 3. The leakage is considerable amount.

Photo 7 to 9: Photos above show the IR camera image of boiler drum right side safety valve passing.

Photos 10 12: Photos above are IR camera images of start up vent exhaust piping in boiler 3. There is some passing experienced here.

Photos 13 15: Photos above are IR camera images of left side drum safety valve exhaust piping in boiler 4. There is some passing experienced here. Photo 16: There is no passing seen in right side safety valve in boiler no 4.

ANNEXURE 10CONTAMINATION IN RETURN CONDENSATE AND BLOW DOWN

Photo 1: Economiser tube which was available at water testing lab was inspected. The tube indicates the iron oxide deposits, which comes from return condensate. This can leads to under deposit corrosion at weldments in plain economiser coils. In chemical recovery boiler, this has created stress corrosion cracking at the tube to fin weld.

Photo 2: The above photo shows the under deposit hydrogen crack of stud welded bed coil tube. This is a stressed tube due to fin welding. The boiler water pH was low. Under the deposit, the water had concentrated to low pH and led to hydrogen crack. In the event of alklaine water, the gouging would have taken place.

Photo 3 & 4: The blow down losses increase when the TDS in boiler water is maintained low. This is done because the blow down is perhaps based on silica limit. The blow down loss can be reduced by 1% if condensate polishing unit is used. In this plant make up is high. Hence it is possible to cool the condensate before polishing.

Photo 5: Steam drum with condensate contamination will look as above.

Photo 6: Steam drum without any condensate contamination would look like this.

ANNEXURE 11 RADIATION HEAT LOSS

REPORT ON RADIATION LOSS USING IR CAMERA FOR FBC-03 Radiation loss survey was carried out in FBC 03. Hot spots were observed at following locations and the photographs are attached herewith.

Furnace bed coil header seal box. Buck stay (1st elevation). Nose panel. Furnace outlet expansion bellow. Economiser top rear manhole door. Economiser bypass duct. Economiser Right casing (near top manhole door). Economiser rear casing (near top rear manhole door). Furnace left manhole door-01(Top). Furnace left manhole door-02(Top). Furnace left manhole door-03(Top). Economiser inlet manhole door. Economiser inlet manhole door casing. Furnace outlet duct. Economiser inlet duct un insulated area (left side). Economiser rear side top casing. Drum manhole doors. Super heater headers at roof. Furnace outlet duct (top plate near expansion bellow). APH outlet duct expansion bellow. Economiser bottom header. Bed coil bottom header. Bed coil header seal box. Economiser flue gas bypass duct. Drum safety valve. Start-up vent. Drum pressure gauge. Drum level gauge.

Photo 01 & 02: The above photo was taken at waterwall bottom header seal box.

Photo 03 & 04: The photo was taken at buckstay (1st elevation).

Photo 05 & 06: The photo shows the nose panel hot spot.

Photo 07 & 08: The photo was taken at the furnace outlet expansion bellow.

Photo 09 & 10: The above photo was taken at Economiser manhole door (Rear top).

Photo 11 & 12: The above photo was taken at Economiser Bypass duct

Photo 13: The above photo was taken at Economiser right casing.

Photo 14 & 15: The photo was taken at Economiser right side casing.

Photo 16: The photo shows the location of high heat at Economiser right casing.

Photo 17 & 18: The photo shows the radiation at Economiser rear casing. The damage can occur due to insulation damage on account of improper sealing of joints and open locations for rain water ingress.

Photo 19 & 20: The photo was taken at Economiser inlet manhole door (left side photo). Right side photo shows the Economiser inlet manhole door casing. Insulation box can be added for these doors.

Photo 21: The photo was taken at Furnace outlet duct.

Photo 22: The photo was taken at Economiser inlet duct uninsulated area (left side).

Photo 23 & 24: The photo was taken at Economiser rear casing duct (top).

Photo 25: The photo was taken at Steam drum Left side manhole door. Removable insulation covered can be planned for these doors.

Photo 26: The photo was taken at Steam drum Right side manhole door. Insulation covers are generally provided for these doors at many plants.

Photo 27 & 28: The photo was taken at Super heater header at roof (left side photo). Right side photo shows Furnace outlet duct top plate. The insulation sagging is the reason for this.

