Environmental Assessment

Environmental Audit and Due Diligence Assessment
For R&M of 210 MW, Unit – 6 at Koradi Thermal Power Station
13 October 2008
Environmental Audit & Due Diligence Assessment Report
Contents
EXECUTIVE SUMMARY 3 - 11
è PART 1: INTRODUCTION 12-16
è PART 2: OBJECTIVE AND SCOPE OF WORK 17-19
è PART 3: COMPLIANCE ASSESSMENT 20-28
è PART 4: POLLUTION PREVENTION AND CONTROL ASSESSMENT 29-60
è PART 5: RESOURCE EFFICIENCY ASSESSMENT 61-107
è PART 6: OCCUPATIONAL HEALTH AND SAFETY ASSESSMENT 108-125
è PART 7: INSTITUTIONAL CAPACITY ASSESSMENT 126-134
è PART 8: POTENTIAL RISK AND LIABILITY ASSESSMENT 135-142
è PART 9: ENVIRONMENTAL HEALTH & SAFETY MANAGEMNT ACTION PLAN 143-149
ANNEXURES
DISCLAIMER
Page 1 of 210 Confidential – For Internal Circulation Only

EXECUTIVE SUMMARY Compliance Assessment:
Government of India has launched a programme for Ø During the compliance assessment it was observed that
Renovation and Modernization (R&M) of old coal fired KTPS has complied to most of the conditions specified
power plants in the country. Under this programme, 210 in the consent order issued by pollution control board
MW Unit – 6 of Koradi Thermal Power Station (KTPS), an and as per Maharashtra Factories Rules except for the
existing thermal power station of MAHAGENCO, was few which have been listed below:
considered for R&M.
è flow meters for measurement of fresh water and
In this regard, Ernst & Young Private Limited (E&Y) has effluent in the power plant
been invited to carry out an environmental audit and due è discharge / reuse of storm water with out mixing
diligence assessment (EA-DDA) to review and asses the with trade effluent (The same was not
environmental performance of the plant being proposed for implemented due to practical constraints)
rehabilitation. The overall scope of work for the EA-DDA è no pre-employment medical check up for
also covers Occupational Health and Safety (OH&S) contract workers as well as during the
Assessment and Institutional Capacity Assessment of the employment
plant. è Corporate health and safety policy does not have
the commitment to integrate health and safety in
The final report presented here provides observations and all decisions including those dealing with
recommendations for Compliance Assessment, Pollution purchase of plant, equipment, machinery and
Prevention & Control Assessment, Resource Efficiency material as well as selection and placement of
Assessment, Potential Risk and Liability Assessment, personnel. However, KTPS has framed its policy
Occupational Health & Safety Assessment and Institutional statement at the plant level with the
Capacity Assessment. The report also provides details of aforementioned commitment.
the investment plans, if any, based on the è Corporate health and safety policy is yet to be
recommendation. revised / updated since the formation of
MAHAGENCO from erstwhile MSEB
A summary of key observations and recommendations are
listed below for ready reference.

Pollution Prevention and Control Assessment: Ø Primary data was collected to authenticate the existing
environmental data. Monitoring was carried out for
Ø During the audit period, historical data of the ambient various environmental parameters including AAQ, stack
air quality was analyzed and it was found that there is emissions, water and waste water. Mercury (Hg) was
no degradation of the air shed in the region. The also analyzed in all the parameters to gauge the impact
present particulate matter, NOx and SOx levels are less of pollution due to Hg.
than 50% of the prescribed limit and has the potential to
take additional burden. Ø Air pollution control systems presently available with
KTPS are ESPs and Bag Filters (BF).
Ø Considering the same, KTPS may meet the limit of 100
mg/Nm3 for PM as against 50 mg/Nm3 targeted by Ø Unit 6 has a duel control system of both ESP and BF.
Pollution Prevention Abatement Handbook (PPAH). In Normally BF is in service, with ESP path 15 % open due
rare cases, an emissions level of up to 150 mg/Nm3 may to high dp across the bag Filters. However when the oil
be acceptable. (FO) is fired in the Boiler, only ESP is in service
bypassing the Bag Filters.
Ø The stack emission levels were also analyzed based on
the historic data for 4 years. It was observed that the Ø Based on the data available for stack emission for Unit –
stack emissions were higher than the prescribed limit of 6, it was observed that sometimes the stack emissions
150 mg/Nm3 for all the unit- 7. The PM emission level are exceeding the prescribed limit of 150 mg/Nm3
for Unit 5 was higher than the statute in the year 2003- specified by MPCB.
04 and 2004-05. The same was within the limit for the
year 2005-06 and 2006-07. The decrease in the PM Ø Considering that Unit – 6 has to meet the emission
emission is attributed to the installation of the bag standards of 100 mg/Nm3 as specified by PPAH as well
filter. The PM emission level for Unit 6 was found to be as the proposed revision by the Central Pollution
within the limit for the year 2003-04 and 2006-07. The Control Board (CPCB) the following recommendations
same was exceeding the limit for the years 2004 – 06. are being presented to improve the pollution control
The higher levels during the said period was due to the system of Unit – 6:
inefficiency of the bag filters which was later changed
during the shut down period in the year 2005-06. This è Replacement of BF by upgraded ESP having
contributed to the decrease in the PM emission. higher capacity with more number of fields. The
cost estimate for such an activity would be

approximately INR 250 million. Alternately, preparation which is pumped to the ash bund at
KTPS may also consider replacement of existing Koradi and Khasara. The supernatant is
bags in the BF with more efficient ones. recovered from the ash bund and pumped back
However, the O&M cost for the same is higher into the AHU. Fresh water is used as make up
than that of ESP due to requirement of regular water for ash slurry preparation.
change of bags (i.e. ~every 3 years for cost of è Unit – 6 is equipped with a cooling tower from
INR ~120 million). Therefore, it is not where it is circulated back to condenser. The
recommended. makeup water to the system is received from
è Introducing ammonia to improve the efficiency Pond No. 3 and the over flow of the system is
of the ESP. The same is a plausible alternative circulated to Pond no. 2 which is connected to
and the cost for the same is expected to be INR the main raw water storage pond i.e. no. 3.
0.1 million per MW. The details of the ammonia è One of the ash water supernatant from Khasara
system are given in section – 4.3.8 of the report. ash bund is not being recovered by KTPS. The
quantity of water is estimated to be 33,566
Ø Water is one of the scarce commodities and should be m3/day. However, part of the water is utilized
utilized judiciously. Currently KTPS draws water from back into the system.
the Pench dam which is about 25 km from the plant. è Overflow water from Coal Handling Plant (CHP)
Most of the fresh water used in the plant is being and Booster Pump House (BPH) is being let out
recycled to reduce the quantity of fresh water intake. of the plant boundary with out treatment. The
quantity of water being let out of the plant
Ø During the audit, water flow measurements were taken boundary is estimated to be 16,643 m3/day.
using tracer method and non-contact flow meters. KTPS has initiated work for installation of
Based on the current hydrological scheme of KTPS, the recovery system and tender has been floated.
following were observed: è Boiler blow down and cooling water discharge is
being sent to the ETP for further treatment and
è Raw water is used as makeup water in cooling used for the AHP.
tower as well as for ash slurry preparation.
è DM water is used in the boiler. Ø Based on the observations during the audit, the
è Trade effluent is sent to the ETP, which is following recommendations are being made:
basically a settling tank, from where it is sent to
the ash handling unit (AHU) for ash slurry

è The ash water supernatant from Khasara ash Ø Considering the above scenario, the following
bund should be recovered and recycled back into recommendations are being made:
the system.
è Over flow water from CHP and BPH should be è The raw water pond no. 3 should be cleaned
treated and recycled back into plant. A settling immediately which help in reducing the organic
tank should be constructed near the outlet for load in the pond as well as increase the holding
treatment and recycling. Steps have been capacity.
initiated by KTPS in this regard and tenders have è MAHAGENCO should also see the feasibility of
been floated for the same. constructing a separate pipeline for tapping the
intake water directly from Pench pipeline which
Ø Chemicals are used in the water treatment plant for would help reduce the chemical consumption for
making DM water which is fed into the boiler. Based on water treatment as well as avoid wastage of
the historical data available with KTPS it was observed water such as tapping of water by local
that the chemical usage has been increasing over the population for domestic use.
period. è An estimated 3.0 million could be saved alone
on reduction in the caustic lye used for
Ø Chemicals such as caustic lye have shown increase in treatment of water.
consumption due to increased chloride levels in the raw
water near the raw water pump houses. Also, the Ø KTPS has provided automatic water sprinkler system at
holding capacity of the raw water pond no. 3 has the wagon tipplers and advance fog system at
decreased over the years due to increased conveyers to minimize dust emissions. However no dust
anthropogenic activity around the pond. This has also collection system with dust suppressants is made
resulted in increased organic load and vegetation along available at CHP.
the banks of the pond.
Ø Based on the chemical analysis carried out on the raw Ø Based on the physical observation made during the
water at the source i.e. Pench and near the pumping audit, the following are the recommendations:
house at KTPS it was observed that the chloride levels
are 3-4 times more near the pumping house. The è Dust collection system should be installed at all
treatment using caustic lye to reduce the chloride levels transfer points in the conveyor system to avoid
has increased the financial burden on the KTPS. fugitive dust.

è Dust suppressants should be used during was observed that temperature indicators were not in
sprinkling to retain the moisture level for longer operation in other locations apart from the heaters.
period of time. They are 1.) The outlet feed water temperature, 2.) air
inlet 3.) exit temperature of the air pre-heater etc have
Resource Efficiency Assessment: not been monitored due to the non-availability of
equipments. Therefore it is recommended to identify
The following recommendations are being proposed based the places and install pressure or temperature
on the observations made during the audit period: indicators as per the requirement and monitor the
parameters at regular intervals. However, MAHGENCO
Ø Online power measurement of BFP pumps, ID and FD has installed a central system for monitoring live
fans, CEPs and Coal mills. At present, total auxiliary parameters of all the Power Stations and availability of
consumption is being monitored but by measuring above parameters are addressed in this project.
individual power consumption, the exact loading of the
equipments can be found out. Therefore measurement Ø Measurement of Boiler surface temperature on regular
of power can be included in the log book as a part of intervals. It is recommended to measure the
regular practice temperature of the boiler on regular intervals to check
if the surface temperature is well within the limits. In
Ø Arresting of steam leakages. The steam leakage check case of abnormalities the quality of insulation in the
up can be carried out at regular intervals and arrest the area can be improvised.
same to the extent possible to save energy.
Ø Measurement of coal consumption. Though it is well
Ø Pressure gauges and temperature indicators across known that very few power plants in India have the
the inlet and outlet of the heaters. It was observed facility to measure the coal, but online monitoring of
that some of the pressure guages were not working and the bunkered quantity of coal shall be carried out by
in some places there is no pressure guage. It is also installation of belt weigher to the conveyer belts going
recommended to install temperature indicators at the to the bunker.
inlet and outlet of heaters to measure the steam
temperature and drip temperature. Since the Ø Installation of Smart Wall Blowing System For
performance of heaters would play a major role in Optimizing Wall Blowing And Improving Heat Rate:
efficiency of the plant it is advisable to install the same Installation of SWBS results in following benefits:
and these data can also be included in the log book. It

