INTRODUCTION & BRIEF SCOPE OF OPERATION
LIST OF EQUIPMENTS
WATER, FUEL ANALYSIS AND CRITICAL PARAMETERS
WASTE MANAGEMENT & RECYCLING
FUTURE PLANS

INTRODUCTION & BRIEF SCOPE OF OPERATIONS

The Co-gen power plant was set-up in the year 2004 at unit II to meet the in-house steam and power requirements of the process plant. The capacity of the plant is 2.5MW.

The main components of the power plant consists of a 19 tons boiler operating at a steam pressure of 68 kg/cm2 and a temperature of 485+10 deg C. The steam so produced in the boiler is fed into a power turbine, which drives an alternator of capacity 3125 KVA through a dual gear system to produce power at a voltage of 11000 volts. The power so generated is distributed through 11kV indoor/ outdoor HT power distribution system. The power is step down to 440 volts with the help of outdoor power distribution transformers. The LT Power is distributed to the various sections of process through LT Indoor distribution sub-station for final utilization of the generated power.

The 19 tons boiler is of BI-drum fluidized bed type and has four compartments. It is provided with the facility for boiler bank ash and bed ash disposal. There is also one Electrostatic precipitator to take care of the operation of boiler under pollution norms. The Boiler is provided with the accessories as detailed in annexure no 2 –List of Equipments. The Boiler was Supplied and Installed by M/s Thermax

The TURBINE of 2.5 MW capacity is supplied by M/s Kuhnle, Kopp & Kausch., Germany. This is fitted with Governor of Electro-hydraulic type. This dual turbine has got turbine I which produces an output of 3143 kw. The TURBINE- 1 produces the exhaust steam in the extraction mode at a pressure of 2.5 bar which is utilized by the process plants The Turbine II operation at a team pressure of 2.4 bar, and temp of 244 deg C also produces power in the condensing mode. These two turbines drive the alternator shaft through the dual gear system enabling the alternator to develop a final output of 3125 KVA./2500 KW.

A flow diagram is herewith attached to understand the process from fuel feeding to generation of steam.

WATER SYSTEM, FUEL ANALYSIS, CODES AND STANDARDS

In order to ensure smooth and trouble free operation of the boiler, the following parameters are maintained.

WASTE MANAGEMENT AND RECYCLING:

One number ESP is provided in the boiler as a dust collecting system and the emission from the ESP are maintained < 50 mg/Nm3.

The following are the wastes generated from the boiler:

1. Continuous blow down
2. Cooling water from Ash screw conveyor

The following are the Wastes generated from the Cooling Tower:

1. Blow down waste
2. Water due to Evaporation

All the above waste water except evaporation water are collected in a storage sump. The wastewater is pumped and used for wetting of coal in the coal yard to avoid dust pollution. Hence there is no let out of water of ETP for treatment.

RECYCLING:

The steam supplied to the process plant returns as condensate back to
Boiler feed. DM water is used as make up for boiler feed water. The
DM water to return condensate is in the ratio of 25: 75. Hence the return condensate is harnessed to the optimum in this plant.

Ash:

The ash produced after the complete combustion of coal in the boiler is disposed off immediately in closed trucks to local manufacturers of fly ash bricks. Hence there is also no storage of fly ash with in the factory Premises.

FUTURE PLANS:

Presently the process plant power requirements is 1800KW and extraction Steam requirement is 14 MT/hr. Hence there is further scope of optimize the Power generation. As such plans are under way to generate the extra power Of 1MW and wheel to our sister company at unit 1 (Nellore) for captive use. Further at the Nellore unit the import power which is drawn from the Grid of The State Electricity Distribution Company will be minimized.

SAFETY:

To ensure maximum safety of the men, Machinery and Surrounding Public areas we have embarked up a novel of safety awareness among all employees through continuous training, mock drills, shop floor demonstrations, quiz programs, welfare oriented safety initiatives.

Safety is developed as a part of the daily routine activities commencing from the job allocation to work process to deliveries.

Regular / frequent with intimation / with out intimations audits and checks are conducted by the safety committee of allsections and primary responsibility of this core team is to ensure a safe
process at every stage. Monthly safety meetings – training through external safety faculties are a few of the various safety systems in plan.

All manufacturing locations are subjected to details safety audits, risk Management according to our disaster management plan.

All process activities and work instructions are done in accordance to a Safety management plan keeping in view the latest technology standards and amendments in regulating mechanism. All jobs / activities are taken up with a safety permit system.

Fire hydrant system and fire extinguishing system are in place to ensure safety fire / chemical burns during any emergency.