BOKARO POWER SUPPLY CO. (P) Ltd.

(A Joint Venture of SAIL & DVC)

ISO 9001:2008 (QMS) , ISO 14001:2004 (EMS) , ISO 18001:2007
(OHSAS)

WELCOMES
Sri R.P.Tripathi, Member Tech. ,
DVC
&
Sri M. Biswas, Chairman, BPSCL

BPSCL - INTRODUCTION
Bokaro Power Supply Company Pvt. Ltd. got incorporated on
17.08.2001 by the Company Registrar of Delhi & Haryana
under Companies Act 1956.
DVC and SAIL agreed that they will participate in the Equity
Shares Capital of BPSCL in 50:50 ratio and fully co-operate
to manage its business and affairs in good faith.
It has been agreed between SAIL & DVC that BPSCL shall
maintain the Captive Status of the SAIL Power Plant so
assigned to it by SAIL and SAIL shall purchase the entire
Power and Steam generated there from subject to the
provisions of the Power and Steam purchase Agreement DT: 18.09.2001 entered into SAIL and BPSCL.

Accordingly SAIL and BPSCL have executed the following

agreements: Deed of Transfer and Assignment of Business DT:
18.09.2001 for assignment of Business of CPP to BPSCL
Power and Steam purchase Agreement DT: 18.09.2001
for purchase of Power and Steam by SAIL from BPSCL
Shared Facilities and support services Agreement DT:
18.09.2001 for Bokaro CPP
Agreement to lease DT: 18.09.2001 in respect of Land for

BPSCL BOARD of DIRECTORS

BPSCL is managed by its Board of Directors.
The Board is responsible for the overall functioning of the
Company .

CHAIRMAN
(Nominated by DVC)

DIRECTORS (02)
(Nominated by DVC)

DIRECTORS (03)
(Nominated by SAIL)

FUNCTIONAL HEAD
CEO
(Appointed by the
Board)

BPSCL MANPOWER
Existing Manpower strength of BPSCL
Executive Cadre:Sanctioned Strength: 318

Existing*: 220

Non- Executive Cadre:Sanctioned Strength: 309

Existing*: 89

*as on 20.02.16.

BPSCL - OBJECTIVES

To generate and supply Power and Steam to Bokaro Steel

Plant from the existing Captive Power and Steam generating
at Bokaro and its associated units/facilities of SAIL so as to
maintain its Captive status for the Bokaro Plant.

CAPACITY

BOILERS

5 x 220 = 1100 T/Hr

(Blr#1 to 5)

Krasny Kotelsic, Russia

3 x 260 =

780 T/Hr

Rafaco, Poland (Blr#6, 7 &

1 x 300 =

300 T/Hr

Alstom, India (Blr#9)

8)

2180 T/hr
TURBO GENERATORS
1 x 12
2 x 55
3 x 60
1 x 36

=
=
=
=

12 MW
110 MW
180 MW
36 MW

TG#1 (BPTG) Kaluga, Russia

TG#2 & 3 LMZ, Russia
TG#6, 7 & 8 Zamech, Poland
TG#9 (BPTG) Skoda, Czech Republic

338 MW + 660 Tph (Steam to BSL)

>

BOILER DETAILS
UNIT

DATE OF
COMMISSIONING

Boiler #

17.04.1972

1
Boiler #

14.07.1972

2
Boiler #

06.06.1974

3
Boiler #

15.07.1978

4
Boiler #

23.06.1980

5
Boiler #

14.11.1985

Capacity
(Tph)

Running
Hours

T-156

220

3,36,709

T-156

220

3,35,528

T-156

220

3,27,075

T-156

220

2,89,740

T-156

220

2,85,457

OPG-260

260

Type

(Till 31.01.16)

TURBO GENERATOR DETAILS

UNIT
T.G # 1
T.G #2
T.G #3
T.G #6
T.G #7

DATE OF
COMMISSIONING

Type

31.12.197

P-12-90-

4
13.07.197

37

2
13.10.197
3
25.01.198
6
16.09.198
8

Capacity Running
Hrs
(MW)
(Till 31.01.16)
12

3,07,790

K-50-90-4

55

3,35,641

K-50-90-4

55

3,21,170

9K-66

60

1,84,085

9K-66

60

1,64,223

BRIEF DESCRIPTION
The entire Power Plant has come in three phases i.e.