è Reduced variation in SH/RH spray, hence steady Occupational Health & Safety Assessment:
SH / RH steam temperature. This results in
improved efficiency of boiler and heat rate of Ø It was observed that the number of accidents have
overall cycle. increased during 2002-04. During 2004-05, a declining
è Reduced superheated steam consumption due to trend has been observed in the number of accidents
reduced number of wall blowing. including minor injuries such as pin prick, sprained back
è The soot blower operation is reduces by about or foot, slip on plain road. However, in the year 2006,
55 - 60% compared to conventional wall blowing the plant, on an average, witnessed one accident every
system. second week.
è Reduction in tube erosion due to selective and
reduced steam blowing Ø It was observed that unsafe acts have contributed to
è Annual energy saving of INR 5.25 million was more than half of the accidents that have occurred in
achieved. the plant since 2004. However, the number of accidents
and unsafe acts has shown a decline in the numbers
Ø Introduction Of Super Cleaning Of Turbine Oil: The over a period.
introduction of super cleaning of turbine oil will result in
following benefits: Ø A detailed root cause analysis for each of the
observations has been provided in section – 6.2 of the
è Average Oil consumption has been reduced to 76 report
barrels from 145 per year.
è Reduction in sludge formation at the bottom of Ø Some of the major observations and recommendations
Main Oil Tank. at KTPS with respect to OHS are given below for ready
è No Governing problems are faced due to reference.
chocking of governing components.
è Installation of super cleaning system has è EHS Policy: EHS policy is yet to be revised since
resulted in many tangible and intangible the restructuring of MSEB in 2004. However, it
benefits. Total cost saving of INR 7.196 million was informed by MAHAGENCO that the same
has been achieved. was being revised and will be circulated among
all the plants once approved by the board.
è Risk Analysis Study: KTPS has conducted a Risk
Analysis study at the plant and detailed action

plan is prepared and implemented through è Training for contract workers: Contract worker
OHSAS. participation is very limited in safety specific
è Near Miss Reporting: KTPS has put in place a training and awareness programmes.
near miss incident reporting system. The same è Rotation of Work: Comprehensive
has been communicated to various departments. documentation with regard to classification of
KTPS is also taking steps to increase the diseases based on occupational exposure was
workers participation in the system. not found in place.
è OHS Audit: As per the existing corporate policy, è Comprehensive procedures for administrative
OHS audit is to be conducted every year. Though controls such as rotating employees and
the OHS audit was not conducted every year, imparting trainings on performing tasks in ways
MAHAGENCO has carried out OHS audit during that reduce exposure to work place hazards
2004 & 2007. Subsequently KTPS has also taken were not found in place. It was informed that
initiative to implement OHSAS 18001:2007 despite having medical problems, which may be
management system. aggravated due to occupational exposure,
è Fire Fighting Department: No deviations from workers have not been keen on rotation of work.
scheduled standard test and examination of fire è Reportedly, the workers have resisted attempts
service equipment and fire protection system by the top management to transfer workers from
were observed during the site visit. However, one department to the other. Workers
some deviations were noticed with reference to interviewed during the site visits have also
the recommendations by The Fire Advisor & indicated their preference to continue working in
Chief Fire Officer. The same are already been the same department.
informed to and accepted / approved by the FA è Safety / mock drills: Safety and mock drills with
& CFO. regard to acid leak, chlorine leak, fire and
è House Keeping: During the site visit, Disaster Management Plan (DMP) are
housekeeping, lighting and ventilation were conducted periodically to check the
observed to be poor in the plant for safe working preparedness of the emergency response
of occupant, specifically in the CHP area. At the system, records of which are being maintained
time of site visit, the dust suppression system by the safety department. Observations and
and fresh air system in CHP were found not in recommendations made during mock drill that
operation. Several gas cylinders were found required corrective measures have not been
without seal in the storage yard. addressed promptly.

è Further, it was observed the responsibility of è Observations made during mock drill, which
implementing these observations was not clearly require corrective measures, should be given
assigned to any individual. Also, no priority and addressed immediately for
comprehensive documentation was found in improving the efficiency of the emergency
place with regard to action points / measures preparedness and response. Specific individuals
taken to address observations made during mock should be assigned the responsibility of ensuring
drills these action points are addressed, as and when
è At present, OHSAS 18001 system is being identified. Action points taken and status of the
implemented at KTPS and it was informed by observations requiring corrective measures
KTPS that the above observations are being should be documented to keep track of the
improved upon as part of the management performance of the system.
system. è A comprehensive Root Cause Analysis (RCA) by
è Accident Investigation: Accidents are the Safety Department would help in identifying
investigated and recorded. However, a the root cause for the accident and placing
comprehensive Root Cause Analysis (RCA) of systemic controls and for ensuring avoidance of
all the accidents is not carried out. similar mishaps in future. During the audit, a
sample accident case was taken and a RCA was
Ø Some of the recommendations for OHS are as follows: carried out and provided to the safety
department.
è Safety specific training and awareness programs
should be made mandatory for contract labors. Institutional Capacity Assessment:
è Classification of diseases based on occupational
exposure should be documented. In order assess the institutional capacity at KTPS to handle
è The workers and worker unions should be the R&M of Unit -6, an assessment was carried out on the
sensitized towards the need and benefits of same. Based on the assessment, the following were the
rotation of work. A rotation of work policy could major observations and recommendations.
be framed and workers at the time of
recruitment should be informed about the policy Ø Institutional Setup: The environmental monitoring
and the probability of inter departmental cell (EMC) is headed by section head of Water
transfers. Treatment Plant (WTP) of stage – II.

Ø The safety department and EMC report to different would enable to integrate environmental issues with
Section Engineers (SEs) of two different stages i.e. safety and health issues at the plant level leading a
Stage I and II. comprehensive EHS system.
Ø Training: KTPS has an in-house training facility and Ø Feedback on the training sessions should be taken
trainings at various levels are provided with in- from the people attending the training at the end of
house experts from various departments. the training session. The feedback should be
Ø Feedback is given by the sectional heads to the concealed and the same should be directly
trainers based on the information provided by the submitted to the HR department for further action.
participants from their section. Ø KTPS should also inform the village panchayat office
Ø Addressing stakeholder Concerns: During the the procedure for lodging written complaints with
stakeholder consultation process, the gram KTPS or the concerned authorities responsible for
sarpanch (village head) of Koradi village informed environmental management.
that their office does not have the proper guidance/ Ø KTPS may also provide a drop box at the entrance
information as to whom to approach within the KTPS (near security cabin), which is easily accessible by
to communicate the view or concerns of the the local residents. It shall be used to submit
villagers. It was also informed that the lack of concerns in writing. The drop box would be under
knowledge leads them to raise their issues with the the jurisdiction of PRO of KTPS.
local elected member of the Legislature who in turn
communicates the same with the plant
Ø It was informed by KTPS that a Public Relations
Officer (PRO) has been appointed and same was
communicated to the villagers so that they can meet
the PRO to put forth their grievances. A board has
also been displayed at the entrance of the plant
regarding the same.
Some of the recommendations for the observation made

are given below:
Ø KTPS may bring the sectional heads of EMC and

safety department under one supervisor which

Risk and Liability Assessment: Ø Community Engagement: During the interaction it

was mentioned by the sarpanch that KTPS does not
In order to assess the impact of the plant operation on the have in place a structured process to engage with
local community and the risk and liabilities associated with the community. It was also informed during the
the same, a local stake holder engagement was carried out interview that the village panchayat is not aware of
during the audit period. The observations / findings during a concerned person whom they can approach for
the same are summarized below: assistance with issues related to the community and
KTPS. However, officials from KTPS were
Ø Rehabilitation and Resettlement Programme: The interviewed, who informed that a Public Relations
Sarpanch and the villagers interviewed indicated Officer (PRO) has been appointed by KTPS to
their satisfaction with the resettlement and collect grievances from the villagers and provide
rehabilitation program of the erstwhile MSEB. The appropriate response. A board has also been
interviewed villagers indicated that they were amply displayed at the entrance of the plant which
compensated for their loss and were provided with indicates whom one can meet to discuss their
land in lieu of their land acquired by MSEB and were grievances. The same was also verified during the
provided with employment opportunity at the plant site visit.
as well.
Ø Water pollution and access to potable water: Ø As mentioned above, a drop box can also be used to
During the interview it was informed that the collect the concerns of local residents and the same
surrounding villages have access to potable water can be addressed appropriately by the PRO /
and do not face any problem in terms of water relevant departments of KTPS at regular intervals.
pollution due to the activities of the power plant.
However, the resident of Mhasala village, which is
located adjacent to the Khasara ash bund, indicated
that during summer, due to scarcity of potable
water, they are forced to drink the river water which
has ash supernatant. In order to verify the
aforementioned statement ground water and
surface water samples were collected and analyzed
during the audit period and the water was found to
be adhering to the norms specified by the CPCB.

PART 1.0: INTRODUCTION having multiple units) for rehabilitation in particular has
been proposed. In order to carry out the EA-DDA of KTPS,
1.1. PURPOSE MAHAGENCO has retained the services of Ernst & Young
Pvt. Ltd.
Government of India has launched a programme for
Renovation and Modernization (R&M) of old coal fired 1.2. KORADI THERMAL POWER STATION (KTPS)
power plants in the country. This programme, the
Partnership for Excellence, includes a financing window, In 2005, as per requirement of the Electricity Act of 2003,
funded by the World Bank and GEF, for rehabilitation the Maharashtra State Electricity Board (MSEB) was split
projects that prioritize energy-efficient outcomes. into three companies: Mahanirmiti or Mahagenco
(Maharashtra State Power Generation Co. Ltd.);
Under this programme, 210 MW Unit – 6 of Koradi Thermal Mahavahan or Mahatransco (Maharashtra State Electricity
Power Station (KTPS), an existing thermal power station Transmission Co. Ltd.); and Mahavitaran or Mahadiscom
of Maharashtra State Power Generation Co. Ltd. (Maharastra State Electricity Distribution Co. Ltd).
(MAHAGENCO), was considered for R&M.
1.3. INSTALLED CAPACITY OF KTPS
The following aspects have been covered as part of the
overall EA-DDA KTPS has 7 units adding to a total generation capacity of
(a) Understanding the existing performance of the 1100 MW. The ground breaking ceremony for KTPS was
plant in terms of energy efficiency and held on 25th December 1968 and the first unit (Unit -1) of
environment 120 MW was commissioned in the year 1974. The following
(b) Techno-economic aspects with respect too which are the details of the installed capacities of KTPS, Nagpur:
the benefits would be achieved through R&M
Stage I – Units 1 to 4: 120 MW each (Boiler: ABL Kolkata;
In order to assess the energy efficiency and environmental TG: ZAMECH, ELBLAG, Poland)
performance of the plant being proposed for rehabilitation, Stage II – Unit 5: 200 MW (Boiler and TG: BHEL India);
an Environmental Audit, that would provide information Unit 6 and 7: 210 MW (Boiler and TG: BHEL India)
about key environmental issues related to overall
performance, as well as the state of compliance (with Unit 1 to 4 have been de-rated to 105 MW each from its
applicable regulations and industry best practices) in the original capacity of 120 MW each by Central Electricity
plant in general and in the unit proposed (in case of plants Authority (CEA).

