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4X135 MW CAPTIVR POWER PLANT, DONGAMAHUA

RAIGARH (DISTRICT), CHATTISGARH


PROJECT IDEA SHEET
JSPL owns captive mining facility at village Dongamahua in District-Raigarh. Large amount of middling and fines will
be generated during process of yielding washed coal from the un-graded coal mining. Reports and analysis
suggests that yield will be 18%; by the time spin-off middling and fines will be tune of 57%. Precisely, every 01 T
of washed coal yield attributed for generating 03T of middling and fines.

These middling & fines has lower potential and considered as unusable for power generation in general. CFBC
Technology is apt for firing these low GCV coal with high combustion efficiency rate with very low emissions of Nox,
Sox etc.

JSPL initiated a pit-head power plant of 4x135MW Capacity eyeing multiple gains such as best utilization of the
upgraded low GCV coal, negligible fuel handling cost, catering power demand of existing and upcoming plants of
JSPL, Raigarh, evacuating surplus power to power starved Chattisgarh and so on.
General parameters
Coal Property:
_____________________________________________________________________________
Proximate Analysis:

Ultimate Analysis:

Total Moisture

: 10% 14 %

Total Moisture

: 10% 14 %

Ash

: 50% 58%

Ash

: 50% 58%

Volatile matter

: 15% - 21%

Carbon (C)

: 23% 28%

Fixed Carbon

: 13% 20%

Hydrogen (H)

: 2.3% 3.0%

GCV Kcal/Kg

: 2200 2700

Nitrogen (N)

: 0.7% 0.95%

Sulphur

: 0.4% 0.6%

Oxygen (O) by : 4.5% 6.0%


difference

Boiler:
SN

Description

Type

2
3
4

Boiler Capacity
Pressure (at SH O/L Header)
MS Temperature at SH O/L

5
6
7

FW Temp at Eco I/L


MS Temp at RH O/L
Boiler Efficiency

Unit

Value at 100% BMCR

Value at 100% TMCR

Natural Circulation, Single Drum, Water Tube, Balanced Draft, Uncooled


type Cyclone
TPH
460
426
2
Kg/cm (g)
141
135.2
0
C
540+/- 5
540+/- 5
0

C
C
%

249
540+/- 5

245.5
540+/- 5
81.5

Steam Turbine:
SN
Description
1
Type
2

Unit
Value at 100% TMCR
Value at VWO
Tandem compound, single Re-Heat, Re-Generative, Condensing, Multi
Cylinder (HP&IP, LP) Casing
MW
135
141.373 (at 3%
makeup)
TPH
418
447
Bar (g)
132.4
132.4

3
4

Electrical Power output at Generator


Terminal
MS Flow at I/L of HP Turbine
Pressure at HP Turbine I/L

5
6
7

MS Temperature at HP Turbine I/L


Condenser Pressure
CW I/L Temperature

C
Ata
0
C

CW O/L Temperature

535
0.1186
33

535
0.1186
33

42

42

Generator:
SN
1

Rated O/P

Description

Unit
MW

MVA Rating

MVA

Power Factor

Terminal Voltage

No. of Phases

RPM

Frequency

Type of Cooling (Stator winding, core and rotor)

Type of excitation

10

Type of AVR

KV

13.8
3
3000

HZ

50
Air
Brushless
Digital

Unit
0
C
Cst
0
C
% Max
% Max
% Max

IS:1593
66
2.0-7.0
12
0.025
0.05%
0.1%
1.8%

Total Sulphur by weight

% Max

Carbon residue (rams bottom)

% Wt

Approximate GCV

Ash:
SN
1
2
3
4
5
6
7
8
9
10

169
0.80 Lagging

Light Diesel Oil:


SN
Description
1
Flash Point
2
Viscosity at 150C max
3
Pour point
4
Ash content by weight
5
Free water content by volume
6
Sediments by weight

10

Value at 100% TMCR


135

Kcal/ Kg

Sp gravity at 15 C max

Description
Silica
Alumina
Iron Oxide
Titaneum Oxide
Calcium Oxide
Magnesium Oxide
Sulphuric Anhydride
Manganese
Potassium pentoxide
Alkalis & undermined

In the order of 11000


0.81

Abb.
Silica Sio2
Al2o3
Fe2o3
Tio2
CaO
MgO
SO3
Mn
P2O5

IS:1593
58-62
23-26
7-10
0.15-3
3-5
1.5-3
0.15-0.4
0.02-0.04
Traces
Remaining

POWER STATION BASICS


STEAM CYCLE THEORY AND CYCLE CONSTRAINTS
Over the years, and particularly the last three decades the size and terminal conditions of generating plants
has continuously increased at a remarkable rate as shown in table below:Steam
Pressure