Thermal Power Plant (TPP), Captive Power Plant (CPP)

and Unit #9.
TPP consists of 05 nos. of multi fuel boilers (Blr # 15) each of 220 TPH, 01 No. of 12 MW back pressure
turbo generator (100 ata / 39 ata) and 02 nos. of 55
MW condensing Turbo Generators.
Captive Power Plant (CPP) consists 03 nos. of multi
fuel boilers (Blr # 6,7,8) each of capacity 260 TPH and
03 ns of 60 MW condensing type turbo generators.
Unit #9 consists of 01 nos. of multi fuel boiler (Blr
#9) of capacity 300 TPH and 01 no of 36 MW Back
Pressure Turbo Generator. (100 ata / 8-12 ata with
control extraction of 39 ata)
The total steam generation capacity is 2180 TPH at

BRIEF DESCRIPTION
Besides Power Generation, BPSCL supplies Steam to
BSL
Steam at 100 ata pressure 540 0 C is being supplied to Turbo
Blower Station to run the turbo blowers (8 Nos.) for Blast
Furnace. This steam is being tapped from the 100 ata main
steam headers of the power plant. All the boilers feed the
100 ata steam to 100 ata steam headers.
Steam at 39 ata pressure 420 - 440 0 C is being supplied to
Turbo Blower Station to run Turbo Compressors(4 Nos.) for
Oxygen Plant and to exhauster of Coke-Oven. This steam is
being tapped from the 39 ata steam headers. There are two
sources of this steam,
Tapped from extraction of BPTG of TG #1 at 39 ata.
Tapped from 100 ata main steam headers through
HSPRDUs which reduces the pressure of steam from 100
ata to 39 ata.
Steam at 8-12 ata pressure & 240 - 220 0 C is being supplied
to Blast Furnace , HRM, CRM, RMP, SMS and different shops
(Condensate of this process steam is not returned to the
power plant). This steam is being tapped from

BRIEF DESCRIPTION

BPSCL also supplies soft water to BSL

besides Power Generation.

BPSCL is having its own water chemical

treatment
plant.
TPP
water
chemical
treatment plant produces 300 TPH demineralized water for TPP boilers and 300
TPH soft water which is supplied to SMS,
HRM & RMP for their low pressure boilers.
One 50 TPH capacity DM water plant is also
installed for feeding DM water to CPP
boilers.

STEAM DISTRIBUTION SYSTEM

TO
STEEL
PLANT
(PROCE
SS
STEAM)

8 12 ATA / 2400 STEAM

COLLECTORS II
8 12 ATA / 2400 STEAM COLLECTORS
I

1
PRDUs OF CPP

PRDU 2
PRDU 1 PRDUS OF TPP

To TBS

PRDU 4

FROM 100 ATA / 5400 STEAM

COLLECTORS

FROM 100 ATA 5400 C STEAM COLLECTORS

To TBS

100 ATA / 5400 C STEAM

COLLECTORS II

100 ATA / 5400 C STEAM COLLECTORS

220
T/H

.BLR

BLR 3

220
T/H

220
T/H

TG 1

HPRDU 1

To TBS
&
CO-OVEN

BLR 4

220
T/H
TG 2

HSPRD
U2

39 ATA/440 C
0

39
ATA/4400

BLR 5

220
T/H

BLR 6

260
T/H

BLR 7

BLR 8

BLR 9

260
T/H

260
T/H

300
T/H

TG 6

TG 3

HSPRD
U3

TG 7

6 ATA
PRDU
3

TG 8

HEATING
STEAM
TO
DEARAT
OR

39 ATA / 4400C STEAM COLLECTORS II

39 ATA / 4400C STEAM COLLECTORS I

TG 9

39 Ata
Steam
Extraction
21 T/HR

BLR 1

100 ATA/5400 300

T/HR

36 MW BPTG
8 12 ATA / 4400C STEAM
OUTLET 79 T/HR

EVACUATION OF POWER
All the Turbines are connected with 11.5 KV

generators. TG #1, TG #2, TG #3 & TG #6 is

connected to 4 nos 11 KV sections. All these four 11
KV sections, TG #7 & TG #8 are connected to 132 KV
bus bars through 11 KV / 132 KV transformers.
TG #9 is connected with 11 KV bus which is
connected with grid by 11 KV / 132 KV transformer.
Some emergency 11 KV feeders are taken directly
from 11 KV sections which supply the CATEGORY I
load to BF, SMS, Pump House, Oxygen Plant, Cokeoven & auxiliaries of power plant. Rest of the power
is stepped up to 132 KV and supplied power to
Sintering Plant by two lines (1C, 2C), to MSDS-I by
two lines (3C, 5C), INOX oxygen plant (from Bay 14)
and CRM 3 (from Bay 15). One 132 KV line 4C comes
from CTPS and is connected to 132 KV bus bar to

ELECTRICAL SCHEME OF BPSCL

FUELS USED
All the boilers in BPSCL are multi fuel fired boilers.

