NTPC UNCHAHAR TEAM

WELCOMES YOU ALL

IN

“10 NATIONAL
th

SUGGESTION SUMMIT”
 Unchahar

Energy Conservation
through
Modification in
Blow Down Water System
 Team Member
Mustak Ali Dy. Supdt (EEMG)

Ashish Kumar Asstt. Engr (AMG)

NTPC UNCHAHAR TEAM WAS
2nd PRIZE WINNER IN
“9th NATIONALSUGGESTION
SUMMIT” 2007
AMONG
NON - MANUFACTURING GROUP
KANPUR 120
130 KM
KM

UNCHAHAR

85
KM

ALLAHABAD
1050 MW installed capacity, Feroze Gandhi
Unchahar Thermal Power Station is situated in
Distt. Raebareli (UP). Its foundation stone was
laid by then Prime Minister Late Smt. Indira
Gandhi on 27.06.81.
The station was taken over by NTPC from the
Govt. UP on 13.02.92 and PLF of Unchahar
has steadily risen from 18% to 97.69%. Today,
the station stands 2nd in rank among NTPC
and fifth in country.
The credit goes to the sincere and dedicated
workforce of this power plant.
 IMPRESSIONS
“Unchahar Thermal Power Station was
acquired by the NTPC LTD from the
Government of Uttar Pradesh. Performance
was improved dramatically by using
debottlenecking techniques…………
These dramatic results have been obtained
under ordinary or even oppressive
circumstances, and despite the absence of
recognition by the system.”

Extract from the book “INDIA 2020 – A Vision for

the New Millennium” authored by the Dr A.P.J.
Abdul Kalam.
10000 9010
9000
7467
8000 6451 6782 7041
7000 6149
6000
5000
4000
3000
2000
1000
0
02-03 03-04 04-05 05-06 06-07 07-08
100 95.59 97.69
95.69

95 92.17

90 87.43

83.56
85

80

75
02-03 03-04 04-05 05-06 06-07 07-08
 What is Blow Down Water
To maintain the TDS (Total dissolve solids) of
CW system specified quantity of water
withdrawn form CW circuit is called Blow Down
Water.
It is a clarified water and chemicals are added in
water to maintain the desire TDS of CW system.
This is cold water and is used as a cooling water
in various system.
Our system is designed for zero discharge
hence it is also used for make up in Ash
Handling system.
 BLOW DOWN PUMPS

CHP CW AHP CW SERVICE WATER SEAL WATER

SYSTEM SYSTEM MAKE UP FOR AHP CT MAKE UP

CW DISCHARGE HEADER
 AREA WISE WATER CONSUMPTION

ST - II AHP CW System M3/hr 378.10

CHP Cooling Water tank make up M3/hr 345.00
ST - II CT make up M3/hr 293.20
ST - II Service water make up M3/hr 100.00
ST - II AHP Seal water TANK make up M3/hr 60.00
ST - III AHP tank make up M3/hr 33.40
ST - III Service water make up M3/hr 29.85
Total M3/hr 1239.55
BLOW DOWN WATER CONSUMPTION (%)

5% 3% 2%
8% 30%

24%

28%

AHP CW System CHP

CT make up Service water make up
Seal water AHP st - 3 make up
Service water make up
 PURPOSE OF MODIFICATION

 Optimization of Blow down and Raw

water consumption.
 Increase COC of existing blow down
water system.
 Reduction in pumping power
consumption by reduction in water
consumption.
 Reduction of chemical consumption. 
 Reduction in maintenance cost.
 To stop spill away water or over flow
water from make – up tanks.
 AHP COOLING WATER SYSTEM

BLOW DOWN WATER

AHP COOLING
WATER
COMPRESSORS MAKE UP TANK
TAC VACUUM COOLING
DRAIN 6 NOS PUMPS WATER

Spill
Away
AHP COOLING WATER PUMPS water
 AHP CW PUMPS (AFTER MODIFICATION)

BLOW DOWN WATER

AHP COOLING
WATER
MAKE UP TANK
COMPRESSORS
TAC VACUUM COOLING
Service 6 NOS PUMPS WATER
water
make up

