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COMPANY PROFILE- Nava Bharat Energy India Limited (NBEIL) is a subsidiary of Nava

Bharat Ventures Limited (NBVL). NBEIL is operating a 150 MWCoal Fired Power Plant at Paloncha in Telangana, India.

- This Power Plant employs:I. Steam turbine from Dong Fang Power Systems, China.II. 150 MW Generator from M/s Shandong Jinan Power Equipment

Factory (JPEF).III. 520 TPH Circulating Fluidized Bed Combustion (CFBC) boiler

from Wuxi Huaguang Boiler Company Limited, China.IV. Two – stream Electro Static Precipitator from Alstom, India.

- The Power Plant was commissioned and synchronized with A.P.Power Grid on 28th February, 2013.

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ASH STORAGE AHP CFBC

Boiler

CHP

COAL STORAGE

Super Heater

Re-Heater

Economizer

Air preheater

To Chimney

Flue Gases

Air

HPT IPT LPT Generator

Condenser

CW Pump CT Fans

CT Sump

CEP

LPHBFP

HPH

TO POWER GRID

LEGEND

COALASHAIRWATERFLUE GASSUPER HEATED STEAMRE-HEATED STEAMCOOLING WATER

SCHEMATIC DIAGRAM OF COAL FIRED POWER PLANT

PERFORMANCE INDICES

1039

1137

1042

2013-14 2014-15 2015-16

Generation in Million units

10.82

10.279.89

2013-14 2014-15 2015-16APC %

2528

24732492

2013-14 2014-15 2015-16

SGHR in kcal/kWh

79.05

86.52

79.08

2013-14 2014-15 2015-16

PLF (%)

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ENERGY BREAK-UP IN NBEIL

38%

32%22%

2%1% 4%1%

0%

BoilerTurbineCWCHPAHPESPMACLighting

GenerationAuxiliary

9.89%

LIST OF ZERO INVESTMENT PROJECTS

S No FY of Implementation Title of Project

Electrical Savings in

kWh

Cost savings in Rupees Million

1 2013-14 Stopping of one Secondary air fan dueto larger design margin at rated load 1634815 8.11

2 2013-14 Reduction of transmission line lossesby improving the power factor to unity 1064656 5.28

3 2013-14Reduction in Generator fieldconsumption by reducing thegenerating reactive power.

406640 2.02

4 2013-14 Reduction of BFP Discharge Pressurefrom 185kg/cm2 to 170 kg/cm2 698941 3.47

5 2013-14Reduction in Power consumption atCHP (reduced from 2.21 to 1.99kWh/ton of coal crushed)

112029 0.56

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LIST OF ZERO INVESTMENT PROJECTS

S No FY of Implementation Title of Project

Electrical Savings in

kWh

Cost savings in Million Rupees

6 2013-14 Energy saving in lighting Using EnergyEfficient Lights 100359 0.50

7 2013-14 Reduction in power consumption for ashconveying by modifying the drains 179247 0.89

8 2013-14 Provided compressed air for ash fluidizinginstead of roots blower in Fly ash silo 247902 1.23

9 2014-15 Optimum utilization of coal feeders and bedash coolers as per load. 734219 2.20

10 2014-15

Modifications in the system operation andcontinual improvement at ash handling plantlike switching level mode to timer mode asper requirement for conveying anddecreasing vessel pressure.

337718 1.18

LIST OF EnCON PROJECTS WITH INVESTMENT

S No Title of Project Annual Savings (Rs Million)

Investment(Rs Million)

FY 2013-14

1 Connecting Boiler Continuous Blow Down vent steam to De-aerator. 2.95 0.03

2 Diverting boiler blow down water to CT sump to save 50 KLD of ground water 0.47 0.05

FY 2014-15

1Automation of Main Air Compressors and Installation of Intelligent Flow Controller in Compressed air system

3.19 0.60

2 Retrofitting of Boiler fans as per system requirement 45.42 20.65

Continued…

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S No Title of Project Annual Savings (Rs million)

Investment (Rs million)

FY 2014-15

3 Replacing Catridge of Boiler Feed Pumps as per system requirement 9.77 3.96

4 Replacing HT motor of CEP to LT motor with VFD 6.69 2.80

FY 2015-16

1 Replacing CT fan-1 blades from GRP to aero foil FRP blades 0.93 0.35

2Installed 6 no’s of Sonic soot blowers in zones of High Temperature Super-heater and Re-heater in boiler

4.72 0.55

3 Replacing Old AC’s with energy efficient & CFC free air conditioners in AAQMS station 0.04 0.11

LIST OF EnCON PROJECTS WITH INVESTMENT

Year

Annual Electrical

Saving (kWh)

Annual Electrical Cost

Saving (Rs Million)

Annual Thermal

Saving by Coal

(Ton/year)

Annual Thermal Saving by

Coal(Rs Million)

Total Annual Savings

(Rs Million)

Investment Made

(Rs Million)

Payback (Months)