The following fuels are used.

COAL
FURNACE OIL
BLAST FURNACE GAS
COKE OVEN GAS

Middling Coal is procured from different coal companies

like CCL, BCCL, TATA and CCSO. BPSCL has FSA with CCL
& BCCL.
ACQ with CCL
- 962182 MT/ year.
ACQ with BCCL
- 552000 MT/ year.
The remaining requirement is fulfilled by procuring coal
from other sources like TATA and CCSO. Presently
agreement has been done with TATA for procurement of
125000 MT of coal till 31.03.16.

AVERAGE POWER GENERATION (in MW)

* Data for FY 2015-16 is till

Jan 2016

AVERAGE STEAM GENERATION (in TPH)

* Data for FY 2015-16 is till

Jan 2016

COMPARISON
OF
BPSCL PERFORMANCE
LAST FOUR FYs

POWER GENERATION (in MW)

* Data for FY 2015-16 is till

Jan 2016

STEAM GENERATION (in TPH)

1500

1400

1,368
1,319

1,304

1,325

1300

1200

1100

1000
2012-13

2013-14

2014-15

2015-16

* Data for FY 2015-16 is till

Jan 2016

SPECIFIC OIL CONSUMPTION (in ml/KWH)

* Data for FY 2015-16 is till

Jan 2016

SPECIFIC COAL CONSUMPTION (in kg/KWH)

* Data for FY 2015-16 is till

Jan 2016

BF GAS CONSUMPTION (in x 1000 Nm3/hr)

* Data for FY 2015-16 is till

Jan 2016

CO GAS CONSUMPTION (in x 1000 Nm3/hr)

* Data for FY 2015-16 is till

Jan 2016

AUXILIARY POWER CONSUMPTION (as a % of Steam

Generation)

* Data for FY 2015-16 is till

Jan 2016

DEEMED PLANT LOAD FACTOR (%)

COMPARISON
BETWEEN
PERFORMANCE
INDICATORS OF
BPSCL & NSPCL

COMPARISON OF DESIGN PARAMETERS

BPSCL Units 6,7,8 (CPP) is comparable with Units of NSPCL
(Durgapur & Rourkela) as all of them are polish make and of
similar specification.
BPSCL
CPP (Unit
#6-8)

NSPCL
Durgapur

NSPCL
Rourkela

Load (Turbine) (MW)

60

60

60

Main Steam pressure

before QSV (ata)

90

90

91.2

Main Steam Temperature

before QSV (deg C)

535

535

525

Total Steam Flow (T/hr)

227

227

232

Condenser Back Pressure

0.085

0.085

0.089

FW temperature at HPH-2
outlet (deg C)

230

230

230

29

29

33

Parameter

CW Inlet Temperature
(deg C)

Deemed Plant Load Factor (%)

For the Financial Year 2015-16 (Apr-Jan)

Auxiliary Power Consumption as a % of

Generation
For the Financial Year 2015-16 (Apr-Jan)

Specific Oil Consumption

(ml/KWH)
For the Financial Year 2015-16 (Apr-Jan)

NEW INITIATIONS
&
HIGHLIGHTS
IN
FINANCIAL YEAR
2015-16

PERFORMANCE HIGHLIGHTS
BPSCL is on the verge of breaking the annual
power generation record. The last generation record
was of 175 MW in the year 2006-07. In the current
Financial year, the annual power generation is 195
MW till date.

