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Prepared by:

1. Sandeep Kr. Sharma, Sr. Mgr. (BMD)

2. Arpit Jha, Sr. Mgr. (MTP-O&E)


PROFILE OF AUTHOR

1. Sandeep Kumar Sharma


Sr. Mgr. (BMD), PP-II, Bhilai

Professional Profile
Presently he is working in NSPCL (a joint venture of NTPC & SAIL) posted at Bhilai. He initially
joined Operation, PP-III Expn, Bhilai, later was posted to Fuel Management & subsequently to BMD,
PP-II in 2017. He has been looking after Maintenance of Non-pressure parts, CO gas system & Mill
Maintenance since 2017.

2. Arpit Jha
Sr. Mgr. (MTP-O&E), PP-II, Bhilai

Professional Profile
Presently he is working in NSPCL (a joint venture of NTPC & SAIL) posted at Bhilai. He initially
joined Corporate Contracts & Material Deptt. at EOC, Noida in NTPC and was later posted at Power
Plant-II of Bhilai Steel Plant upon promotion in May’17. He has been looking after Maintenance
Planning, O&E and Vibration Analysis at PP-II since then.

7th O&M Meet Coke Oven Gas System of NSPCL, Bhilai PP- II Page 2 of 3
ABSTRACT

NTPC SAIL POWER COMPANY LIMITED (NSPCL) is a joint venture formed by NTPC Ltd. with
SAIL on 50:50 basis in March 2001. Initially, NSPCL took over captive power plant-II located
at Durgapur Steel Plant (2X60 MW) and Rourkela Steel Plant (2X60 MW) from SAIL. BESCL,
a 50:50 JV between NTPC & SAIL, took over captive Power Plant-II located at Bhilai Steel
Plant (2X30 MW+1X14 MW) from SAIL. Subsequently, BESCL was amalgamated with
NSPCL in 2006.

It may be mentioned that Bhilai Steel Plant (BSP) is India's sole producer & supplier of world
class rails for Indian Railways including 260 metre long Welded Rail Panels, and a major
producer of large variety of wide and heavy steel plates and structural steel. Captive Power
Plant-II (PP-II) has an installed capacity of 74 MW with steam supply of 150 T/hr. PP-II has 2
No’s Condensing Turbines of 30 MW capacity and 1 No. of Back Pressure of 14 MW capacity.
PP-II has three boilers with a steam capacity of 150 T/hr with an operating pressure of 65
kg/cm2 and operating temperature of 492 0C. Steam is supplied to BSP at 18 ata & 8 ata for
process heating as well as used in creating vacuum above hot metal. Therefore, PP-II caters
to steam requirement & power for critical loads in BSP.

There are 12 numbers of coal nozzles, 16 numbers of gas burners and 3 number of flame
scanners per boiler. Three boilers of CPP–II are fed with CO (Coke Oven) gas along with Coal
for combustion. CO gas is used for light up (start-up fuel) as well as for raising load up to 25%
BMCR. Balance load is raised by firing pulverised coal & CO Gas in the boilers.

CO gas comprises mainly of hydrogen, methane, carbon monoxide & therefore, is highly
explosive & poisonous. As CO gas is being supplied by BSP from their CO gas pipeline
network, it is emergent that any mishap in their network is likely to have an impact inside PP-
2. In this regard, the potential hazards associated with the CO gas line in PP-2 have also been
assessed. It may also be noted that PP-II has had nil accident in last ten years. However, due
to the recent accident pertaining to CO gas line, an emergent need was felt for a thorough
review by an external agency of the existing CO gas system inside PP-2 including
maintenance practices already in place & to suggest improvement as well as recommend
measures for safe operation, isolation and maintenance. Accordingly, based on the
suggestions/recommendations given by the consultant viz. MECON, certain jobs in CO gas
firing system have also been planned in Boiler AOH in this FY 2019-20. This paper describes
the hazards of CO gas, existing CO gas system, brief of recommendations & measures being
taken and planned.

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