Main Steam
Temperature

Reheat
Steam
Conditions

Bar

Deg C

Deg C

41.4
62.1

Type

Design Efficiency
of Power Plant

Size of
plant

MW

462
482

27.5
30.5

30
60

103.4

566

33.7

100

103.4

538

538

Reheat + Regeneration

35.7

120

162

566

538

Reheat + Regeneration

37.3

200

158.6
158.6

566
566

566
566

Reheat + Regeneration
Reheat + Regeneration

37.7
38.4

275
550

158.6

566

566

Reheat + Regeneration

38.4

350

241.3

593

566

Supercritical

39.0

375

158.6

566

566

Reheat + Regeneration

39.25

500

The main incentive to keep striving for bigger and better plant is that one expects the thermal efficiency to improve
with size and capital cost per MW decreases with the increase of size.

It can be seen that steam temperatures have increased at quite a slow rate. This is because increasing steam
temperature is intimately bound up with metallurgical advances and such advantages are painfully slow. On the
other hand, by increasing the steam pressure, introducing reheat and rapidly increasing output it has been possible
to reduce the cost per MW of installed plant considerably.

Increased output is normally associated with increasing pressure and temperature conditions. This is because:-

1. The higher cost of high temperature components is partly affected by a reduction in the number of
components per MW.
2. Losses become proportionately smaller in the large machine.
3. High density steam must be associated with large flows to give reasonably sized H.P. blades.

Rankine Cycle

The Rankine cycle is the simplest theoretical cycle using vapour as the working medium. The basic arrangement of
this, the simplest of all vapour cycles is shown in fig 1 (Scheme) and Fig 2 (TS Diagram).

Fig 1 Schematic representation of power plant

Fig 2 Rankine cycle on T-S diagram


Temperature Entropy Diagram (T-S Diagram)
The temperature (T-S) diagram is probably the most useful diagram of all illustrating certain fundamental
points about steam cycles. Ideal condition for a unit on a T-S diagram is indicated in fig-3 mentioned. The unit uses
steam at a pressure of 100 bar absolute, temp. 566 oC (839

K) and rejects it to the condenser at 30m bar abs.

(saturation temp. 24.1 o C).


At point A the condensate is at boiling temperature corresponding to the back (condenser) pressure. Heat
(sensible) is added to this water to raise its temperature and pressure. At the point B it reaches its saturation temp.
(310.961oC obtainable from steam table) at a pressure of 100 bar. Evaporation beings at the pt. B. Heat (latentbecause no rise in temperature between B & C, as evident from the diagram) addition continues. At C all the water
evaporates and superheating commences. This shown by the curve CD and at D and superheated steam
temperature is 566oC.

Fig 3 Sensible, Latent and Superheat, 100 bar, 566 oC Cycle on T-S Diagram

Steam then expands isentropically i.e. enters the turbine and rotates it, as shown by the line DEF. At point
E there is no superheat left in the steam and so from E to F there is increasing wetness. At F and steam is at a
pressure of 30 m bar abs. Steam is then passed out of turbine to the condenser and condensation of steam takes
place as represented by the line FA. At point A the steam has all been condensed and condensate is at boiling
temperature ready to begin another cycle.

To summaries the above,


AB Heating of feed water (i.e. sensible heat addition)
BC evaporation of water in boiler (i.e. latent heat addition)
CD superheating of steam (i.e. superheat addition)
DF expansion of steam in turbine point E denotes and demarcation between superheated and wet steam.
FA condensation of steam in the condenser
An important basic fact to remember is that heat is product of absolute temperature and change of
entropy. In other words the heat is represented by the area under the curve.
Sensible heat addition
In fig above the heat added is represented by the area AB. At A the temperature is 24.1 oC and at B it is 311oC.
Now amount of sensible heat addition can be found as:
Sensible heat at A = 101 kJ/Kg and Sensible heat at B = 1408 kJ/Kg (Both the values taken from the steam table)
So, sensible heat added = B A = 1408 101 = 1307KJ/Kg
It should be noted that increasing pressure in boiler to get more output in turbo alternator (i.e. more MW) means
more sensible heat per kilogram. Fig 2 also presents it graphically. As maximum sensible heat is supplied in feed
heaters and economizers, number of feed heaters or area of feed heating surface shall increases with increase of
steam condition. Table below, shows the increase of sensible heat with corresponding pressure.