The monthly power generation record was created

twice in the current financial year. In March 2015,
the monthly power generation was 203.59 MW
which was subsequently broken in Oct 2015 with
monthly power generation of 205.59 MW.
BPSCL has significantly reduced the furnace oil
consumption. The annual furnace oil consumption
for current financial year stands at approx 2700 KL
against the budgeted quantity of 8000 KL. BPSCL
has broken the previous consumption record of 5100

NEW INITIATIONS
Replacement of Boiler Feed Pumps. -Three number of
old Russian Boiler feed pumps have been replaced with a
State of Art pump from M/s KSB . The efficiency of the
new pump is 78.5% whereas the efficiency of the old
pump was 60.6% which results in saving of 330 KW
energy over the previous pump. Savings amount to Rs 84
lakhs per pump per year.
Installation of deva plate and replacement of nozzle
segment, rotor seal & diaphragm seal along with total
replacement (6800 nos) of condensor tubes in TG #7.
This has resulted in reduction of specific steam
consumption
along
with
restricting
the
turbine
expansions within allowable limits.
Changing DC Dust Feeder to AC VFD System in Boilers
#1 - 4 (In Progress). In Boiler#5, this system has already
been installed. This shall result in reduced maintenance
and shall also increase the stability of the Boiler. Load

NEW INITIATIONS
Installation of Static Excitation System in TG #3 and
TG# 7. This increases the stability of the Turbo Generator
as well increase in the protection of generator rotor of
TGs along with reducing auxiliary consumption.

Retrofitting of 11KV and 6.6 KV VCBs. Benefits are

reduced maintenance and increased stability.
Retrofitting of numeric distance protection relay in 132
KV Line# 3C.
Commissioning of magnetic flow meters in all the
incoming water lines.
Replacement of old Turbo-supervisory system by state
of the art digital Turbo-supervisory system.
Installation of Solar panels (100 KWP)

NEW INITIATIONS
Boiler Jobs (Boiler #4 and #3)

Most of the damaged beams of different sizes & structural elements at

roof replaced. This has been done for the first time.

APH blocks replaced.

Both ID fan motors replaced with higher capacity motors.

All burners along with SA Snail, BF Gas Chest, BF & CO sector gate and CO
gas headers replaced.

Due

to

continuous

service

as

well

as

ageing

there

was

severe

misalignment of complete pressure parts . Pressure parts and headers

were aligned to original level.

Boiler #1

Complete S panel of water wall hopper was replaced.

Boiler #2

Central column was severely damaged which has been replaced .

Most of the damaged beams of different sizes & structural elements at

roof replaced.

Complete ceiling SH panel replacement .

All burners along with SA Snail, BF Gas Chest, BF & CO sector gate and CO
gas headers replaced.

FUTURE
INITIAVES PLANNED
FOR
FINANCIAL YEAR
2016-17

NEW INITIATIONS PLANNED

R&M of TPP Boiler.
Augmentation of Coal Handling Plant
Revamping of protection system of TG #2 by latest numeric
relay.
Installation of side stream filter in RCPH.
Installation of dry fog suppression system in Coal Handling
Plant.
Installation & Commissioning of Fire Detection and Alarm
System.
Commissioning of online SOx - NOx monitoring system.
Installation of AAQ Monitoring System in BPSCL ADM Building.
Initiative has been taken for the disposal of Sludge of Furnace

POLLUTION CONTROL
AND
ENVIRONMENTAL
INITIAVES

POLLUTION CONTROL INITIATIVES

Online monitoring for Stack emission

effluent water has been implemented.

&

In-house lab has been set-up for monitoring

of Ambient Air Quality, Stack emission, Noise
Level & effluent water.
BPSCL is committed to maintain an eco
friendly environment. BPSCL has developed an
eco-friendly garden inside plant premises by
utilizing fly Ash.
Burnt transformer oil is being sent back to
BSL for safe disposal as per the trans boundary
safe disposal rule.

HAZARDOUS WASTE MANAGEMENT INITIATIVES

BPSCL has Engaged M/s MSTC for Generation

of Wealth from sale of solid waste through EAuction. The items being auctioned are
Fly Ash
Bottom Ash,
Cenosphere generated
Auction of 2.5 MT of
generated Rs 3.9 Lakhs.

in Ash Pond.
Cenosphere has

Scraps, Ferrous & Non Ferrous materials.

Scrap ACSR conductor Auction of 2.1

FLY ASH UTILIZATION

The evacuated ash is disposed off in nearby area in
the form of ash mound.
9,000 MT of ash has been utilized to develop an
echo-friendly garden in RCPH area.
BPSCL has explored some quarries and low-lying
areas in BSL premises which has been surveyed by
both BPSCL and BSL and agreed upon to backfill those
low-lying lands and quarries to make those areas
useful.
BPSCL is using 100% fly-ash bricks in construction
works.
BPSCL is about to install and commission the brick
manufacturing Plant inside BPSCL premises within 01
Month.