AHP COOLING WATER SYSTEM

Blow down water consumption reduction

 Reuse of Ash Handling Plant cooling

water.
 Reuse of CHP hydraulic coupling cooling
water.
 CHP cooling water switch over from blow
down water to service water.
 CT pump make up pit over flow optimized.
 Stage - II AHP seal water tank make - up
valve made auto functional with tank level.
 Stage - III Ash water make-up switch over
from blow down water to raw water.
After adjustment / substitution of Blow Down
water with low value water it was observed that

 Blow down header pressure increased

 Header pressure variation was

0.30 Kg/cm2 during opening of any system
valves.

 Stoppage of one number Blow down

pump.
 Two NOS AHP cooling water pumps
stopped.
 BLOW DOWN PUMPS (AFTER MODIFICATION)

CHP CW AHP CW SERVICE WATER SEAL WATER CT MAKE UP

SYSTEM SYSTEM MAKE UP FOR AHSP

CW DISCHARGE HEADER
 Energy Consumption before modification

Energy consumption by Blow down pumps

= 1208880 KWH / annum

Energy consumption by AHP CW pumps

= 385440 KWH / annum

Total = 1594320 KWH / annum

 Energy Consumption after modification

Energy consumption by Blow down pumps

= 805920 KWH / annum

Energy consumption by AHP CW pumps

= 00.00 KWH / annum

Total = 805920 KWH / annum

Comparison of Energy consumption
(KWH per annum)
1594320

1600000
1400000
805920
1200000
1000000
800000
600000
400000
200000
0
Energy consumption Energy consumption
before modification after modification
 Comparison of Blow down water
(Cubic Meter per annum)

10858370
12000000

10000000
7238914

8000000

6000000

4000000

2000000

0
Blow Down Water before Blow Down Water after
modification modification

Blow down water consumption

reduced by 3619456 M3 / annum
 Reuse of Blow Down water
(Cubic Meter per annum)

3837756

4000000
3500000
3000000
2500000
2000000
1500000 0
1000000
500000
0
Reuse of Blow Dow n Water Reuse of 'Blow Dow n Water
before modification after modification
 RAW WATER CONSUMPTION
(Cubic Meter per annum)
10858370
12000000

10000000

8000000
6000000 3401158

4000000

2000000

0
Raw Water consumption Raw Water consumption
before modification after modification

Raw water consumption

reduced by 7457212 M3 / annum
 Investment

 Scrap / used pipes of Ash slurry system.

 Approximate Rs. 0.30 lacs for labour and

electrode charges.
 Description Unit Value
Cost saved by stopping of
Blow Down and Cooling Lac / annum 14.19
Water pumps.

Saving in Raw water Lac / annum 14.60

pumping cost
Saving in Chemical cost Lac / annum 31.00
Saving in Maintenance Lac / annum 1.20
cost
Saving in Raw water cost Lac / annum 25.25
(consumptive+cess)
Total Tangible Gains Lac / annum 86.24

Considering unit price of energy is Rs. 1.80

 But the more important is

 Saved Electricity can enlighten 182 houses.

 This modification work leads to reduction

of carbon di oxide emission by 1550 MT/yr.

 Saved raw water can fulfill demand of ~

26000 peoples every day.
or
 ~ 13140 acres land can be irrigated every
year.
Fundamental Premise
“If it can be measured,
and it is measured;
it can be improved”
 Modification work
   AHP cooling water tank bypassed from
circuit.
 Cooling water pump suction and
discharge header connected together.
 AHP CW pumps discharge diverted in
service water fore bay.
Effect of Modification
 Blow down header pressure increased.
 AHP CW pumps suction header pressure
was more than discharge pressure.
  
IMPRESSION OF HON’BLE PRIME MINISTER

“NTPC is a great success story of our

times. It is imbued with the spirit of ‘Can
Do It’. My best wishes for the future
growth of this magnificent National
Enterprise.”

……Dr. Manmohan Singh