Absolute pressure (bar)

Saturation Temperature (oC)

Sensible Heat (kj/kg)

50
100
150
200
221.2

263.9
311.0
342.1
365.7
374.15

1154.5
1408.0
1611.0
1826.5
2107.4

Fig 4 Sensible heat at Saturation Temperature at Various Pressures


Latent Heat addition
As stated before almost all-sensible heat is supplied in the feed heaters and economizer. Water entering
the boiler water wall tubes is almost at boiling temperature, fast bit of sensible heat is added to water at lower part
of water wall tubes and thereafter latent heat addition starts taking place.
As there is no change in temperatures (line BC in fig3 indicates so) the water/ steam mixture is about
constant temperature from the bottom to top of the tubes. The area nBCl represents the latent heat added. It
amounts can be calculated in the following way:

Latent heat required = T (S2- S1)


Where, T=temp. of boiler water at B=311degC=584.15K
S2=Entropy at C=5.6198Kj/Kg.K
S1=Entropy at B=1319.7Kj/Kg deg. K
It should be noted that unlike sensible heat at amount of latent heat required to convert boiling water to dry
saturated steam reduces with increase of pressure. At critical pressure of 221.2 bar absolute it is zero.

Fig 5 Latent heat at various pressures


Table -II Latent heat at Saturation Temperature
Absolute Pressure
Saturation temp.(deg C)

Latent heat(Kj/Kg)

50
100
150
200
221.2

1639.7
1319.7
1004.0
591.9
0

263.9
311.0
342.1
365.7
374.15

Superheat addition: The curve CD shows the process of steam being superheated at a constant pressure of 100 bars from the state of
dry saturated steam at 311 deg C to the designed stop valve temp. of 566 deg C.The area plCD represents the
amount of superheat. The amount of heat required by deducting the total heat at C from total heat at D and is
equal to 811.6 Kj/Kg. Quantity of heat required to superheat steam to a given temperature varies with pressure.

Table3 Variation of superheat for different pressure (final temp 570 deg C)
Pressure Bar absolute
50
100
150
200
Thermal Efficiency of the cycle:Useful heat
Thermal efficiency

=
Total heat

Superheat required KJ/Kg


800.9
821.5
885.4
1033.2

Useful heat means that part of total heat which is used in rotating the turbine i.e. when the steam expand
adiabatically(adiabatic expansion means no heat accepted or rejected during the process; all work done by steam
at the expense of its internal energy) in the turbine represented by line DEF fig - 6. Expansion of steam takes place
up to a pressure of 30 m bar (24.1 deg C). The condensation takes place at a constant temp. as indicated by line
FA, until all latent heat is removed.

Heat removed from steam or useless heat is shown or useless heat is shown by rectangular pmAF. Amount of this
rejected can be calculated as follows:

FIG- 6: Basic Ideal Cycle showing useful rejected heat components

Heat rejected = T x (S2 S1) where,


T = Absolute temperature of FA = (24.1 + 273.15) = 297.25oK
S2 = Entropy at F = 6.803 kJ/kg
S1 = Entropy at A = 0.3455kJ/kgK
So, Rejected heat = 297.25 X (6.8043 0.3544) = 1917.2kJ/kg

Now, total heat = Sensible heat + latent heat + superheat


= 1307 + 1319.7 + 811.6

= 3438.3kJ/kg

Useful heat = Total heat Rejected heat


So, Thermal Efficiency

Total heat Heat rejected


Total heat

=1-

Rejected Heat

1 -

Total heat

1917.2

3438.2

= 0.4423 or 44.23%
This is the highest possible efficiency for a basic Rankine Cycle with steam at 100 bar absolute, 566oC and
backpressure is 30m bar. Ofcourse, in practice a turbine operating under this cycle will be less efficient. It can also
be noted that how superheating of steam adds to efficiency. If steam is not superheated the total amount of heat
in this cycle will be addition of sensible heat and latent heat only i.e.1307 + 1319.7 = 2626.7kJ/kg
So, Thermal efficiency= 1 Rejected heat
Total heat

= 1 - 1917.2
2626.7

= 0.2701 or 27.1%
Hence, efficiency of basic Rankine Cycle can be improved by increasing the superheat. But this scope
becomes limited due to limitations of materials, which can withstand very high temperature and the cost associated
with it.
REHEATING
To increase the heat available compared to the heat rejected is to increase the superheated steam
temperature. Unfortunately this is only possible to a very small degree because of metallurgical limitations. Thus
there is very little scope in this direction. Therefore the alternative is to probably expand the steam in the turbine to
some suitable intermediate condition and then pass it back to the boiler to be reheated to some high temperature.
It is then piped back to the turbine to continue expansion.