The plant is certified with ISO 14001:2004 and 9001 Ø Mr. R P Gokul
management systems. The plant is also implementing Ø Mr. Raja Raghavan
OHSAS 18001:2007 management system. Ø Mr. Jayanth Chetlur
Ø Ms. Shilpi Singh
1.4. ENVIRONMENTAL SETTINGS OF KTPS
During the site visit, the following officials of KTPS were
Koradi Thermal Power Station (KTPS), one of the power contacted to discuss and understand the operations of
generation units of MAHAGENCO, is located in Koradi KTPS with regard to Environmental Health and Safety
approximately 11 kms from Nagpur (The Orange City) on performance as well as resource efficiency assessment.
the Nagpur - Chindwara highway. Table – 1 provides the The key persons among them were:
details of the environmental setting of KTPS.
Ø Dr. V. V. Wanjari (Medical Superintendent)
1.5. SITE VISITS, DATA COLLECTION & REPORT Ø Mr. P. K. Khurana (Ex. Chemist, Stage II)
DISCUSSIONS Ø Mr. D. S. Dhakate (Exe. Engineer - POG)
Ø Mr. A. K. Kapoor (Safety Officer)
An initial site visit was carried out during 18th July 2007 Ø Mr. Ajay G. Telang (Dy. Executive Engineer –
and 21st July 2007 by Ernst & Young Pvt. Ltd. (E&Y) R&M)
team to collect all the necessary basic information to Ø Mr. M. N. Naisal (Dy. EE-CHP)
understand the EHS performance of KTPS. Ø Mr. Milind Dharmadhikari (Chemist, Stage II)
Ø Mr. S. S. Bagchi (Chemist, Stage II)
The site visit included data collection and reconnaissance Ø Mr. Mongse (Chemist, Stage II)
survey of the plant and its associated facilities. Prior to the
initial site visit, E&Y had communicated to KTPS, the
preliminary list of documents / information which would be
required to carry out the Environmental Audit and Due
Diligence Assessment (EA-DDA).
The E&Y team comprised of the following members:
Ø Mr. Sujeet Kishen

Ø Mr. Hemant Nandanpawar

TABLE 1: ENVIRONMENTAL SETTING
S. No. Particulars Details

1. Location
I Village Koradi
II District Nagpur
2. Latitude 21° 15.341’ N
3. Longitude 79° 05.071’ E
4. Elevation above MSL 304.75 m
5. Climatic conditions
I Mean Annual Temperature Maximum 45.8oC (May)and Minimum 8.4oC (Dec)
II Relative Humidity 60%
III Wind Speed Range Maximum 20 km/hr and Minimum 6 km/hr
IV Predominant Wind Direction Monsoon: Southwest; Winter: Northeast and
Summer: All directions predominantly from Southwest
V Average Annual Rainfall 1074.56 mm
6. Nearest National Highway Nagpur – Chindwara Highway
7. Nearest Railhead Nagpur
8 Nearest Airport Nagpur
9 Nearest Tourist Place Nagpur
10. Archeological important places -
11. Ecological Sensitive Areas -
(Wild Life Sanctuaries)
12. Reserved/Protected Forest within 10-km -
radius
13. Industries in 7-km radius Khaparkheda Thermal Power Plant, MAHAGENCO
14. Nearest major city with 3,00,000 population Nagpur, 11 Kms
15. Nearest Town -

16. Villages within 1-km radius surrounding the Koradi

project
17. Nearest River Peanch River
19. Source of Water River Water, Peanch River
20. Soil Type Silty Clay to Loam

FIGURE 1: DISTRICT MAP OF NAGPUR
Koradi Village -
Plant Site
Source: Maps of India

PART 2.0: OBJECTIVE &SCOPE OF WORK w Assessment of environmental clearance /

consents applicable under different
2.1. OBJECTIVE environmental regulations
w Compliance with applicable environmental
The objective of the assignment is to establish and assess standards / stipulations for the various
the baseline environmental performance of the KTPS with environmental aspects coal use, water use,
respect to: stack emissions, noise generation, effluent
generation, effluent quantity and effluent
Ø compliance with regulatory requirements; disposal, AAQ, ambient noise levels, pollution
Ø adequacy and effectiveness of pollution prevention in water bodies receiving effluent from the
and control measures, waste minimization and plant, disposal / utilization of ash, and any
resource conservation measures, and other specific stipulations that are applicable
Ø occupational health and safety management systems; to the plant.
w Assessment of the special
with a view to identify appropriate technical, financial, requirements/conditions stipulated for the unit
institutional and management measures to improve the vide various consents / clearances.
environmental performance of the plant including w Assessment against the applicable World Bank
mitigation of potential / perceived environmental risks / standards i.e. as per Pollution Prevention and
liabilities as part of the proposed rehabilitation program. Abatement Handbook guidelines.
2.2. SCOPE OF WORK Ø Pollution Prevention and Control Assessment: This

includes reviewing the adequacy and effectiveness of
The scope of work for the Environmental Audit and Due the pollution control equipments in reducing the
Diligence Assessment (EA – DDA) as per the Work Order pollution for the entire facility. The assessment
presented include the following aspects: includes:
Ø Compliance Assessment: Regulatory compliance w Measures / systems to improve coal quality,

assessment for the entire plant covering all the 7 combustion efficiency and heat recovery;
units and its common facilities includes the following: w ESPs / other particulate collection systems in
different units
w NOx control systems

w Noise control systems q Workers safety equipments

w Water recycling systems and effluent treatment q Safety drills
systems q Periodic health check up for workers
w Dust suppression systems q Rotation of work and minimization of
w Ash pond (ash water decanting and containment exposure
of ash slurry in the pond) q Emergency management plans
Based on the data collected, baseline pollution parameters Ø Potential Liabilities / Risks: This includes
for the following to be established: particulate matter consultation with the following stakeholders to
(kg/kWh), SO2 emissions (kg/kWh), NOx (kg/kWh), identify potential environmental liabilities to the
mercury emissions (g/MWh) and ash generation (kg/kWh) power plant:
Ø Occupational Health, Safety Assessment (OHS): This w Plant management,

includes verifying the following with regards to OHS w people living in the vicinity,
and emergency management aspects. w project affected persons,
w PRIs,
w Regular protocols for safety of workers w local NGOs, and
working in hazardous work place; w State Pollution Control Board (SPCB)
w Records of accidents and emergency
responses; Pollution effects due to presence of Mercury (Hg) will also
w Systematic monitoring and maintenance of be studied as part of the risk and liability assessment.
health records, etc;
w Evaluate readiness and capacity of the Ø Resource Efficiency Assessment: As part of the
emergency management systems to cope with resource efficiency, the following shall be reviewed
incidents varying from small spills to major for a detailed resource efficiency assessment for
accidents; Unit – 6 will be carried out which is proposed for
w Specific review with respect to the following R&M
for evaluating their adequacy and
effectiveness; w Assessment of historical performance of
efficiency parameters and comparison with
q Fire fighting systems

their design parameters. The parameters • Ensuring compliance with the applicable
include national and state level regulatory
requirements and any specific stipulation on
q Primary fuel use the plant
q Auxiliary fuel use • Meeting the requirements of applicable PPAH
q Unit heat rate guidelines and an assessment of their
q Specific water consumption feasibility
q Auxiliary power consumption • Improving the various resource efficiency
parameters of Unit – 6 towards their
w A detailed material and energy balance respective design parameters as well as
assessment will be carried out for different towards the industry best practices,
stages of power production to identify the applicable to similar plant and technologies
losses which could be minimized. • Preparing a matrix comparing the proposed
interventions against their environmental
Ø Institutional Capacity Assessment: This will review benefits related to reduction in pollution,
the institutional setup and resources available improvement in energy efficiency, reduction
within the plant for ensuring sound environmental in greenhouse gas emissions and risk
performance and assess their adequacy and mitigation.
effectiveness. The review would include the
following: Ø Preparation of investment plan: Based on the
measures identified to mitigate the potential
w Institutional setup for environmental risks and liabilities, a cost benefit analysis for
management different interventions to be made by developing
w Systems and procedures a matrix. Any additional investments required to
w Training achieve the industry best practices to be
w Mechanisms for addressing public concerns specified and provided separately in the report.
Ø Identification of interventions: This includes

identification of interventions with regard to the
following:

PART 3: COMPLIANCE ASSESSMENT 3.2. OCCUPATIONAL HEALTH & SAFETY (Laws &
Regulations)
The applicable environmental laws and regulations for
Koradi Thermal Power Station (KTPS) are presented Ø The Factories Act & Maharashtra Factories Rules
below for reference. The compliance assessment of plant Ø The Electricity Rules
has been carried out taking into consideration the below Ø Gas Cylinder Rules
mentioned laws and regulations. Ø The Petroleum Act & Rules
Ø SMPV Rules
3.1. ENVIRONMENTAL (Laws & Regulations) Ø Boiler Act & Regulations
Ø Dangerous Machines (Regulations) Act.
Ø Air (Prevention & Control of Pollution) Act & Rules Ø The Maharashtra Factories (Control of Industrial
Ø Water (Prevention & Control of Pollution) Act & Major Accident Hazards) Rules
Rules Ø The Maharashtra Safety Officers (Duties,
Ø Water (Prevention & Control of Pollution) Cess Act Qualifications and Conditions of Service) Rules
& Rules
Ø Public Liability Insurance Act & Rules
Ø National Environment Tribunal Act
Ø CPCB Charter on CREP
Ø Environment Protection Act
o Environment Protection Rules
o Hazardous waste (Management & Handling)
Rules
o MSIHC Rules
o Noise (Regulation & Control) Rules
o Batteries (Management & Handling) Rules
o Bio-Medical waste (Management & Handling)
Rules
o Fly Ash Notifications
o EIA Notification

3.3 ENVIRONMENTAL COMPLIANCE Ø Show Cause Notice under Clause (b) of Sub-Section
(4) of Section 25 of the Water (P&CP) Act, 1974
The first unit of KTPS was installed in the year 1968 and vide letter no MPCB/PCI-II/TB/SCN/B-3660 dated
the last unit (Unit -7) was commissioned in the year 1984. 06/11/2006
Since all the units of KTPS were installed prior to the
formulation of the Environmental Protection Act, 1986, 3.3.1. Summary of Findings
KTPS did not require a Environmental Clearance for
establishment as well as operation from Ministry of During the audit it was observed that most of the
Environment and Forest (MoEF), New Delhi. The first conditions specified in the consent order are being followed
Consent to Operate was issued to the plant in the year by KTPS except a few. The detailed checklist of compliance
1989 by Maharashtra Pollution Control Board (MPCB). The assessment is provided below.
latest Consent to Operate, was issued by MPCB, under the
Air Act, Water Act and Hazardous Waste (M&H) Rules, on
28th December 2006 and is valid till 30th September 2011.
The same document has been considered for assessing the
compliance against the conditions specified in the consent
order.
KTPS has been served Show Cause Notice thrice in the

past, by the MPCB, for violation of the environmental
regulations. The compliance to these notices was also given
by KTPS to MPCB, which were accepted by MPCB. The
details of the Notices issued has been given below:
Ø Show Cause Notice vide letter no.