2013-14 4482246 22.51 663.35 2.95 25.47 0.08 0.035

2014-15 16030135 68.45 0.00 0.00 68.45 28.00 4.90

2015-16 276270 0.97 1942.43 4.72 5.69 1.01 2.12

SUMMARY OF LAST THREE YEARS EnCON PROJECTS

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Company Station Gross Heat Rate (kcal/kWh) Auxiliary Power Consumption (%)

NBEIL 2491 9.89

Nearest Competitor – 1(with same technology) 2500 9.95

Nearest Competitor – 2(with same technology) 2583 10.55

National Benchmark 2500 10.5

Target for FY 2016 - 2017 2480 9.7

ENERGY BENCHMARKING

Note: National Benchmark reference is taken from "Government of India, Ministry of power,Central Electricity Authority for the tariff period 2014-19 Section-1, Table-1 (Prevailing Normsby CERC) for CFBC units Consider 1.5 percentage more than the AEC norms of Coal BasedGeneration Station "

ROAD MAP TO BENCH MARKS

• Providing VFD for AHU blower in VFD room for control of roomtemperature and also to reduce power consumption.

• Providing VFDs for BFPs (2no’s.) to reduce power consumption.• Installing 10 more Sonic soot blowers in Boiler (Economizer-2no’s, Air Pre-

heater – 4 no’s, Re-heater – 2 no’s and High Temperature Super Heater –2 no’s) for reducing steam consumption.

• Replacement of GRP blades of 7 CT fans with Aero foil FRP blades.• Conversion of V belt to Poly flat belt for Air compressors• Avoiding Recirculation of Boiler Feed Water by installing multi-stage

reduction valve in Boiler Feed Pump recirculation line to De-aerator.• Anti-corrosive and glass flake coating of impellers & casings of pumps for

Circulating Water, Auxiliary Cooling Water and Ash Conditioning forretaining design efficiency.

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INNOVATIVE PROJECTS

S No TITLE OF THE PROJECT

1 Maintaining uniform Boiler Efficiency at all loads

2 Bypass chute arrangement for Primary Crusher

3 Reduction of LDO consumption for Cold start up by reducingboiler static bed height

4 CT sump makeup by Gravity

MAINTAINING UNIFORM BOILER EFFICIENCY AT ALL LOADS

Instead of conventional conveying of coal directly from bunkers to Coal Conveying Feeders(CCFs), we have installed intermediate equipment called Drag Chain Feeder (DCF) along withVFDs to regulate and blend different coals proportionately with the help of weigh feeders, tomaintain consistent boiler efficiency at all loads and seasons irrespective of quality of coal.

INNOVATIVE PROJECT

SAVING OF INPUT ENERGY REDUCTION IN CO2

29245.5 Million kcal. 18169 MT

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BYPASS CHUTE ARRANGEMENT FOR PRIMARY CRUSHER

The imported coal received will be 20-40mm of size. As the size of coal is less than primarycrusher output, conveying coal through primary crusher can be bypassed. For bypassing theprimary crusher, a bypass chute arrangement is made, because of this primary crusherconsumption while stocking imported coal is eliminated.

INNOVATIVE PROJECT

ENERGY SAVED CO2 REDUCED0.08 Million kWh 62.4 MT

REDUCTION OF LDO CONSUMPTION FOR START UP BY REDUCING BOILER STATIC BED HEIGHT

• By reducing the static furnace bed height, oil consumption for startup is reduced andstartup time is also reduced.

INNOVATIVE PROJECT

53 5059

48

33 3125

Feb-14 Aug-14 Dec-14 Feb-15 Sep-15 Nov-15 Feb-16

LDO CONSUMPTION in kL

FUEL SAVED SAVINGS5 kL Rs. 1.325 Million

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AMMONIA DOSING OF ESPAmmonia helps to reduce resistivity of fly ash resulting in betterionization of the particles and increase in collection efficiency of ESPfields.

Principle of Ammonia Dosing

Arrangement for Ammonia Dosing

ENVIRONMENTAL PROJECT

DUST SUPPRESSION SYSTEMInstalled Dust Suppression System for internal roads to reduce dust emissions due to internal vehicle movement.

ENVIRONMENTAL PROJECT

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EMPLOYEE SUGGESTIONSS No SUGGESTION GIVEN BY

1 Providing Intelligent Flow Controller in Compressed air system JM – MM2 Compressor automation according to discharge set pressure M – C&I3 Reduction of BFP discharge pressure from 185 kg/cm2 to 170 kg/cm2 DM – OPN4 Change of BFP cartridge as per system requirement AM – MM5 Modification of AHP conveying airline tapping from bottom to top DM –MM6 Providing the AHP compressor’s air for silos in place of service air M – OPN7 Bypassing primary crusher while stocking imported coal. JM – MM8 Usage of night vision camera for security and also for reducing lighting consumption M – EM9 Change of PA, SA and ID fan impellers for energy saving DM – MM