Let us consider the same 100bar cycle, now with reheat. Fig - 7 below shows the cycle. Steam as usually
starts expanding after being superheated. At the point G when the pressure had dropped to 20 bar the steam is
taken out of turbine and reheated to 566oC as shown by the line GH. It is then fed to the LP turbine where it
expands to the condenser pressure.
The efficiency of the cycle is determined in a similar manner to the previous cases and works out to be
46.09%.
So, reheating had improved efficiency from 44.23% to 46.23% to 46.09%. A further advantage of
reheating is that the wetness of the exhaust steam is reduced considerably.

Fig 7 Modified Basic Cycle to incorporate reheat

REGENERATIVE FEED HEATING


Steam in a thermal cycle will normally reject heat in two ways. Firstly the heat rejected can go to waste via the
condenser cooling water and secondly, the steam can reject heat to the feed water by means of feed heaters. In
the second case, all the heat is kept within the cycle and not lost. The more steam which can be prevented from
going to the condenser, the more heat will be saved from rejection to waste. Consequently, if the steam is allowed
to expand to a certain extent in the turbine and perform useful work before it is allowed to transfer its remaining
heat to feed water, then the quantity of work is obtained without any condenser loss and the efficiency is improved.
In modern design of high capacity units the bled steam has been used for turbine driven feed pump and its exhaust
used for feed water heating in addition to the conventional extractions.

Let us see the previous 100 bar cycle, this time with regenerative feed heating (Fig 7). The steam
expands isentropically in the turbine until the temperature is 250oC after which the steam is bled to an infinite
number of feed heaters. The result is quantity of heat represented by area under the curve KL is transferred to the
water side shown by the area LFpr has been given to feed water whereas before it would have been rejected in the
condenser. The heat represented by the area LKF has also been transferred to feed water, where as formerly it
would have done some useful work in turbine, so there is some loss of work too. Yes, but on the balance its is
better to loss the power from the triangle LKF to save the heat represented by large rectangle LFpr that would have
been wasted.

Regenerative feed heating elevates the condensate temperature represented along the boiling water line to
M and the remaining sensible heat is supplied in the economizer and boiler to point B.
Let us find the efficiency with reheat;
Total heat supplied = sensible heat from M to B + Latent heat + superheat
Amount of latent heat and superheat in this cycle are same on the previous cycle with superheat and eual; to
1319.7kJ/kg and 811.6kJ/kg respectively.
Now, sensible heat

= Total heat at B total heat at M

= 322.2 kJ/kg

So, total heat supplied = 322.2 + 1319.7 + 811.6

= 243.5 kJ/kg

Heat rejected

= Area under ALRM

= 1192.2kJ/kg

So, efficiency

1 - Rejected Heat
Total Heat

- 1192.2
2453.5

= 0 .514 or 51.4%
Hence you find how efficiency of Rankine cycle changes with reheating and feed heating.

Basic efficiency (Fig 6)

= 44.23%

Reheat efficiency (Fig 7)

= 46.09%

Feed heating cycle efficiency (Fig 8)

= 51.4%

A combination of reheating and feed heating will give higher ideal cycle efficiency.

Fig 8 Modified Basic Cycle to incorporate feed heating


The main factors affecting the cost of plant are:
1)

The improvement in thermal efficiency permits a reduction in the size of boiler as it has less heat input to do
for a given load.

2)

The increased amount of steam tapped for feed heating increases the cost of the feed heaters and the steam
piping between turbine and heaters.

3)

The increase in the total steam consumption increases the cost of the steam piping between the boiler and
the turbine, the cost of high pressure end of the turbine and that of feed piping and feed pumps.

4)

The decrease in the amount of steam flowing through the low-pressure end of the turbine and the amount of
steam to be condensed. It decreases the cost of low-pressure end of the turbine and the cost of condensing
plant, C.W. culverts, etc.

5)

The higher feed temperature consequent upon the use of extensive regenerative feed heating would cause
the flue gases to leave the boiler economizer at a higher temperature, thus inevitably reducing the boiler
efficiency to an extent which could largely counter balance the increase in turbine thermal efficiency. For this
reason it is necessary to employ a further regenerator in the form of an air heater in which the heat of the
flue gases is transferred to the combustion air supplied to the furnace.