MPC/NRO/1653/2004 dated 16/09/04
Ø Proposed Directions under Section 33A of the Water
(P&CP) Act, 1974 and Under Section 31A of the Air
(P&CP) Act, 1981 vide letter no.
MPC/NRO/Directions/52/2490/2004 dated
25/11/2004

S. Compliance Requirement Observations

Compliance
No.
1 Quantity of Trade As per the consent order, the trade Based on the data reviewed during
Effluent effluent quantity should not exceed the audit it was found that the trade
69522.0 cu.m./day effluent quantities are not
exceeding the consent limits.
However, the actual quantities of Partial Compliance
the effluent discharge could not be
verified as there are no water
meters / flow meters installed to
measure the same.
2 Quantity of Sewage As per the consent order, the domestic Based on the data reviewed during
Effluent effluent quantity should not exceed the audit it was found that the
2000.0 cu.m./day domestic effluent quantities are not
exceeding the consent limits.
However, the actual quantities of Partial Compliance
the effluent discharge could not be
verified as there are no water
meters / flow meters installed to
measure the same.
3 Treatment of Trade As per the consent order, KTPS should Based on the review of test reports
Effluent provide comprehensive treatment of treated effluent it was found that
system consisting of primary/secondary KTPS is meeting all the required
and/or tertiary treatment as in standards prescribed as per the
warranted with reference to influent consent for treated effluent
Yes
quality and operate and maintain the discharge.
same continuously so as to achieve the
quantity of the treated effluent to the
standards prescribed in the consent
order.


Compliance
No.
4 Separate meters to As per the consent order, the factory Energy meters are provided to
monitor energy authorities shall install separate meter monitor the energy consumption of
consumption for showing consumption of energy for the ETP.
STP and ETP operation of domestic and industrial
effluent treatment plants. The quarterly The quarterly returns of the energy
Yes
returns of the energy consumption shall consumption are being submitted to
be submitted to Board Office under the Board as required by the
intimation to respective Regional and Consent Order.
Sub-Regional Officer on each 10th of
January, April, July and October.
5 Flow meters for As per the consent order, KTPS should Flow meters have not been provided
measurements of provide flow meters for measurement of as required by the consent order.
flow of the effluent flow of the effluen No
6 Daily water As per the consent order, the daily water The quantities of water used for the
consumption consumption should not exceed as given aforementioned purposes were
under found to be with in the limits
prescribed in the consent based on
Consumption the data made available by KTPS
(Cess records). However, due to
S. Description Quantity non-availability of flow meters, Partial Compliance
NO. (m3/day) actual measurements were not
1 Domestic 12000 possible.
2 Industrial 15000
Process
3 Industrial 90000
cooling/boiler


Compliance
No.
7 Dust collection As per the consent order, KTPS should KTPS has initiated the work for
system at CHP provide dust collection system at the provision of dust collection system
CHP to control the SPM from the crusher at CHP. In-progress
units and other sources.
8 Hooding and As per the consent order, the coal KTPS has initiated the work for
Ventilation handling system shall be covered with provision of hoods and ventilation
arrangements for proper hooding and ventilation system at CHP.
In-Progress
CHP arrangements connected to dust
suppression agent so as not to allow any
fugitive emissions
9 Installation of As per the consent orders dated Daily monitoring of AAQ with
continuous ambient 22/11/2001 and 28/12/2006, KTPS CAAQMS, as suggested in the
air quality and should install three continuous ambient consent order, is not being carried
micrometeorological air quality and micro-meteorological out and the same is not being
monitoring station monitoring station at location indicated reported to State Board. However,
by SPCB. Also, as per consent order the AAQ is being monitored twice a
dated 22/11/2001, KTPS shall install week as per NAAQ standards. In-Progress
continuous ambient air quality
monitoring station and in the event the The continuous AAQ monitoring
same cannot be provided, the AAQ will system is being installed.
be monitoring every day and the daily
report be submitted to the Regional
Office.
10 Disposal of As per the consent order, KTPS should The hazardous waste including ETP
hazardous waste sell the used/spent oil to the SPCB sludge containing chemical waste is
authorized third party and waste being disposed as required by the Yes
containing oil and chemical sludge from MPCB norms.
ETP should be disposed off in the TSDF.


Compliance
No.
11 Mixing of storm As per the consent order, KTPS should The storm water from the storm
water and discharge not allow mixing of storm water and water drains is being let into the
No
from other premises discharge from other premises with the ETP and mixed with the trade
(Not practically
with trade effluent trade effluent. effluent which is being used for
feasible)
preparation of ash slurry and then
disposed off in the ash pond.
12 Factory License KTPS currently holds the license to It was informed that KTPS employs
employ 2500 employees. KTPS currently following numbers of contract labor
has 2141 employees on its rolls a) 477 nos for cleaning, b) 1009
nos for annual maintenance, c)
1005 nos Plant maintenance.
Partial Compliance
Daily Attendance records to
demonstrate that the number of
employees employed in a day has
not exceeded the licensed number
were not produced on request.
13 Medical Check up KTPS currently has 2141 employees on The health register in Form 7
its rolls. provided indicated that Medical
Checkup was conducted only for Partial Compliance
1785 employees.
14 Medical Check up U/r 73-V (1) (b) of the Maharashtra The health register made available
Factories Rules, 1963, Workers indicated that the workers are being
employed in a ‘hazardous process’ shall examined once in a year.
be medically examined by the Factory No
Medical Officer once in a period of 6
months to ascertain the health status of
all the workers in respect of occupational


Compliance
No.
health hazards to which they are
exposed. Power Generation is included in
the First Schedule to the Factories Act,
1948 as a hazardous process.
15 Medical Check up U/r 73-V (1) (b) of the Maharashtra Records for medical examination of
Factories Rules, 1963, Workers contractor workers were not
employed in a ‘hazardous process’ shall provided on request.
be medically examined by the Factory
Medical Officer once in a period of 6 The number of workers employed
months to ascertain the health status of through contractors were not
all the workers in respect of occupational included in the returns filed.
No
health hazards to which they are
exposed.
U/s 2 (l) of the Factories Act, 1948,

worker means any person employed,
directly or by or through any agency
including a contractor.
16 Communication to U/r 73-W (2) of the Maharashtra Certificates for the said qualification
Chief Inspector Factories Rules, 1963, the Factory were not produced on request.
about appointment Medical Officer (FMO) shall possess a
of Factory Medical Certificate of Training in Industrial
No
Officer Health of minimum three month duration
recognized by the State Government or
possess a diploma in Industrial Health or
equivalent.
17 Pre-employment U/r 73 V (1) (a) of the Maharashtra Records for pre-employment
Medical Check up Factories Rules, 1963, Workers medical examination of contractor In progress
for Contract labour employed in a ‘hazardous process’ shall workers were not provided on


Compliance
No.
be medically examined by the Factory request.
Medical Officer once before the
employment to ascertain physical fitness
of the person to do the particular job.
18 Testing of Pressure U/r 65 (4) of the Maharashtra Factories Test reports for the pressure
Vessels Rules, 1963 Every pressure plant in vessels were produced on request.
Yes
service shall be thoroughly examined by
a competent person.
19 Health & Safety U/r 73-L (5) (f) of the Maharashtra The health and safety policy of the
Policy Factories Rules, 1963, The Health and corporate does not have the said
Safety should specify its intention to commitment. However, KTPS has
integrate health and safety in all framed its own policy statement
Partial Compliant
decisions including those dealing with with the above commitment.
purchase of plant, equipment, machinery
and material as well as selection and
placement of personnel.
20 Health & Safety U/r 73-L of the Maharashtra Factories KTPS has initiated the work for
Policy Rules, 1963, the occupier shall revise obtaining OHSAS certification and
the Safety Policy as often as has prepared its plant level policy
appropriate. statement. However, the Safety Partial Compliant
Policy at the corporate level has not
been updated since restructuring of
MSEB.
21 Structural Stability U/r 3-A of the Maharashtra Factories The said certificate for testing
Certificate Rules, 1963, no manufacturing process conducted within the last five years
shall be carried out in any premises of a was produced on request.
Yes
factory unless a fresh certificate of
stability in Form1-A is obtained from a
competent person.


Compliance
No.
22 Certificate of U/r 73-W (4) of the Maharashtra The said communication to the Chief
Training for Factory Factories Rules, 1963, Within one month Inspector was not provided on
Medical Officer of the appointment of the Factory request.
No
Medical Officer (FMO), the occupier of
the factory shall furnish to the Chief
Inspector the particulars of the FMO.
23 Application for The data provided in Column 4 against Male: 1567.91 and Women: 28. 58.
Renewal of license “Maximum number of workers to be The register was produced as
employed on any during the year” in the requested.
Yes
application for the license in Form 3 to
be filed under Rule 8 for the renewal
license was
24 Data provided in The annual return filed U/r 119 (1) of The numbers of workers employed
Annual Return the Maharashtra Factories Rules, 1963 through contractors were not
for the year 2006 year indicated the included in the returns filed.
number of Male workers as 2104 and
Women workers as 37. These were the
permanent employees of Mahagenco. No
U/s 2 (l) of the Factories Act, 1948,

worker means any person employed,
directly or by or through any agency
including a contractor.
25 Register for U/r 65 (7) (1) of the Maharashtra The said register was produced on
Pressure Vessels Factories Rules, 1963, the manager shall request.
Yes
maintain a register of pressure plant or
pressure vessels with its particulars.

PART 4: POLLTUION PREVENTION AND CONTROL Ø Assessing plant’s overall performance vis-à-vis
ASSESSMENT applicable national and state level laws and
regulations.
Koradi Thermal Power Station (KTPS) and MAHAGENCO
are committed towards maintaining a sound environmental The areas covered during the study included assessing the
management of the plant and are aiming towards achieving efficiency of ESPs / Bag Filters of all the units, NOx control
the same by recognizing the sources of pollution and taking systems, Noise Control Systems, Water Recycling Systems,
preventive and control measures to keep the same within Effluent Treatment Systems, Dust Supression Systems and
the standards / stipulated limits. As part of the initiative, Ash Pond (ash water decanting as well as containment of
KTPS has also taken up Environmental Management ash slurry in the pond).
System as per ISO 14001.
Our approach for pollution prevention and control
As part of the overall EA-DDA, the pollution prevention and assessment has been provided in subsequent page of the
control assessment was carried out to review and assess report
the adequacy and effectiveness of the existing pollution
control systems at KTPS and to suggest necessary
measures to improve the environmental performance of the
plant in terms of prevention and control of pollution.
The key objectives of the assessment included:
Ø Understanding the various sources of pollution from

the plant;
Ø Establish the baseline pollution (with the present
set of pollution control systems) for various
parameters such as Particulate Matter, SOx, NOx,
and Hg;
Ø Review of the existing pollution prevention and
control initiatives;
Ø Assessing the adequacy and effectiveness of the
existing pollution control systems; and

APPROACH FOR POLLUTION PREVENTION AND CONTROL ASSESSMENT
Understand the existing sources of pollution from KTPS
Establish baseline pollution for various parameters
Review the existing pollution prevention and control initiatives
Assess the adequacy and effectiveness of the pollution prevention and

control systems
Assess the plants overall performance against the applicable laws and
regulations in terms of pollution prevention and control
Mitigation measures / recommendation for improvement in the systems