ECO FRIENDLY GARDEN INSIDE BPSCL

ECO FRIENDLY GARDEN INSIDE BPSCL

FINANCIAL PARAMETERS

BPSCL - INTRODUCTION
Bokaro Power Supply Company Private Limited (BPSCL)
started business on 18.09.2001 when SAIL has assigned
its business pertaining to the captive power plant of 302
MW Capacity

with

steam generation 1880 T/hr. of BSL

with following Financial parameters: Total Fixed Assets value at Rs. 560 crore.
Debt Equity ratio of 70:30
Authorised Equity share capital of Rs. 1200 crore.
Issuied & Paid up Capital of Rs 168.05 crore.
Transfer its store (Depo 58) as Working capital loan
carrying

interest @ 6.75% p.a..

BPSCL - INTRODUCTION
SAIL and BPSCL signed a Power Purchase Agreement (PPA) on
18.09.2001 and mutually agreed for supply of entire generated
steam and power to SAIL by BPSCL, on cost plus basis with
following financial parameter:BPSCL raises its bill to SAIL by 7th day of each month
SAIL reimburses all the operating expenses to BPSCL, like: Cost of coal, furnace oil water consumed
Salary Expenses
Repair & Maintenance cost
Stores & spares consumed
SAIL also reimburses following to BPSCL, like: ROE(Return on Equity) @ 15.5%
Incentive @ 2%
Interest on Normative working capital and
Depreciation on its Fixed assets.
Surcharge on late payment @ 2% per month

Sales ( in Lakhs)

Gross profit ( in Lakhs)

Selling Price of Power

Distribution of COST incurred

Cost Sheet for Power

CONSTRAINTS FACED

CONSTRAINTS FACED
Acute shortage of funds in BPSCL due to deferred payment of
Power Bills from SAIL. As on 26.02.2016 the dues from SAIL is
approximately Rs 123 Crores.
Very poor and inconsistent gas availability. Gas is required for
proper combustion in TPP boilers (05 nos), n absence of which
leads to higher % of un burnt carbon and fly ash.
Manpower problem due to Impending retirements.
Frequent stoppage of work in Ash Pond due to protest of
villagers. Matter being discussed with concerned BSL and state
government officials.
CTO certificate from JSPCB has been issued under various
conditions, chief among them being the condition that Ash from
Ash Pond be evacuated to abandoned mines of CCL. The
Contract for the said job Evacuation of Ash from different
filled up ash ponds of BPSCL and nuisance free transportation to
abandoned mines of CCL has not yet been finalized.

UPCOMING PROJECTS

STATUS OF 2x250 MW PROJECT

1.

Right to Use for 900 acres of land given by BSL to BPSCL on 21.03.07.

2. Final DPR of 2*250 MW prepared by MECON on July 2008.

3. Final LOI placed on MECON for Project Engineering and Consultancy Services
on 04.08.08.
4. Work order placed on HSCL for construction of Boundary Wall on 04.08.08.
5. Following studies have been carried out and report submitted:
. Geo-technical Investigation
. Water Intake Studies
. Power Evacuation study
. EIA / EMP studies
. Study for setting up Railway Siding Facility
. Financial Appraisal
6. Public Hearing conducted successfully on 21.08.08
7. Statutory Clearances obtained:
. Chimney Height Clearance from Airports Authority of India
. Defense Clearance from Ministry of Defense

STATUS OF 2x250 MW PROJECT

Water Allocation from DVRRC
Permission for transmission of Power from JSERC
Permission for setting up of Railway Siding Facility from
S.E Railways
8. Right of Use of land withdrawn by BSL on 25.11.10.
9. LOA for Coal Linkage withdrawn by CCL on 08.03.11.
10. Right to Use of land re-issued by BSL on 10.01.13.
11. Possession letter of 836 acres of land (transferred by State
Government to SAIL) and map thereof provided by BSL to BPSCL on
25.01.13.
12. Details of GM Land and Forest Land (transferred by State
Government to SAIL) provided by BSL to BPSCL on 25.01.13.
14. Meeting held among State Government officials, BPSCL and villagers
in the presence of SDO, Chas on 08.02.14. It was decided in the
meeting that a committee shall be formed by the State Government
for facilitating the construction of Boundary Wall around the
proposed site.

THANK YOU