Another consideration with respect to boiler design is that the feed temperature at the economizer inlet must be
higher than the due point of the boiler flue gases, but not high enough to cause steaming in the economizer also,
the temperature of feed water in the economizer outlet must be less than the saturation temperature of water at
that particular pressure, normally difference shall be 20oC.
Familiarization of Boiler and Turbine system at DCPP
Boiler:
Shanghai Boiler Works Ltd. (SEC/SBWL) has supplied JINDAL STEEL & POWER LIMITED four sets of 460TPH CFB
boiler. The boiler mainly consists of drum, membrane water wall furnace, thermal insulation cyclone separator, U type seal pot and back-pass convective heating surface.
1. Steam and water system: The steam and water system consists of economizer, drum, evaporative
heating surface (furnace water wall and evaporate panels), superheater panels, back-pass superheater, final
superheater and re-heater.
The feed water enters low temperature economizer from one side of the pack-pass and then high temperature
economizer. The heated water then enters the drum through 2 connecting pipes. The water in the drum flows
to the furnace water wall through 4 large diameter downcomers, and 02 to the evaporate panels through
downcomers. Then the saturated steam is lead to the drum through link tubes.
The saturated steam is lead to back-pass superheater from drum through 2 connecting pipes. The superheat
steam flows through back-pass superheater, low temperature superheater panels, first-stage de-superheater,
high temperature superheater panels, secondary-stage de-superheater and final superheater.
2. Gas and air system: The boiler is of balanced draft. Zero pressure point is set at the inlet duct of cyclone
separator. The air is send into the air pre-heater by fans (include primary air fan and secondary air fan). The
hot primary air enters wind box arranged under the furnace and flows through the nozzles on the grate and
fluidizes the materials inside the furnace. The hot secondary air is send into the furnace through secondary
nozzles. The high pressure fluidizing air is used as greasing air of seal pot and fluidizing air of ash cooler.
3. Coal & Ash circulation system: Fuel, sorbent and bed materials are fluidized in the furnace by the primary
air. Fuel particles, high temperature materials and sorbent particles are mixed sufficiently. Combustion process
is completed in the dense-phase area, however small particles are carried out by the gas, which are separated
in the cyclone as the heavy particles drop down and the light fly ash are carried by the gas to the back-pass.
Two thermal insulation cyclone separators are arranged between furnace and back-pass. A U type seal pot is
arranged under each separator. Fluidizing nozzles are arranged at the bottom of the seal pot, which fluidizes
the material and send it back to the furnace.
4. Ash drain system: Ash generation will be tune of 50% of the coal firing rate, in which, Fly ash and bed ash
ration is 55:45. Bottom ash is drained from the furnace bottom. The temperature of bed ash is about 800 Deg
C. The bottom ash will drag to ash coolers that will be cooled to as low as 120 Deg. Fly ash is drained from the
back-pass and ESP.

Details of Coal Bunker, feeder, fans & motors:


Coal bunker Capacity:
No

Item

Unit

Value

No of coal bunkers for each boiler

Set

Volume per bunker

m3

1150

Effective volume

977.5
3

0.85

Bulk Density

T/ m

Effective Stacking capacity

Tons

830

Plant operation time without filling coal

Hrs

12 (6 Hrs x 2 Bunkers)