4.1 SOURCES OF POLLUTION the locations identified by the State Pollution Control
Board.
KTPS is a coal based electricity generation plant. The major
sources of pollution from a coal based thermal power Historic data of 4 years on stack emissions and AAQ was
station are air emissions, waste water discharge and solid collated, during the audit period, in order to understand the
waste discharge. existing environmental scenario in and around the plant
based on the data and also to gauge the authenticity of the
4.1.1. AIR POLLUTION data based on the independent monitoring at the site
during the audit period.
The major sources of air emissions are from the stacks
attached to the ESP/Bag filter and fugitive emissions at The data included monitoring reports from the third party
CHP. The details of the stacks are tabulated below as Table laboratory carrying out monitoring on behalf of
- 2. MAHAGENCO. The analysis of the data provided is
presented below.
4.2 POLLUTION CONTROL EQUIPMENT
The pollution control equipment for control of stack

emissions is Electrostatic Precipitators (ESP) and Bag
Filters (BF). Units 5 & 6 have dual system of ESP and BF.
Units 1 to 4 and 7 have ESP. The ESP along with BF is
taken in service with 10% maximum opening, if Flue Gas
APH Outlet temperature exceeds 160oC, or DP exceeds
200, or Furnace draft goes positive.
4.3 EXISTING ENVIRONMENTAL MONITORING DATA
KTPS has been regularly carrying out monitoring of

environmental parameters such as stack Monitoring, AAQ,
noise, water and waste water by employing a third party
monitoring agency. The monitoring is being carried out at

TABLE 2: STACK DETAILS (Source: Monitoring Report, VIMTA LABS)
Stack Details (Unit) Stack Duct Dia(m) Flue gas Flue gas velocity(m/s) Pollution Control
Height(m) Temp(oC) Equipment
Stack 1 (Unit 1 & 2) 76 2.98 x 6.50 Unit 2: 122 Unit 2: 10.5 ESP
Stack 2 (Unit 3 & 4) 76 2.98 x 6.50 Unit 3: 129 Unit 3: 11.2 ESP
Stack 3 (Unit 5) 90 2.80 x 4.00 A: 140 A: 16.70 ESP / Bag Filter
B: 141 B: 24.53
Stack 4 (Unit 6) 90 2.80 x 4.20 A: 145 A: 23.14 ESP / Bag Filter
B: 143 B; 22.21
Stack 5 (Unit 7) 90 3.15 x 3.15 A: 142 A: 14.4 ESP
B: 145 B: 17.4

4.3.1 Ambient Air Quality from the aforementioned reason, PM emissions from the
stack especially Units of Stage II i.e. Units 5, 6 & 7 are
Ambient Air Quality (AAQ) is being monitored at three contributing to the increase in SPM levels.
locations specified by the SPCB. The monitoring is being
carried out twice a week at all locations by KTPS. In order to authenticate the existing data, ambient air
quality monitoring was carried out during the audit period
In order to analyze the air shed quality in the area, AAQ at 5 locations. The location where the AAQ monitoring was
data of four years i.e. from 2004-05 to 2007-08 has been carried out has been presented below. The locations were
considered. The data was compared with the applicable selected based on the norms prescribed by the Central
standards to check the compliance with the limits Pollution Control Board (CPCB) and the predominant wind
prescribed i.e. 500 µg/m3 for particulate matter (24 direction in the area during the monitoring period.
hourly) as the area is categorized as industrial zone.
It was observed that the parameters such as SPM, NOx and
The review of the data showed that the SPM, SOx and NOx SO2 were found to be within the prescribed limits for AAQ.
values were well within the prescribed limits at each RSPM (PM10) levels in one of the location i.e. time office
location. The graphical representation of the individual of stage – II was found to be higher than the prescribed
parameters has been given as Figures – 3 to 4. limit during the monitoring period. This may be attributed
to the dust laden wind in the area as most of the roads in
As can be seen from the Figure - 2, there has been a are not completely paved outside the plant area.
steady increase in the SPM levels at all the locations over
the period of 3 years. Based on the review and analysis of the data for 3 years
and primary data collected during the audit period, it can
Two of the locations, i.e. Railway Siding and Raw Water be seen that the area still has a buffer of more than 50% in
Pump House (RWPH), are within the plant boundary and in terms of air emission compared with the limits. This shows
the upwind and downwind directions respectively. The that the air is not degraded and can with stand increase in
increase in the SPM levels can be attributed to the heavy the emission levels.
vehicle movement on the highway and increased activities
in the surrounding villages. The activities include brick
manufacturing and also the use of wood and charcoal
during cooking by villagers leading to uncontrolled burning
and contributing to the particulate matter levels. Apart

Ambient Air Quality Monitoring Locations

FIGURE – 2: AAQ (SPM) – AVERAGE ALL LOCATIONS FIGURE – 4: AAQ (NOx) – AVERAGE ALL LOCATIONS
Average SPM Level (All Locations) Average NOx Level (All Locations)
600 140
SPM Level (micro gms/Cu.m)
NOx (micro gms/Cu.m)

120
500
100 Railway Siding
400
80 Club No.1
300
216 199 60 RWPH
187 164 163 Railw ay Siding
200 148 152 133 Standard
106 121 Club No.1 40 27 22 25
92 115 21 20 20 21 20 21 21 20 20
100 RWPH 20
Standard
0 0
2004-05 2005-06 2006-07 2007-08 2004-05 2005-06 2006-07 2007-08
Year Year
FIGURE – 3: AAQ (SO2) – AVERAGE ALL LOCATIONS FIGURE – 5: AAQ (SPM) – AVERAGE ALL LOCATIONS
(SEPTEMBER 2007)
Average SO2 Level (All Locations)
Average SPM Levels (All Locations)
SO2 Level (micro gms/Cu.m)
140
120 600
SPM (micro.gms/cu.m)
100 Railway Siding 500
80 Club No.1 400
60 RWPH 300
40 Standard 200
20 16 18
20 11 11 11 11 10 10 11 10 10 100
0 0
2004-05 2005-06 2006-07 2007-08 Time Office Club - 2 Railway Siding KTC Koradi STP colony
Stage - 2
Years
SPM
Locations
Standard

FIGURE – 6: AAQ (PM10) – AVERAGE ALL LOCATIONS FIGURE – 8: AAQ (SO2) – AVERAGE ALL LOCATIONS
(SEPTEMBER 2007) (SEPTEMBER 2007)
Average PM10 Levels (All Locations) Average SO2 Levels (All Locations)
180 140
PM10 (micro.gms/cu.m)
SO2 (micro.gms/cu.m)
160 120
140
100
120
100 80
80 60
60
40
40
20 20
0 0
Time Office Club - 2 Railway Siding KTC Koradi STP colony Time Office Club - 2 Railway KTC Koradi STP colony
Stage - 2 Stage - 2 Siding
PM10 SO2
Locations Locations
Standard Standard
FIGURE – 7: AAQ (NOx) – AVERAGE ALL LOCATIONS

(SEPTEMBER 2007)
Average NOx Levels (All Locations)
140
Nox (micro.gms/cu.m)
120
100
80
60
40
20
0
Time Office Club - 2 Railway Siding KTC Koradi STP colony
Stage - 2
Nox
Locations
Standard

4.3.2. Stack Emission Data Review

As per PPAH, the maximum permission emission level for
4.3.2.1 Stack Monitoring (All Units) Particulate matter is 100 mg/Nm3 however the target
should be 50 mg/Nm3. Based on the data analysis it was
The stack monitoring was carried out twice a week every observed that the particulate matter emission of all the
month by KTPS. Average monthly data and yearly data for units are higher than the prescribed limit of 100 mg/Nm3.
all the units was reviewed to understand the stack emission Figure 16 shows the average PM emissions of all the units
level and overliers, if any, over a period of time. The stack during the years 2003-04 to 2006-07.
emission levels were compared with the exiting local and
statutory norms to check if there were any deviation and Considering that the air shed in the area is not degraded
the reasons for the same have been recorded for reference. and the particulate matter levels are much below the
prescribed limit, a target of 100 mg/Nm3 can be setting
Based on the monthly stack monitoring data conducted by into
KTPS for the year 2003-04 to 2006-07, the average
emission levels of PM, SO2 and NOx were analyzed. SO2 emission levels were monitored at the station level as
the consent order has given a limit in metric tons per day.
Based on the data it was found that the yearly average PM The SO2 emission of 3 years i.e. from 2004-05 to 2006-07
emission of units 1 through 4 (Stage I) were found to be was considered for the analysis. During the years 2004 to
within the prescribed limit. PM emission level for Unit – 7 2006, the limit prescribed by the state pollution control
was found to be higher than the limit. The PM emission board was 118 MT/Day which was later revised to 203
level for Unit 5 was higher than the statute in the year MT/Day in the renewed consent order issued during
2003-04 and 2004-05. The same was within the limit for December 2006.
the year 2005-06 and 2006-07. The decrease in the PM
emission is attributed to the installation of the bag filter. The average SO2 emission at the plant level during the
The PM emission level for Unit 6 was found to be within the years 2004-05 and 2005-06 were 108 and 109 MT/day
limit for the year 2003-04 and 2006-07. The same was which was within the prescribed limit of 118 MT/day.
exceeding the limit for the years 2004 – 06. The higher During 2006-07, the SO2 emission was monitored
levels during the said period was due to the inefficiency of separately for both Stage I and II. During the year, stage I
the bag filters which was later changed during the shut recorded an average SO2 emission of 11.0 MT/day which
down period in the year 2005-06. This contributed to the was much below the prescribed limit of 203 MT/Day. The
decrease in the PM emission. emission levels in Stage II were 23.60 MT/day which was

again less than the prescribed limit. As per the PPAH, there FIGURE – 10: STACK EMISSION (NOx) – ALL UNITS
is no SO2 emission norms prescribed and the plant/unit
should follow the local regulations.
Average NOx Emission (All Units)
NOx emission levels for all the units were found to be within
160
the prescribed limit. No deviations were observed in the 140
NOx emission levels during the period for which the data
NOx Level (P PM)

120 2003-04
was reviewed. 100 2004-05
80 2005-06
FIGURE – 9: STACK EMISSION (PM) – ALL UNITS 60 2006-07

40 Standard
20
Average PM Emission (All Units) 0

Unit 1 Unit 2 Unit 3 Unit 4 Unit 5 Unit 6 Unit 7
700
Units
600
PM Value (mg/Nm3)
500
400
300 FIGURE – 11: STATION LEVEL AVERAGE STACK

200 EMISSION (SO2)
2003-04
100 2004-05
0
2005-06
2006-07 SO2 Emission (Station Level)
Unit 1 Unit 2 Unit 3 Unit 4 Unit 5 Unit 6 Unit 7
Standard
Units PPAH 250.00
Target as per PPAH
SO2 Level (MT/Day)