Photo 29: The photo was taken at APH outlet Expansion bellow.

Photo 30 & 31: The photo was taken at Economiser bottom header.

Photo 32: The photo was taken at waterwall bottom header.

Photo 33 to 35: The photo was taken at right side safety valve. Its shows the steam passing is there in the pipe.

Photo 36 -38: The photos show the start vent valve passing.

VENUS ENERGY AUDIT SYSTEM Log Sheet for Heat loss through Radiation Radiation Loss for FBC-03 Customer name: West Coast Paper Mills Ltd Sl No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
Description A Uninsulated area B 430 500 700 600 700 2800 350 800 800 800 610 700 700 300 700 550 500 3000 2500 360 600 500 700 700 700 600 Dia Area, m2 0.88 4.17 0.25 4.76 0.36 0.42 11.20 0.21 0.62 0.62 0.62 0.37 0.49 0.35 0.54 3.85 0.24 0.25 2.10 1.75 0.25 0.36 Accounted area for heat loss Qty m2 0.88 4 4.17 0.25 4.76 0.36 0.42 11.20 0.21 0.62 0.62 0.62 0.37 0.49 0.35 0.54 3.85 0.24 0.25 2.10 1.75 0.25 0.36 4 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 Total

Total Temp, Heat Lost, Remark Area, m2 Deg C Kcal/hr

3.50 16.68 0.25 9.52 0.36 0.42 11.20 0.21 0.62 0.62 0.62 0.37 0.49 0.35 0.54 3.85 0.24 0.25 4.20 3.50 0.25 0.36 58.39 250 250 140 248 170 300 180 80 130 170 160 250 250 170 280 140 260 130 90 90 100 230 8089.10 38559.59 201.23 21708.08 423.27 1313.13 14629.88 35.59 424.14 724.27 645.97 859.99 1132.47 411.51 1506.86 3099.00 586.28 172.13 1107.80 923.17 91.54 722.84 97367.85

Furnace bed coil seal box. st Buck stay (1 elevation). Nose panel Furnace outlet expansion bellow Economiser top rear manhole door Economiser bypass duct Eco RHS casing (near top MH door) Eco rear casing (top rear MH door) Furnace left manhole door-01(Top) Furnace left manhole door-02(Top) Furnace left manhole door-03(Top) Economiser inlet manhole door Economiser inlet manhole door casing Furnace outlet duct Economiser inlet duct un insulated area (left side) Economiser rear side top casing Drum manhole doors Furnace o/t duct (top plate near EB) APH outlet duct expansion bellow APH outlet duct expansion bellow Economiser bottom header Bed coil bottom header

1750 500 9700 500 6800 600 600 4000 600 770 770 770 610 700 500 1800 5500

EQUIVALENT COAL LOSS- BOILER NO 03

Coal GCV (adb) Chargaon 4550 Majri 4480 Gandhar (imp-Indo) 5480 Gujarat NRE coke ltd 3940 Gupta (imp-Indo) 5505 Agarwal (imp-Indo) 5700 Bhatia 5725 Maheshwari (imp-Indo) 5700 Singrani 4550 Mahavir 4555 Average coal loss due to radiation loss Name of the coal

IM 8.5 5.4 9.8 1.8 12.3 10.2 12.4 8.5 8.8 9.6

TM 15.2 12.4 32 10.1 35.8 32.8 32 33 19.3 10.6

Coal GCV (afb) 4216.83 4148.5 4131.26 3606.99 4029.89 4265.48 4444.06 4173.77 4026.15 4504.61

Heat Lost, kcal/hr 97368 97368 97368 97368 97368 97368 97368 97368 97368 97368

Coal loss to radiant (kg/hr) 23.09 23.47 23.57 26.99 24.16 22.83 21.91 23.33 24.18 21.62

Coal loss to radiant (kg/day) 554.16 563.28 565.68 647.76 579.84 547.92 525.84 559.92 580.32 518.88 564.36

Remark

REPORT ON RADIATION LOSS USING IR CAMERA FOR FBC-04 Radiation loss survey was carried out in FBC-04. The following areas hot spots were noted.