Unit

Value

Gravimetric

Gravimetric Coal Feeder


No

Item

Type

Max O/P

TPH

60

No. per Boiler

Set

Unit

Value

Centrifugal

Primary Air Fan


No
1

Item
Type

Inlet air capacity

27

Capacity

m3/ Hr

165486

Static pressure rising

mmwc

2345

Flow control device

IGV

Motor rated power

KW

1200

Voltage

6600

No for each boiler

Set

Unit

Value

Centrifugal

Secondary Air Fan


No
1

Item
Type
Inlet air capacity

27

Capacity

m / Hr

135505

Static pressure rising

mmwc

1567

Flow control device

IGV

Motor rated power

KW

800

Voltage

6600

No for each boiler

Set

Induced Draft Fan


No
1

Item

Unit

Value

Double suction inlet

Type

Centrifugal
Inlet air capacity

139.5

Capacity

m / Hr

604337

Static pressure rising

mmwc

854

Flow control device

Hyd Coupling

Motor rated power

KW

1700

Voltage

6600

No for each boiler

Set

Unit

Value

Constant volume

High Pressure Blower


No
1

Item
Type

(displacement type)
2

Inlet air capacity

27

Capacity

m3/ Hr

19118

Static pressure rising

mmwc

7608

Motor rated power

KW

400

Voltage

6600

No for each boiler

Set

Unit

Value

Double chambers and

Electrostatic Precipitator
No
1

Item
Type

eight fields
2

Inlet flue gas temperature

Flow of gas

Flow area

Pressure drop

Ash collection efficiency

Dust emission at ESP Outlet

No for each boiler

154.6

m3/ Hr

962280

m2

333

mmwc

<30

>99.97

Mg/ m3

<40

Set

Reheat Condensing Steam Turbine


Shanghai Turbine Co. Ltd. (SEC/STC) has manufactured more than 200 turbine units of 135MW capacity so far.
Their brand-new D151 type turbine unit is developed on basis of MHIs technique. This steam turbine is a super
high-pressure reheat unit of reaction condensing type with double exhaust arrangement. Its features are combined
HP and IP cylinder and inverted flow path arrangement, as main steam flow and reheated inlet flow are gathered at
the middle part of HP-IP cylinder. The LP cylinder is radial diffusing type with double exhausts, reducing axial
length of turbine and lowering exhaust resistance by the greatest extend.
The HP-IP cylinder is a single-shell casing, with a single-row control stage and 13 pressure stages in the HP section.
The reheated steam enters the combined reheat valve which is controlled by 2 oil-relays in left-right arrangement
via two pipes, and then goes into the IP section via two rigid admission pipes. The IP section has 13 pressure
stages. The upper half of IP exhaust section is designed upright to lead the exhaust steam into the LP cylinder via
two flexible IP and LP crossover pipes. The LP cylinder is double-flow and double-exhaust type.

Performance evaluation of Power Station


Evaluation of power station performance shall be pronounced as performance of boiler and TG as boiler receives
energy from outside so as to produce steam while Turbine attributed to electricity generation.

Power station output or capacity mentioned in terms of MW in general. Kilo-Watt-Hour or KWh is the basic unit of
electricity.
Heat rate:
Heat rate is a significant indicator of power station performance. Heat rate defined as Heat Input (Kcal or KJ) per
Unit electricity generation (KWh). Lower the heat rate, higher the plant efficiency.
1. Turbine Heat Rate: Turbine heat rate is defined as heat input to turbine (in Kcal) per unit generation. At
DCPP, guaranteed turbine heat rate is 2042 Kcal/ KWh.
2. Unit heat rate: Turbine heat rate divided by boiler efficiency leads unit heat rate. For DCPP, guaranteed
boiler efficiency is 82.7% and their by unit heat rate will be 2469 Kcal/ KWhr. (NB: 2042/.827= 2469)
3. Station / Plant heat rate: Auxiliary power consumption of Thermal power plant is considered at 10% of
the plant total capacity. So, the power output can be calculated as 90% of total generation and the station
heat rate will be 2743 Kcal/ KWhr.(NB:2469/.90=2743)
Boiler efficiency:
Efficiency of boiler can be calculated in two ways viz; direct method and indirect method.

Direst method: Direct method is simple Output / Input method.


Efficiency: Main Steam Flow (TPH) X 1000 X (hs- hf) + RH Flow (hhrhs hcrhs)
Coal fired / Hr in Kg x GCV of coal in Kcal/ Kg

Indirect method: Indirect method counts various losses and their by considered as more accurate than
direct method of finding efficiency. However, blow down loss is omitted in indirect method. There are
reference standards for Boiler testing at site using indirect method namely British Standard BS 845: 1987
and US standard ASME PTC-4-1 Power test code steam generating units. Indirect method is also called
heat loss method, covers various losses such as

Heat loss due to dry flue gas


Heat loss due to moisture in fuel
Heat loss due to moisture in combustion air
Heat loss due to hydrogen in fuel
Heat loss due to radiation
Heat loss due to Unburnt in fly ash
Heat loss due to Unburnt in bed ash

Station costing model (tentatively given for understanding concepts)

Estimated project Cost of 4 x 135 MW Captive Power Plant is Rs.2259.00 Crores. The CPP will cater to ever
increasing power demand of not only the existing but also the upcoming Steel complex at Raigarh.

The Project is financed in two phases.


The total project cost and financing plan for Phase I & II is as under:-

Sl.
1

Project cost

Description
Total Project Cost

Phase I
Rs.1179.00 Crores

Phase II
Rs.1080.00

Cost calculation sheet (combined for Phase I & II)

Generation
Item

Unit

Quantity

Remark

Turbine Maximum Continuous rating (TMCR)

MW

135.00

Maximum Generation per day

MU

3.24

Average achievable generation per day

MU

2.92

at 90% PLF

Auxiliary power consumption per day

MU

0.29

at 10% of generation

Net saleable units per day

Per Hour generation in Million Units

MU

2.62

Average generation - Aux Power

Rs in Cr

1.14

at Rs 4.35 / Unit (i.e. KWhr)

MU

78.73

Monthly revenue

Rs in Cr

34.25

Yearly generation

MU

944.78

Considering 12 months

Yearly achievable generation

MU

866.05

considering 01 Month S/D

Unit Yearly Revenue

Rs in Cr

376.73

From one Unit

Plant yearly Revenue

Rs in Cr

1506.93

From 04 Units

Per day revenue (Rs in Crores)