200.00
150.00 Plant Average

100.00 Standard
50.00
0.00
2004-05 2005-06 2006-07 (Stg I) 2006-07 (Stg II)
Years

4.3.3 Environmental Monitoring as part of Audit Particulate Matter: The stack emission monitoring showed
that the particulate matter emissions of Units 5, 6 & 7 were
Environmental monitoring is carried out by KTPS on a much higher than the standard limit of 150 mg/Nm3. The
regular basis at the locations specified by the state emission levels of unit 2 & 3 were recorded below the
pollution control board and the same is report to the Board standard limit.
regularly. As part of the environmental audit 5 days
monitoring was carried out for various environmental As per PPAH, the maximum permission emission level for
aspects. This data provided an independent perspective on Particulate matter is 100 mg/Nm3 however the target
the existing status of environmental conditions in and should be 50 mg/Nm3. In rare cases, an emissions level of
around KTPS. The monitoring was carried out by an up to 150 mg/Nm3 may be acceptable. Based on the data
independent environmental lab M/s Vimta Labs, Hyderabad analysis it was observed that the particulate matter
during 25th and 29th September 2007. Later the emission of all the units are higher than the prescribed limit
monitoring was repeated twice during September-2007 and of 150 mg/Nm3. Figure - 12 shows the emission levels of
January 2008 by M/s Mahabal Enviro engineers, Nagpur. particulate matter.
The details of the monitoring location are provided in the
Annexure - II. The locations are identified on the map given Sulphur di-oxide (SO2): SO2 emissions were analyzed for
as Plate – 1. the stack emissions. It was observed that the standard
limitfor SO2 emissions is 203 MT/Day. As per PPAH, it is
4.3.3.1 Stack Emissions recommended that the SO2 emission levels meet regional
load targets.
Vimta Labs carried out the stack emission monitoring
between 26th and 28th September 2007. The stack Based on the analysis of the stack emissions, the SO2
emission of Units 2, 3, 5, 6 and 7 were monitored during emission were observed to be with in the prescribed limit.
the period. Unit 1 and 4 were not monitored as Unit 4 was The Figure - 13 shows the emission levels of SO2.
under shut down and oil firing was underway in Unit 1 and it
was suggested by KTPS not to monitor the emissions Oxides of Nitrogen (NOx): In order to determine the
during oil firing. concentration of NOx emissions from stacks, flue gas
analyzers were used and monitoring was carried out. The
The stack emissions were monitored at the existing port NOx emissions were higher than the prescribed limit of 150
holes provided on the duct of the outlet from ESP /Bag PPM for Unit 6 (LHS) based on the readings based on one
Filter. The results of the stack monitoring are as follows: grab sample. However during other sets of readings NOx

level found well within the prescribed limits. The NOx FIGURE – 13: STACK EMISSION (SO2)
levels for remaining units were also found well within the
prescribed limits. The NOx levels for the remaining units Stack Emission (SO2)
were found to be within the prescribed limit. Figure - 14
shows the emission levels of NOx.
SO2 Concentration (MT/Day)

250.0
200.0
Note: NOx conversion: mg/Nm3 to PPM (multiply by 150.0
0.487) [Source: PPAH]
100.0
50.0
FIGURE – 12: STACK EMISSION (PM)
0.0
2 3 5a 5b 6a 6b 7a 7b
Stack Emission (Particulate Matter) SO2 (MT/Day)
Unit (Duct)
Standard
2500
PM Level (m g/Nm 3)
2000
1500 FIGURE – 14: STACK EMISSION (NOx)
1000
500
0
Stack Emission (NOx)
2 3 5a 5b 6a 6b 7a 7b
180.00
Unit (Duct) SPM (mg/Nm3)
160.00
Standard (mg/Nm3)
NOx Level (PPM)

140.00
120.00
100.00
80.00
60.00
40.00
20.00
0.00
2 3 5a 5b 6a 6b 7a 7b
Unit (Duct) NOx (PPM)
Standard (PPM)

4.3.4 Pollution Load

Mercury (Hg), which is one of the pollutants released into
In order to determine the emissions per unit (kWh) of the atmosphere during the combustion of coal, was also
electricity generated, the plant load at the time of stack analyzed in the stack emissions. The Hg levels in the stack
monitoring was recorded. Based on the plant load and the emission unit wise are provided as Table - 4.
emission levels of particulate matter, SO2 and NOx,
emission levels per unit of electricity generated was Based on the analysis and data presented, it can be seen
calculated. The same is presented as Table – 3 below for that the Hg load ranges from 0.042 to 0.126 g-Hg/MWh.
reference. The highest was recorded in Unit 6 (Duct – b) and the
lowest in Unit 7 (Duct – a). The analysis of Hg in the stack
TABLE – 3: POLLUTION LOAD (PM, SO2 & NOx) emission showed that the levels were in the range of 0.01
mg/Nm3 to 0.03 mg/Nm3.
Unit Rated Load during SPM SO2 NOx
Capacity stack Load Load Load There are no prescribed guidelines for the limit of Hg
(MW) monitoring (Kg/ (Kg/ (Kg/ emission from stack by the local authority. The Central
(MW) kWh) kWh) kWh) Pollution Control Board (CPCB), the governing body for
1 Not Operational environmental standards and guidelines, has also not
provided any standard for Hg emission. Therefore, it is not
2 105 88 0.00110 0.00557 0.00087
possible to determine if the Hg emissions are within the
3 105 83 0.00127 0.00618 0.00106 limits.
4 Not Operational
5 200 155 0.00129 0.00307 0.00053 Therefore, the following data presented is only indicative
6 210 155 0.00363 0.00201 0.00128 and can be treated as baseline for future monitoring
7 210 124 0.00283 0.00332 0.00055 purposes.
As can be seen from the table above, Units 2 & 3 was

operational at more than 90% load and the remaining less
than 75%. Considering the load factors of all the units, it
can be inferred that the pollution loads are much higher.
The values presented as based on the grab sample
collected at one instance and are not conclusive.

TABLE – 4: POLLUTION LOAD (Hg)

KTPS measures the efficiency of the pollution control
Unit Rated Load during Hg Hg equipment i.e. ESP/Bag filter by monitoring the flue gas
Capacity stack (mg/Nm3) Load parameters at ESP inlet and outlet. The same was carried
(MW) monitoring (g-Hg/MW) out during 14th February – 1st March 2007 for all the units.
(MW) Based on the data available, the following was the
1 Not Operational efficiency recorded during the period as given Table - 5.
2 105 88 <0.01 0.083
As can be seen from the table, the efficiency of the
3 105 83 0.02 0.189 pollution control equipment is more than 99% w.r.t to all
4 Not Operational the units expect for Unit -7 where the highest outlet SPM
5 200 155 0.01 0.045 level was recorded during a grab sample i.e. 910 mg/Nm3
6 210 155 0.025 0.106 as against the prescribed 150 mg/Nm3. The design of the
7 210 124 0.01 0.049 present ESP with 99% efficiency is 248 mg/nm3 this is the
design limitation of the present ESP (being designed at the
4.3.5 Air Pollution Control Systems time when present norms did not exist). In order to reduce
the SPM levels using chemical dozing, the contract has
KTPS has installed ESP and Bag Filter as the pollution been given to M/s Chemptrol Pvt Ltd. recently
control equipment for control of stack emissions. Unit 1
through 4 has ESP as the pollution control system. The TABLE – 5: EFFICIENCY OF POLLUTION CONTROL
outlet duct from ESP is then attached to the stack. Unit 1 & SYSTEM (Source : KTPS)
2 have 1 stack of 76 mts and Unit 3 & 4 have 1 stack of 76
mts. Unit 5, 6 & 7 have dual system of ESP and Bag Filter. Unit Rated Load Average Average Efficiency
The stack heights of Units 5,6 & 7 are 90 mts each Capacity during SPM inlet SPM oulet (%)
respectively. The design details of the existing ESP and Bag (MW) stack (mg/Nm3) (mg/Nm3) E=(A-
Filters are provided as Annexure – I for reference. monitoring B)/A*100
(MW) A B
The ESP along with BF is taken in service with 10% 1 105 87 35355 139 99.61
maximum opening, if Flue Gas APH Outlet temperature 2 105 81 26058 145 99.44
exceeds 160oC, or DP exceeds 200, or Furnace draft goes
positive. 3 105 82 30035 138 99.54

Unit Rated Load Average Average Efficiency The retrofitting work for ESP of Unit – 7 was delayed and
Capacity during SPM inlet SPM oulet (%) an extension in the date was requested. The same was
(MW) stack (mg/Nm3) (mg/Nm3) E=(A- accepted by MPCB and time was extended till 31st March
monitoring B)/A*100 2008.
(MW) A B
4 105 92 21342 140 99.34 Limitations
5 200 189 43302 137 99.68 The efficiency of the pollution control equipments could not
6 210 168 49990 120 99.76 be carried out based on the monitoring as it was observed
that the portholes provided for the monitoring of stack
7 210 175 45112 910 97.98
emissions was not as per the prescribed norms of CPCB. As
Note: Subsequently, KTPS had carried out stack monitoring during per CPCB guidelines, to ensure laminar flow, sampling ports
September 2007 and January 2008, during which, the average SPM
levels at Unit -7 were recorded as 475 and 461 mg/Nm3 respectively.
shall be located at least 8 times chimney diameter down
stream and 2 times up stream from any flow disturbance.
Maharashtra Pollution Control Board (MPCB) had served a
notice to KTPS for high PM emission from Unit 5, 6 & 7 This was not observed at the site where all the portholes
during the year 2005. KTPS sent a detailed action plan were either placed close to the gate valve or close to the
against the notice on 2nd August 2005, where in it was bends which leads to disturbance in the laminar flow and
informed that the retrofitting works for Unit – 5 were inaccurate results.
already completed and bag filter commissioned.
The CPCB norms as referred are applicable to the Power
Partial replacement of bags for Unit – 6 was carried out Stations after 1997 and these are not applicable to the
during March 2008. New order was placed for 8022 bags Units erected prior to 1997. Also, for the existing stack, it
(PTFE membrane type) on 27/08/08 with temperature is practically not possible to make such arrangement.
limit of 2600C. The guaranteed service hours for the
proposed bags was indicated as 32000 Hrs and the cost per 4.3.6 Recommendations
bag is INR 12182.24. An additional cost of INR 2243.16 is
required for providing suitable cage for above new design. The following recommendations are being proposed for
Installation, testing & commissioning charges would be increasing the efficiency of the pollution control system for
additional and costs INR 24 Lakhs. The bags will be Unit - 6:
replaced in O/H of Unit 6 scheduled in Oct-08.

Present Status Recommendation Plausibility

Plausible.
Unit - 6 may be retrofitted with 32 field ESP i.e. 16
fields in each path. The bag filters may be
The technical feasibility of
dismantled and only ESP made the primary pollution
the same should be studied
control system. The ESP should be designed to
3 for designing the ESP.
Unit - 6 has a dual system of Bag Filter meet an emission level of 100 mg/Nm for PM.
However, if the proposed
and ESP. The ESP has 20 fields with 10
recommendation cannot be
fields in each path Cost Estimate: The cost estimate for the proposed
implemented due to any
installation of an ESP with 32 fields (16 fields in
reason, the below
each path) would be approximately 25 Crores. The
mentioned
cost includes auxiliaries such as ID Fans, etc. The
recommendations may also
manufacturer of the ESP is BHEL.
be considered.
Plausible.
The O&M cost required for

changing the bags every 3
Replacement with high quality bags: The existing
Bag filters: ESP is taken into services, years is approximately 12
bag filters may be replaced with more efficient
if Flue Gas APH Outlet temperature Crores. Considering the
bags. The design of the bag filter has to be studied
exceeds 160oC, or DP exceeds 200, or same, up-gradation of the
to understand the cause of failure of bags before
Furnace draft goes positive. ESP is more feasible.
replacement of the same with new bags.
However, a detailed
technical and financial
feasibility of the same
should be studied further.
Ammonia injection in ESP may be carried out to Plausible.