10 Replacing HT motor of CEP by LT motor with VFD M –EM11 Modification of stair case lighting with separate switch Eng. – EM12 Modification of main conveyor inter locks and discharge chute AM –MM

13Reduction of LP bypass attemperation pressure from 13 kg/cm2 to 11 kg/cm2, thereby reducing discharge pressure of CEP and thus saving energy

Eng.– OPN

14 Changing BFP auto start interlock for Generation <70MW for single pump operation. M – OPN

15 Generator breaker open to AHP and Secondary stop interlock incorporated tominimize MD charges

AM – EM

DAILY MONITORING FORMAT

SHIFT INCHARGE OPERATIONS INCHARGE CGM (O&M)

S No Description UOM25.04.2016 Total till

dateWtd. Avg till

dateValue1 Generation kWh 3386904 79275000 31710002 Average generation MW 141.12 NA 132.133 Plant Load Factor % 94.08 NA 88.084 Auxiliary Consumption Incl. Tr. losses kWh 328904 7963000 3185205 Auxiliary Consumption % 9.71 NA 10.046 Export to Grid (Billed) kWh 3058000 71312000 28524807 Average export to grid (billed) MW 127.42 NA 118.858 Export to Grid (Unbilled) kWh 0 96523 3860.929 Power import from Grid kWh 0.00 0.00 0

10 Average frequency HZ 50.01 NA 50.0211 DM Water consumption m3/day 115 2454 9812 Transmission losses kWh 10730 284000.00 11360.0013 Un-Burnt Carbons % 0 NA 0.0014 Coal consumption: Qty. (MT) SCCL 2496.31 62678.66 2507.1515 LDO Consumption kL 0.00 0.00 0.00

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MONTHLY MONITORING FORMAT

OPERATIONS INCHARGE CGM(O&M)

S No Description UOM April 2016 April 20151 Total generation kWh 95667906 889296002 Auxiliary power ( Excl. Tr. Losses) kWh 9243806 86792643 % of auxiliary power (Excl. Tr. losses) % 9.66 9.764 Avg. GCV of coal (AFB) kcal/kg 3184 36965 Total coal consumption MT 75159 597336 Sp. Coal consumption kg/kWh 0.79 0.677 DM water consumption m3 2986 33768 LDO consumption kL 0 09 Turbine heat rate kcal/kWh 2066 2059

10 Plant heat rate Kcal/kWh 2501 248311 Plant load factor % 88.58 82.3412 Unit availability % 100 10013 Boiler efficiency % 82.61 82.9414 Total export kWh 86074000 7989100015 Transmission losses kWh 350100 35933616 Import from grid kWh 0 0

METHODOLOGY FOR QUANTIFICATIONS No Description UOM Quantified Through

1 Total Generation kWh Power Quality Meter2 Auxiliary Power kWh Energy Meters (Tri-vector Meter)3 % Of Auxiliary Power % (Auxiliary Power x 100)/(Generation)4 Avg. GCV Of Coal (AFB) kcal/kg Feed Coal Analysis5 Total Coal Consumption MT Belt Weighing6 DM Water Consumption m3 Flow Meters7 LDO Consumption kL Flow Meters8 Turbine Heat Rate kcal/kWh Steam input method9 Plant Heat Rate kcal/kWh From Sp. Coal and Coal GCV

10 Plant Load Factor % (Generation x 100)/Installed Capacity11 Boiler Efficiency % Heat Loss Method12 Total Export kWh ABT Meters13 Transmission Losses kWh ABT Meters/Energy Meters (Tri-vector Meter)14 Import From Grid kWh ABT Meters

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CORRECTIVE AND PREVENTIVE ACTIONSS No Non Conformity Action Taken

1 Noise levels at Generatorbrush gear air outlet

Arrangement of Exhaust silencer for Generator brush gear air outlet is done. Noise levels reduced from 105 dB to 88 dB

2 Noise levels in TG building found high.

Arrangement of Generator enclosure is done to reduce the noise levels. Noise levels reduced from 97dB to 88 dB

3 Temperature in TG building12mts. Elevation is high.

Installed Forced Air Cooling System for TG building, thus improving work environment and also helps in improving life of Cables and Instruments. Floor temperature reduced by 4OC

IMS AND EnMS IMPLEMENTATION IN NBEIL

OHSAS18001:2007

QMSIS0 9001:2008

EMSISO 140001:2004

EnMSISO 50001:2011

• NAVA BHARAT ENERGY INDIA LIMITED is certified by Indian Register Quality System

for implementing OHSAS 18001:2007, ISO 9001:2008, ISO 14001:2004 on 13th April

2015.

• NAVA BHARAT ENERGY INDIA LIMITED is certified by Indian Register Quality System

for implementing ISO 50001:2001 on 24th August 2015.

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AWARDS & RECOGNITIONS

Nava Bharat Energy India Limitedis awarded with Certificate ofAppreciation from National SafetyCouncil on National Safety Day