Monthly Generation

Coal
Item

Unit

Quantity

Remark

Max Coal Consumption per hour BMCR

Tones

162

Max Coal Consumption per hour TMCR

Tones

145

Avg. Coal consumption per Day

Tones

130

for 460 TPH, 2300 Kcal/ Kg GCV coal


For 435 TPH, 2042 Kcal/ Kg heat
rate, Boiler efficiency at 82.7%
At 90% PLF

Coal consumption per day

Tones

3120

Specific coal consumption

T/MW

1.075
0.28

Cost of coal per month

Rs in Cr
Rs in Cr

8.42

Cost of coal per annum per unit

Rs in Cr

92.66

Cost of fuel per annum for 04 units

Rs in Cr

370.66

Cost of coal per day

at Rs 900/ T of Middling
Considered 01 month S/D

Fuel Oil
Item

Unit

Quantity

LDO Consumption (Per light up)

32.00

Cold startup

LDO Consumption (Per light up)

12.00

Hot Startup
06 cold startup & 12 hot startup

Total consumption / annum

336.00

Rs/T

30000.00

Fuel cost per annum

Rs in Cr

1.01

Fuel cost for 04 Units

Rs in Cr

4.03

Fuel cost

Remark

One unit

Miscellaneous costs
Item

Unit

Quantity

Maintenance cost and other Misc cost such as


Manpower (staff & operators), Ash transportation,
Rs in Cr
113
chemicals, DM Water etc
Calculation sheet
Item

Unit

Quantity

Total revenue per annum

Rs in Cr

1506.93

Expenditure

Rs in Cr

487.69

Net Savings

Rs in Cr

1019.24

Remark
5% of capital cost of 2259 Crores

Remark
From 04 units

Simple payback period:This is the simplest technique that can be used to appraise a project proposal. The Simple Payback Period can be
defined as the length of the time required for the running total of net saving before depreciation to equal the
capital cost of the project. Shorter the payback period, more attractive the project becomes.
Simple payback period (SPP)
: Capital cost of the projects / Net annual saving.
SPP (of DCPP) : 2259 / 1019
: 2.21, to say 2 years 03 months
Discounted cash flow methods:Even though, SPP is a simplest technique for a quick evaluation, it has a number of major weaknesses as below:

SPP does not consider savings that are accrues after the payback period is finished.

SPP does not consider either interest, inflation etc. Other way, time value for money is not been considered
in SPP Method.

Net present value: NPV method calculates the present value of the all yearly cash flows (i.e. capital costs and
net savings) incurred or accrued throughout the life of a project, and summates them. Costs are represented as
negative value and savings as positive. The sum of all the present value termed as NPV. The higher the NPV, the
more attractive the proposed project.
PV = S x DF; DF = (1+IR/100)-n
PV is the Present Value of S in n years time, S is the value of cash flow in n years time, DF is the discount
factor or simply interest on capital.

Profitability Index: Profitability index termed as sum of the discounted net savings per capital cost.
Net Present Value and Profitability Index for a 10 Year span
Discount factor is nothing but accrues figure of interest, depreciation and inflation. Here, we have considered 10%
interest, 10% depreciation and 4% inflation
Net Present Value and Profitability Index for a 10 Year span
Year

Discount at 16% (Interest,


inflation and Depreciation)

Capital investment (In


Crores)

Net Savings

Present Value

-2259

-2259

1
2
3
4
5
6
7
8
9

0.862
0.743
0.641
0.552
0.476
0.41
0.354
0.305
0.263

0
0
0
0
0
0
0
0
0

1019
1019
1019
1019
1019
1019
1019
1019
1019

878
757
653
562
485
418
361
311
268

10

0.227

1019

231
NPV

2666

Profitability index

1.18

VARIOUS PACKAGES ALONGWITH VENDORS & THEIR OWNERSHIP


S.N.

PACKAGE NAME

VENDOR FOR PH-II

VENDOR FOR PH-II

Owner

BTG PACKAGE

Shanghai Electric
Company (SEC), China

Shanghai Electric
Company (SEC), China

Boiler: Mr Aravindaran

Turbine: Mr U K Ghosh

MAKE-UP WATER
SYSTEM

"RAUNAQ International
Ltd

"RAUNAQ & Jindal Saw


Pipes

Mr Balamurugan / Mr T V
Gopi

PTDM Plant

TRIVENI

TRIVENI

Mr Sunil Porwal

COOLING TOWER (2
Nos.)

"PAHARPUR COOLING
TOWERS LTD."

"PAHARPUR COOLING
TOWERS LTD."