Furnace outlet duct Economiser outlet header hand hole Boiler left top seal box Super header hand hole ( Left & Right ) Right side water wall panel. Right side Convection bank header Furnace Right side top manhole door Water wall bottom header hand hole APH inlet duct PA fan inlet & outlet Duct damper Furnace left side manhole door-01 Furnace left side manhole door-02 Furnace left side manhole door-03 Buck stay Economiser bottom header Furnace left side manhole door Convection bank bottom header Furnace outlet to convection bank flue gas inlet duct bottom Economiser manhole door(front top) Economiser casing

The losses are however found to be minimum. There is some passing of drum left side safety valve.

Photo 01 & 02: The above photo was taken at Furnace outlet Duct. This is due to improper joint sealing between mattresses.

Photo 03: The above photo was taken at Economiser outlet header hand hole. These handholes may be provided with removable insulation boxes.

Photo 04 & 05: The above photo was taken at boiler left seal box (left photo) at header to header joints of side waterwall. Right side photo shows the SH header hand hole.

Photo 06: The above photo shows boiler top seal box (Left) and SH header hand hole.

Photo 07 & 08: The above photo was taken at Right side water wall, where the insulation mattress has sagged out from location.

Photo 09 : The above photo was taken at right side convection bank header hand hole.

Photo 10 & 11: The above photo was taken at Drum manhole door. Drum manhole door is provided with insulation box. So there is no radiation loss unlike FBC-03.

Photos 11 - 13: The above photos were taken at Water wall bottom header hand hole.

Photo 14 & 15: The above photos were taken at APH inlet duct. The support beams are not insulated.

Photo 16 & 17: The above photos were taken at PA fan inlet and outlet duct damper. These dampers may be provided with insulation as these are not removed any time.

Photo 18 & 19: The above photo was taken at left side manhole door-01&02. Parts of the seal boxes are not filled with insulation castable properly.

Photo 20: The above photo was taken at Left side manhole door-03.

Photo 21 & 22: The above photo was taken at Economiser bottom header (left side photo). Right side photo shows Furnace left side manhole door.

Photo 23: The above photo was taken at Furnace left side Outlet duct uninsulated area (left side photo). Right side photo shows Convection bank bottom header hand hole.

Photo 24 & 25: The above photo was taken at Furnace outlet to convection bank flue gas inlet duct bottom.

Photo 26: The above photo was taken at Furnace outlet to convection bank flue gas inlet duct bottom (closer view).

Photo 27 & 28: The above photo was taken at Economiser top manhole door (Boiler front side).

Photo 29: The above photo was taken at Economiser top manhole door (Boiler front side).

Photo 30: The above photo was taken at Economiser casing. Insulation is found to be ok.

Photo 31: The above photo was taken at Furnace outlet expansion bellow. The bellows may not be wrapped with insulation mattress.

Photo 32 & 33: The above photo was taken at Drum left safety valve.

VENUS ENERGY AUDIT SYSTEM Log Sheet for Heat loss through Radiation Radiation Loss for FBC-04 Customer name: West Coast Paper Mills Ltd Sl No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Description A Uninsulated area B 210 860 500 600 600 200 210 400 210 500 210 210 1300 1100 300 Dia 710 360 1100 6000 600 280 530 360 300 360 500 360 360 370 370 6000 Area, m2 0.40 0.08 0.95 3.00 0.36 0.17 0.11 0.08 0.12 0.08 0.25 0.08 0 08 0.08 0.48 0.41 1.80 Accounted area for heat loss m2 0.40 0.08 0.95 3.00 0.36 0.17 0.11 0.08 0.12 0.08 0.25 0.08 0 08 0.08 0.48 0.41 1.80

Qty
3 1 3 1 2 2 2 1 8 2 1 2 1 8 8 1 Total

Total Temp, Heat Lost, Remark Area, m2 Deg C Kcal/hr

1.19 0.08 2.84 3.00 0.72 0.34 0.21 0.08 0.96 0.15 0.25 0.15 0 08 0.08 3.85 3.26 1.80 18.94 198