ESP efficiency improvement systems
reduce the SPM levels. Dosing the flue gase with
Not available
ammonia results in improved electrical properties of Considering that the

the ash particles, enables them to agglomerate technology has been

better and results in improved collection efficiency proven and widely
at the ESP. acceptable, the same is
recommended for
The ammonia injection system includes ammonia improving the ESP
storage tank, ammonia vaporiser, knock out drum, efficiency.
steam system, instrumentation and controls.
Ammonia is evaporated through a steam coil
vaporizer and the ammonia vapor is maintained at a
constant pressure through a pressure regulating
and a pressure control system provided on the LP
stream supply. A knock-out drum is provided to de-
entrain any ammonia liquid droplets entering the
system. Down stream of the ammonia knock-out
drum, an auto regulating, pressure reducing valve
with a pilot valve facility is provided in order to
maintain a constant down stream pressure of 2.8
kg/cm2(g). The entire ammonia storage system is
also provided with safety relieving devices, pressure
and temperature gauges, and a vent header at an
elevation of 22 meters in order to safely disperse
ammonia in an unlikely emergency situation. The
sample schematic of the ammonia dosing system is
given as Figure - 15.
The ammonia is dosed at the inlet of each pass of

the ESP through a fine control provided through a
needle valve. Air is mixed through air blower system
to maintain the concentration of ammonia in the
1
Chemithon Engineers Ltd., (CEL)

inlet at a value of about 0.5% to 1.5% depending on

the level of ammonia required for the system. This
also helps in proper mixing of ammonia in the flue
gas. The ammonia concentration in the flue gas can
be varied from 20 ppm to 70 ppm.
The dual flue gas conditioning technology offers

cost effective solutions as the investments for the
ammonia based dosing system is in the range of Rs.
1 lakh per MW1.
As per the Environmental Protection Act, 1986 and

amendments thereon, the NOx emission limit is
specified only for gas based power plant. However,
as per the consent order issued by MPCB to KTPS,
the NOx limit has been specified as 150 PPM and no
specific NOx control system has been mentioned. As NOx levels are well
KTPS has not put in place any specific NOx control below the prescribed limits
system. KTPS has also requested MPCB to relax the by MPCB/CPCB,
NOx limit vide a letter no. KTPS/CGM (Gen considering the
NOx Control system not in place
O&M)/WTP-II/ENV/1539 dated 24th Jan 2007. unwarranted additional
cost burden for R&M
In order to further reduce the NOx emissions, KTPS activity, Low NOx burners
may install low NOx burners. Low-NOx burners limit is not recommended.
the formation of nitrogen oxides by controlling the
mixing of fuel and air, in effect automating low-
excess-air firing or staged combustion. Compared
with older conventional burners, low-NOx burners
reduce emissions of NOx by 40–60%.

Figure - 15: Schematic of Ammonia Injection System
Others Recommendations:
Ø KTPS may consider providing portholes for

monitoring of stack emissions at ESP inlets for all
paths as per the CPCB norms during R&M.
Ø KTPS should complete the retrofitting activity of the

unit 7 ESP at the earliest possible to reduce the PM
emission from the unit which is exceeding the
prescribed limit.

4.4 ASH GENERATION & UTILIZATION TABLE – 6: ASH GENERATION (Source – KTPS)
Coal, the raw material for power generation at KTPS, was Year Coal Ash Fly Ash Bottom Ash
analyzed to determine the ash content. Both proximate and Consumption Generation (80% of ash (20% of ash
ultimate analysis was carried out on the bunkered coal for (MT) (MT) generation) generation)
Stage I and II of KTPS. Based on the analysis it was found (MT) (MT)
that the ash content in the coal is 35%. By considering the 04-05 4969783 1739424 1391539 347884
average ash content of 35% in the coal, the quantity of fly 05-06 4914121 1474236 1179389 294847
ash generated during the years 2004-05, 05-06 and 06-07 06-07 5479652 1643896 1315116 328779
is given in the Table - 6.
KTPS has entered into an agreement with M/s Manikgad
As the quantity of the fly ash and bottom ash cannot be
Cements (MC) for collection and utilization of fly ash. As
quantified, a theoretical norm of 80:20 for fly ash and
per the agreement, the cement manufacturer would collect
bottom ash has been taken to arrive at the quantities.
the entire quantity of fly ash from Unit -5 and half quantity
from Unit-6. The same is on a Built-Own-Operate basis.
As on date, KTPS has not installed any system where the
KTPS has also entered into an agreement with M/s Murli
captured fly ash can be utilized. All the fly ash is
Agro for the collection and utilization of dry ash from Unit-
transported to the ash handling plant where the ash is
6 and Unit-7.
mixed with treated effluent and raw water to prepare ash
slurry and is sent to ash pond. The ash slurry supernatant
4.4.1 Ash Utilization Plan
is partly recovered and recycled back into the AHU for
preparation of ash slurry.
Based on the aforementioned arrangement for fly ash
utilization, the following ash utilization plan is provided
As per the Fly Ash Notification issued by Ministry of
below.
Environment and Forest (MoEF), New Delhi in 1999 (Draft
Notification 2007 yet to be finalized), all thermal power
The ash generation for Unit 5 & 6 has been considered
plants based on coal / lignite shall provide fly ash to
based on the average coal consumption in the respective
cement / brick manufacturers free of cost to for
units and the ash content of coal.
manufacturing concrete, bricks and use in other
construction activity.

TABLE – 7: ASH GENERATION
Year Ash Generation Ash Utilization %

(MT/day) (MT/Day) Utilized
Unit Unit Total Unit Unit Total
5 6 5 6
2008 1400 1400 2800 1400 700 2100 0.75
20102 1400 1398 2798 1400 699 2099 0.75
Considering that the coal consumption would reduce by 1%

if there is an increase in efficiency of the plant by 1%, the
same quantity of ash generation would be reduced after the
R&M activity. If Manikgad Cements would utilize the same
quantity of ash as being done presently, the percentage
utilization of ash would remain the same.
Also, the quantity of water required for ash slurry

preparation would reduce from 2100 KL to 2098 KL3.
2
This is considering that the R&M activity will be completed by the year
2010 which would improve the efficiency of Unit – 6 by 1%.
3
This is considering that 3 KL of water is required per MT of ash for slurry
preparation.

4.5 WATER SOURCE AND RECYCLING SYSTEM towers. For Stage I, all the units have cooling towers. For
Stage II, only Unit 6 and 7 have cooling towers. Unit 5 has a
The source of water for KTPS is from the reservoir of natural cooling system i.e. pond – 2.
Pench Dam located approximately 25 km from the plant.
The water is supplied to the Pond No.3 through gravitation FIGURE - 16: DM & COOLING WATER SYSTEM
flow. From pond no.3 the water is pumped into the plant.
After in-house consumption, most of the water is circulated Lift Unit 5, 6 & 7
back into the pond – 3 for reuse. The schematic diagram of Pump
the water flow system at KTPS has been provided as Plate SW Units 1,2, 3 & 4
- IIa for ready reference.
WTP - I
DM
4.5.1 Water Scheme SW
Sq.
Tank
There are 2 Raw Water Pump Houses (RWPH) at Pond No. WTP-II Raw water tank
3 for pumping of water to various units. RWPH I supplies RWP - II RWP - I
Domestic (Colony &Plant)
water to Stage 1 units and RWPH II supplies water to Stage
II units. Dalmia Pump House (DPH), which supplies water Dalmia pump
house
Inflow
to both Khaperkheda power plant and KTPS, also draws from Pond No. 3
water from pond – 3. Pench
Dam
The water thus pumped is sent to the raw water tank at
KTPS which is later sent to Water Treatment Plant (WTP) The return water from the cooling tower flows back to
of stage II where the water is treated and the DM water is condenser. Water in this close cycle is circulated with CW
used for power plant and chlorinated water is used for Pumps located at condenser inlet and Cooling Tower Lift
domestic purpose. Water from the raw water tank is also Pumps (CTLP) located near Cooling towers. On return
supplied to the Ash Handling Plant (AHP) for slurry path of the water from the cooling towers to the condenser
preparation. is a tank i.e. junction box (JB). Overflow of this JB goes to
Pond No. 3. Unit 5 has a natural cooling system where the
DM and Cooling water system: After DM water is used at hot water from condenser is let out to pond no. 2 for
individual units for steam generation, the condensate cooling which later joins pond. -3.
extracted from the LP exhaust is sent to the cooling

The water from pond – 2 joins the raw water source pond – (settling tanks) and no secondary treatment using
3 via two different channels. One channel from pond – 2 is chemicals is carried out. The treated water from the
divided into 2 streams with a ratio of 60:40. The 60% settlers is sent to the effluent outlet sump from where it is
stream joins pond – 3 after traveling a distance of about pumped to the new raw water pump of Unit 7, clear water
6.5 km through the villages surround the plant and the 40% pump of unit 5 and slurry tank of unit 6.
stream after traveling a distance of approximately 1 km.
The solid waste from ETP mainly contains ash which is
FIGURE - 17: COOLING WATER CIRCULATION SYSTEM recovered and supplied to local brick manufacturers.
Unit 5 The detailed schematic diagram of the ETP and waste

Cooling tower
water flows is provided in Plate - IV of the report.
Unit 6 & 7
During the audit period, the process effluent analysis and
treated effluent analysis was carried out to understand the
RWPH II
Cooling tower characteristics of the effluent before and after treatment.
Units 1, 2, 3 &
4 Process effluent analysis and treated effluent analysis
RWPH I
Junction
given as Annexure – III.
Box
Overflow
The pH in the ETP outlet was recorded as 8.2. The
Pond No. 3 Pond No. 2
suspended solid level in the ETP outlet was recorded as
40% Channel
106 mg/l and oil and grease as 5 mg/l. Chromium and Hg
60% Channel were found to be less than 0.01 mg/l.
Sewage Treatment Plant (STP): KTPS has a residential

colony about 2 kms from the plant boundary on the west
Effluent Treatment Plant (ETP): An ETP has been provided side of the Nagpur – Chindwara highway. Domestic water
at KTPS for treatment of trade effluents. supply to the colony is from the water treatment plant after
filtration and chlorination.
The waste streams from both stage I and II are collected in
the settling tanks from where it is pumped into the settlers. The domestic sewage from the colony is sent to STP for
The ETP at KTPS is only used for primary treatment treatment which is designed for a capacity of 100 cu.m/hr.

The treated water is used for gardening. Overflow from the Additional raw water required for make up and preparation
STP is discharged out of the colony area. Sludge from the of the slurry is in AHU in pumped from pond – 3. The un-
STP is used as manure for the gardens and plants in colony recovered water from ETP joins a stream from pond – 2
and plant. which later joins pond – 3.
The detailed schematic of the STP is provided in Plate 5 of FIGURE - 18: ASH WATER RECYCLING SYSTEM
the report. The inlet and outlet characteristics of the
Un-
sewage have been given in Annexure - III. recovered
Ash Bund
It is observed that the treated sewage meets the AWR Khasara
requirements of the on-land disposal standards set by CHP + BPH FFPH
CPCB. The pH was recorded as 7.4 and COD was recorded Overflow
as 23.5 mg/l and BOD of <5 mg/l. The treated water is
being used for gardening in plant and colony. AWR Koradi Ash Bund Booster PH
(Koradi) AHP - I
Ash water recycling system: The streams from the both the
stages are sent to ETP where the solids are settled using
clarifiers. The treated water is pumped into the Ash
Stage I and II surface
Handling Unit (AHU). The ash collected from the ESP/bag AHP - II ETP runoffs, Pre-treatment
filter is mixed with the treated water to prepare slurry. The effluents and boiler blow
slurry is then pumped into the Booster Pump House (BPH) downs
from where it is pumped to the ash pond.
Water flow measurements were carried out to determine
Part of the supernatant from the ash pond is collected into the quantity of water intake from Pond No. 3 and outlets
the Ash Water Recovery (AWR) scheme and pumped back from the plant.
into AHU. The remaining part of the supernatant is let out
into open stream which joins a river. Another water stream Flow measurements were carried out using Non-Contact
from the ash pond is let out as open channel which is not Flow Meters (NCFM) and Tracer Method. During the
recovered into AWR. measurement, the pump rated capacities and the running
capacity was also noted to co-relate the flow
measurements.