Mr Sunil Porwal

EOT CRANE

"CSD,RAIGARH"

"CSD,RAIGARH"

Mr U K Ghosh

CHIMNEY

GDC

Mr A Kar/ Mr U K Ghosh

CIVIL & STRUCTURAL


WORK

SIMPLEX Infrastructure
Ltd
SIMPLEX Infrastructure
Ltd

GDC

Mr A Kar/ Mr U K Ghosh

CW & ACW PUMP

"WPIL LTD."

"WPIL LTD."

Mr Sunil Porwal

SWITCH YARD (For


10Bay)

"Siemens"

"Siemens"

Mr S K Garai

10

POWER/GENERATOR
TRANSFORMER

"AREVA" T&D LTD.

"AREVA" T&D LTD.

Mr S K Garai

11

ST & UAT

"T & R ltd."

"T & R ltd."

Mr S K Garai

12

Service Transformer

13

CHP

"Crompton Greaves
Ltd."
Enviro abrasion
Resistant Ltd.

14

AHP

"Crompton Greaves
Ltd."
Enviro abrasion
Resistant Ltd.
"Mecawber Beekay
Ltd."

15

BTG Erection &


Commissioning

EDAC Engineering Ltd

16

HT Switchgear

Siemens

17

MISCELLANEOUS PUMPS

"WPIL LTD."

18

COMPRESSED AIR
SYSTEM

19

HT POWER CABLE

"Mecawber Beekay Ltd."

Mr S K Garai
Mr R Verma
Mr Vinay Krishan
Boiler: Mr Aravindaran

Sunil Hi-Tech
Turbine: Mr U K Ghosh
Mr S K Garai
"WPIL LTD."

"Atlas Copco LTD."


"KEI LTD"

Mr Vipin Chaudhary
Mr S K Garai
Mr Balamurugan / Mr T V
Gopi
Mr Balamurugan / Mr T V
Gopi

CW & ACW PIPING


20

Mr Sunil Porwal

"LLOYD LTD."
FUEL OIL SYSTEM

21

BATTERY & BATTERY


CHARGER

"HBL LTD."

"HBL LTD."

Mr S K Garai

22

RE JOINT

"CORI ENGINEERING
LTD."

"CORI ENGINEERING
LTD."

Mr U K Ghosh

23

BF VALVE

"TYCO VALVE LTD."

"TYCO VALVE LTD."

Mr Balamurugan / Mr T V
Gopi

24

BUSDUCT

"CONTROL &
SWITCHGEAR LTD."

"CONTROL &
SWITCHGEAR LTD."

Mr S K Garai

25

C&I

M/s YOKOGAWA LTD.

M/s YOKOGAWA LTD.

Mr J Kole

Tyko fire

Tyko fire

Mr Sarkar

M/s Macmet India Ltd

M/s Macmet India Ltd

Mr Balamurugan / Mr T V
Gopi

26
27

FIRE detection and


protection system
STOP LOG GATES &
SCREENS

M/s Unitech Machines


Ltd.
M/s UB ENGINEERING
LTD.

M/s Unitech Machines


Ltd.

28

LP PIPING

29

BOP ELELCTRICAL

30

DG SETS

31

LT switch gear

32

Air conditioning

M/S VOLTAS LTD

Mr Vipin Chaudhary

33

Ventilation

M/S SK SYSTEM

Mr Vipin Chaudhary

34

Misc crane and hoist

35

Elevator

36

LT Power Cable

37

220 KV Transmission
Line

M/s Nirmala Constructions

38

Logistics

M/s Ruby infra logistic TRANSPORT LTD.

39
40

Plate type Heat


Exchanger
Third Party Inspection in
china

Mr S K Garai

M/s STERLING & WILSON


M/s Schneider Electric
India Pvt. Ltd.

M/s Century Crane


Engineers Pvt ltd
M/S OMEGA
ELEVATORS

Mr Sarkar

M/s Schneider Electric


India Pvt. Ltd.

M/s Century Crane


Engineers Pvt ltd
M/S OMEGA
ELEVATORS

M/S KEI

Mr Vipin Chaudhary
Mr S K Garai

Mr Sunil Porwal
Mr Aravindaran
Mr S K Garai

M/s Tranter India Ltd

Mr S K Garai

Mr Balamurugan

M/s Lloyd register Asia ltd.

41

O&M Contract

M/s SEC

42

Supervision of
Refractory Application &
Furnace drying

M/s SEC

Mr Ravindrakumar

43

33 kV Switchyard

M/s Siemens

Mr S K Garai

44

33 kV Transformers

"AREVA" T&D LTD.

Mr S K Garai

45

SCADA

Mr S K Garai

46

Effluent Treatment

Mr Sunil Porwal

47

Public Address System

Mr J Kole

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