Furnace man hole door Economiser bottom header hand hole Furnace manhole door Conv bank flue gas duct bottom plate Economiser top man hole door Economiser casing Economiser inlet gas duct Economiser top header hand hole Furnace left side top seal box Super heater hdr hand hole (R/L) Right water wall panel Conv bank header hand hole (RHS) WW bottom hdr hand hole (RHS) PA fan I/L & O/L damper PA fan I/L & O/L damper APH inlet duct

124
170 320 130 217 120 217 130 250 277 273 260 120 120 150

1840.38 46.91 3336.80 10428.15 495.74 610.73 122.11 137.42 660.99 349.45 685.30 404.61 186 56 186.56 2216.33 1875.36 1665.03 25061.88

EQUIVALENT COAL LOSS- BOILER NO 04

Name of the coal

Coal GCV (adb) Chargaon 4550 Majri 4480 Gandhar (imp-Indo) 5480 Gujarat NRE coke ltd 3940 Gupta (imp-Indo) 5505 Agarwal (imp-Indo) 5700 Bhatia 5725 Maheshwari (imp-Indo) 5700 Singrani 4550 Mahavir 4555

IM 8.5 5.4 9.8 1.8 12.3 10.2 12.4 8.5 8.8 9.6

TM 15.2 12.4 32 10.1 35.8 32.8 32 33 19.3 10.6

Coal GCV (afb) 4216.83 4148.5 4131.26 3606.99 4029.89 4265.48 4444.06 4173.77 4026.15 4504.61

Heat Lost, Coal loss to kcal/hr radiant (kg/hr) 25062 5.94 25062 6.04 25062 6.07 25062 6.95 25062 6.22 25062 5.88 25062 5.64 25062 6 25062 6.22 25062 5.56 Average coal loss due to radiation loss

Coal loss to radiant Remark (kg/day) 142.56 144.96 145.68 166.8 149.28 141.12 135.36 144 149.28 133.44 145.248

HEAT LOST FROM UNINSULATED SURFACE- TYPICAL CALCULATION 1. Calculations for Insulation thickness of flat surface Ts 250 Deg C 482 Deg F Surface temperature Ta 40 Deg C 104 Deg F Ambient temperature e 0.11 Emissivity V 0.5 m/s 1.11852 mph Wind velocity Calculations for Heat loss through radiation Qr Heat lost to air by radiation = 0.1713 x e {[(Ts+459.6)/100]^4 - [(Ta+459.6)/100]^4]} = 0.1713 x 0.11 {[(482+459.6)/100]^4 - [(104+459.6)/100]^4]} = 129.108 Btu/h ft^2 = 350.270 Kcal/h m^2 Calculations for Heat loss through convection Ts Surface temperature 250 Deg C 482 Deg F Ta Ambient temperature 40 Deg C 104 Deg F e Emissivity 0.11 Qc Heat lost to air by convection = 0.296 x ( Ts - Ta)^1.25 x ( 1 + 1.277xV)^0.5 = 0.296 x ( 482 - 104)^1.25 x ( 1 + 1.277x1.11852)^0.5 = 768.798 Btu/h ft^2 Qc Heat lost to air by convection = 2,085.749 Kcal/h m^2 Total heat lost Qt = 350.270 + 2,085.749 Heat lost to air by convection & radiation Kcal/h/m2 = 2436.02 a m2 = 3.50 Area Qa Kcal/h = 8526.07 Heat lost to air by convection & radiation HEAT LOST IF THE SURFACE WAS AT 60 DEG C 1. Calculations for Insulation thinkness of flat surface Ts 60 Deg C 140 Deg F Surface temperature Ta 40 Deg C 104 Deg F Ambient temperature e 0.11 Emissivity V 0.5 m/s 1.11852 mph Wind velocity Calculations for Heat loss through radiation Qr Heat lost to air by radiation = 0.1713 x e {[(Ts+459.6)/100]^4 - [(Ta+459.6)/100]^4]} = 0.1713 x 0.11 {[(140+459.6)/100]^4 - [(104+459.6)/100]^4]} = 5.343 Btu/h ft^2 = 14.496 Kcal/h m^2 Calculations for Heat loss through convection Ts Surface temperature 60 Deg C 140 Deg F Ta Ambient temperature 40 Deg C 104 Deg F e Emissivity 0.11 Qc Heat lost to air by convection = 0.296 x ( Ts - Ta)^1.25 x ( 1 + 1.277xV)^0.5 = 0.296 x ( 140 - 104)^1.25 x ( 1 + 1.277x1.11852)^0.5 = 40.675 Btu/h ft^2 Qc Heat lost to air by convection = 110.351 Kcal/h m^2 Total heat lost Qt = 14.496 + 110.351 Heat lost to air by convection & radiation Kcal/h/m2 = 124.847 a Area m2 = 3.5 Qa Heat lost to air by convection & radiation Kcal/h = 436.965 Difference in heat lost Difference in heat lost = 8089.1

ANNEXURE 12: MIS REPORT SAMPLE

BOILER PERFORMANCE REVIEW - MIS - DAILY ANALYSIS REPORT Coal mix- shift 1 Indian coal Imported coal Saw dust Coal mix- shift 2 Indian coal Imported coal Saw dust Coal mix shift 3 Indian coal Imported coal Saw dust Receipt analysis Analysis at ground hopper Tons fed Ash TM GCV Ash TM 1st shift 38 12 3800 40 10 75 6 38 4000 8 36 80 1 38 3200 1.2 36 25 Receipt analysis Analysis at ground hopper Tons fed Ash TM GCV Ash TM 2nd shift 38 12 3800 40 10 65 6 38 4000 8 36 80 1 38 3200 1.2 36 15 Receipt analysis Analysis at ground hopper Tons fed Ash TM GCV Ash TM 3rd shift 38 12 3800 40 10 90 6 38 4000 8 36 30 1 38 3200 1.2 36 2 Fuel Mix at ground hopper Fuel sampled at feeder shift 1 shift 2 shift 3 shift 1 shift 2 shift 3 3805.6 3843.8 3839.3 3700 3900 3850 25.2 25.4 16.8 26 23 24.5 20.4 20.4 31.5 22 23 28.6 Total fed 180 shift 1 5.96 33.79 Shift 2 700 63 480 134 805.34 135.62 Shift 1 Bunker diff 15 Expected shift 2 5.28 29.94 Shift 3 535 61.5 488 132 810.37 133.57 consumed 195 shift 3 8.17 31.32 Total fed 160 Total 19.42 95.06

Ind coal Efficiency expected as per Imp coal standard analysis saw dust % mix 1st shift 41.67 44.44 13.89 % mix 2nd shift 40.63 50.00 9.38 % mix 3rd shift 73.77 24.59 1.64 Loss of GCV 200 2 150 2 -250 2 Loss of GCV 225 2 255 2 -199 2 Loss of GCV Loss of TM Loss of TM Loss of TM

80 80 75 Gain of ash 2 2 0.2 Gain of ash 2 2 0.2 Gain of ash 2 2 0.2 minimum values are selected for GCV

GCV 4000 4150 2950 GCV 4025 4255 3001 GCV 4213 4222 2991

GCV Total moisture Ash

413 2 222 2 -209 2 Selected Fuel parameters shift 1 shift 2 shift 3 3700.0 3843.8 3839.3 26.0 25.4 24.5 22.0 23.0 31.5 Total fed 122 shift 3 12 34 Shift 1 721500000 537189511 74.45 79.31 3.25 4.10 Shift 3 Bunker diff -5 Actual total 36.00 140.00 shift 2 664968750 468803259 70.50 79.53 3.22 4.05

Actual fuel consumed in shifts

Ash generation report Bed ash generation Fly ash generation Unit Steam flow Tons Steam press kg/cm2g Main steam temp deg C Feed water temp deg C MS enthalpy kcal/kg FW enthalpy kcal/kg

@ 15 85 Shift 1 800 63.3 485 135 808.13 136.64

Shift 2 Bunker diff consumed 13 173 Actual shift 1 shift 2 12 12 50 56 unit kcal/8 hrs kcal/8 hrs % % kg/kg kg/kg

consumed 117 Actual ash Calc. ash -16.58 -44.94 Shift 3 449203279 362089942 80.61 79.92 3.65 4.57

Heat input Heat output Actual boiler efficiency Expected efficiency p ratio Actual steam / fuel ratio