4.5.1.1 Raw Water Pump House 4.5.1.2 Ash Disposal
RWPH I supplies water to stage I units and RWPH II supplies The ash slurry from the Booster Pump House (BPH) is
water to stage II. DPH supply water to the WTP II. sent to the ash pond at Khasara. The supernatant from the
ash pond is collected in the pond and pumped back into the
Using NCFM, water flows were measured from RWPH I and plant for ash slurry preparation. The AWR scheme is
DPH. At the time of the measurement, 3 pumps were in provided in Plate - II. At the time of monitoring, the pumps
operation at RWPH I and 1 pump was operational at DPH. at Khasara AWR were not in operation (as cleaning of ash
Of the three pumps, water from 2 pumps at RWPH were from the collection pond was underway). Only one pump
being pumped to one header. From the header, water is was in operation at the Koradi AWR which was pumping
pumped to the units. From the third pump, water is pumped water back to the plant.
directly to units. The pumps at RWPH were running at full
capacity where as the pump at DPH was at 75% capacity. Tracer method was used to measure the flow of ash water
discharge from the ash bund at khasara ash pond. The ash
The flow measurements were as follows: water supernatant flows as two different streams. The flow
rates of both the streams has been measured and
RWPH I : Pipe I – 1314.25 (31542 cu.m/day) presented below:
: Pipe II – 0
Dalmia : 567 cu.m/hr (13604.8 cu.m/day) Ø Stream 1 (Left) – 10,703.8 cu.m/day
Ø Stream 2 (right) – 33566.4 cu.m/day
Tracer method was used for measuring the flow from RWPH
II as the channels were underground. In order to avoid The stream – 1 is partly recovered. The quantity of water
inconsistency, 12 reading were taken at each channel to which is not being recovered could not be quantified as the
arrive at a agreeable average flow rate. The average flow pumps at AWR Khasara were not in operation during the
rate at each channel which supplies water to individual monitoring period. Stream – 2 does not join the AWR and is
units is as follows: let out without recovering as an open channel which later
joins the river.
Ø Unit 5: 287719 cu.m/day
Ø Unit 6: 326021 cu.m/day Waste water from the Coal Handling Plant (CHP) and
Ø Unit 7: 294645 cu.m/day overflow from BPH, is not treated is let out of the plant
premises.

In order to estimate the quantity of waste water being During the time of measurement, only one pump was in
discharged out of the plant without treatment, flow operation running at 75% load. The flow measurement
measurements were taken using the tracer method and the recorded at the ETP pump house was 461 cu.m/hr (i.e.
same was recorded as 693.5 cu.m/hr (16,643 cu.m/day). 11,076 cu.m./day).
In order to estimate the recovery of the waste water which
is being recovered at the AWR Koradi, NCFM was used to 4.5.2 Water Consumption
measure the flow of the water. At the time of measurement
only one pump was operational. Based on the requirement The water consumption details of KTPS, for the year 2007-
2/3 pumps are operated at a time. The flow measured at 084, has been presented below to understand the quantity
Koradi AWR was 704 cu.m/hr (i.e. 16,917 cu.m/day). of water recycled / un-recovered.
4.5.1.3 Cooling Water System Based on the details, the water balance has been prepared.
The following are the details of the same:
As mentioned in the report earlier, all units under Stage I
have cooling tower and the water recovered in circulated WATER BALANCE (All quantities in cu.m / year)
back into the system. For stage II, only Units 6 & 7 has A TOTAL WATER INTAKE (RWP) 309735592
cooling towers. B TOTAL Boiler Feed, CW, 43666591
WATER IN Domestic and Ash
As mentioned in the earlier section, during the monitoring, THE Disposal
the 60% stream was closed due to expansion work on the SYSTEM + Effluents 14054496
recovered/recirculated to
highway. All the water was diverted into the 40% channel.
Pond No. 3
Tracer method was used to estimate the flow rate. The flow
+ Effluents generated 21196682
of the stream was recorded as 9,63,965 cu.m/day.
TOTAL (B) 78917769
4.5.1.4. Effluent Treatment Plant C WATER DISCHARGED BACK TO POND No. 3 (A-B-D) 205349206
D WATER LOSS (Delta) 25468617
Treated water from the ETP is pumped to the AHU for ash BALANCE TOTAL OF B + C + D 309735592
slurry preparation. In order to estimate the amount of
water being pumped, flow measurements were taken at the The details of the water consumption and reuse are given in
pump house of ETP. the Annexure-IX for ready reference.
4
Source : KTPS, Water Cess Records for 2007-08

Limitations of flow measurements Ø Water flow meters are to be installed at major inlet
and outlet points such as Raw Water Pump house,
The following flow measurements were not recorded during WTP I & II Inlets, DM water and Softener Water
the study period: outlets, inlet to cooling tower, inlet and outlet of
ETP and STP, inlet to AWR, outlet of AWR, inlet and
Ø Un-recovered water from ETP joining pond – 2 outlet of AHP. The points where the flow meters are
stream which later joins pond – 3 due to to be installed are shown on the schematic diagram
inaccessibility. in Plate – II B.
Ø 2nd stream from pond – 3 joining pond – 3 due to
inaccessibility Ø Runoff water from CHP and overflow water BPH is
Ø Cooling water joining pond – 2 from cooling tower of presently being discharged without treatment which
unit 6 & 7 as there was no straight open channel for is approximately 16,643 m3/day. The construction
measurement of a primary treatment facility i.e. a settling plant be
Ø Over flow from JB as there was no straight open constructed at the outlet point to remove suspended
channel for measurement solids in the overflow water and the entire quantity
Ø AWR Khasara as the pumps were shutdown for be recycled back into the system.
maintenance of the water recovery pond
Ø Ash water supernatant from Khasara ash bund
Considering the aforementioned limitations, the water which does not join the AWR scheme should be
balance of KTPS could not be arrived upon. However, based recovered. Based on the measurements carried out
on the data provided by KTPS for the year 2007-08, the during the audit period using tracer method,
water balance has been provided. approximately 33,566 cu.m/day of water is being let
out without recovery which can be recycled back
4.5.3 Recommendations into the system.
Based on the study of the water cycle at KTPS and flow

measurements where possible to estimate the quantity of
water being used / recycled, the following
recommendations are being made.

4.6 CHEMICAL USE FOR WATER TREATMENT (DM TABLE – 9: CHEMICAL USE (Source – KTPS)
WATER)
Chemicals UOM 2005-06 2006-07
Raw water from pond no. 3 is pumped to Water Treatment HCL MT 1014 1224
Plant (WTP) of stage I and II for treatment using chemicals Caustic Lye MT 234 248
for preparation of DM water used for steam generation at
the power plant and domestic water for colony and plant. Hydrazine Kg 6800 13000
Lime MT 324 426
The chemicals used for treatment are HCL, Caustic Lye, Alum MT 335 187
Hydrazine (used to eliminate the residual oxygen in the Salt MT 3671 3862
feed water), Lime, Alum, Salt and Poly Aluminium Chloride PAC MT 45 126
(PAC).
TABLE – 10: SPECIFIC CHEMICAL CONSUMPTION
Historical data for the use of chemicals was collected from (Source – KTPS)
KTPS for the years 2005-06 and 2006-07. The quantity of
chemicals used for the treatment of water is given below in
Chemicals UOM 2005-06 2006-07
Table - 9. In order to estimate the specific chemical
consumption interms of total DM water used during the HCL Kg/m3 1.2671 1.3258
particular year, the historical data of DM water Caustic Lye Kg/m3 0.2924 0.2843
consumption at the plant level was collected from KTPS. Hydrazine Kg/m3 0.0085 0.0072
The quantity of DM water used during the year 2005-06 Lime Kg/m3 0.4049 0.4259
was 8,00,234 cu.m and during the year 2006-07 was
Alum Kg/m3 0.4186 0.3503
833,427 cu.m.
Salt Kg/m3 4.5874 3.7807
Based on the data made available regarding the total PAC Kg/m3 0.0562 0.0707
chemical consumption and the quantity of DM water used,
the quantity of chemical used for treatment of 1 cu.m of Excess usage of chemicals in the WTP is due to the high
water was determined and presented in the Table - 9 for turbidity and organic load of the raw water from Pond No.3.
reference. This is due to the increased activity in the surrounding
areas of the pond by villages and agricultural activity. Also,
heavy siltation in the banks of the pond has increased the

vegetation in the banks and physically reduced the areas of S. Parameters Unit Dalmia Stg – II Pench
the pond and water holding capacity. No. Pumphouse RWP intake
for KTPS Water water
The PAC consumption during the year 2006-07 was more (Present)
during 2006-07 compared to 2005-06 by 0.0146 kgs. The 3 pH - 7.5 – 8.5 7.8 – 8.3 7.5 – 8.0
consumption of other chemicals was less than the previous
4 Total ppm as 120 – 150 130 – 160 100 –
year.
Hardness CaCO3 120
5 Total ppm as 70 – 100 75 – 110 10 – 20
4.6.1 Recommendations
Chlorides CaCO3
The following are the recommendations for improving the
water quality of Pond No. 3 which will also help reduce the Ø The cost benefit was calculated considering the
use of chemicals for treatment: above data.
Ø Chlorine levels in the Pench intake water and at the TABLE – 12 : Cost Analysis(Source – KTPS)
raw water pump house were analyzed. It was
observed that the total chlorides as ppm of CaCO3 Designed Dalmia Stg – II Pench
ranged between 10-20 in Pench intake water and Pumphouse RWP intake
70-100 near the raw water pump house (please for KTPS Water water
refer table – 11). (Present)
Anionic Load 102 104 104 44
TABLE – 11: Water Characteristics (Source – KTPS) Anion Exchange 1800 1765 1765 4170
Output (m3)
S. Parameters Unit Dalmia Stg – II Pench No. of - 46 46 20
No. Pumphouse RWP intake regenerations
for KTPS Water water Caustic Soda / - 0.5 0.5 0.5
(Present) Regen (MT)
1 M. Alkalinity ppm as 130 – 150 120 – 150 110 – Total Alkali - 23 23 10
CaCO3 130 required per
2 Conductivity Micro 300 – 450 300 – 400 200 – Month (MT)
mhos/cm 300 Savings in caustic soda 23-10 = 13 MT

consumption (MT) 4.7 NOISE CONTROL SYSTEM

Considering 80% efficiency ~ 10 MT
Rate of caustic soda (Rs. / 25,000/- The major sources of noise at KTPS are the Turbine
MT) Generators, Boilers, Cooling Water Pumps, Air
Saving per month 2.5 Lakhs Compressors and Transformers. Diesel Generators which
are used only during total grid failure are also sources of
Savings per year ~30 Lakhs
noise, however, this is limited to the period of operation.
Ø Considering the aforementioned cost analysis, it is During the audit period, noise levels were monitored at 4
recommended that pond no. 3 should be cleaned locations. The ambient noise monitoring was carried out
immediately which would also help in increasing the continuously for 24 hours with one hour interval. During
holding capacity of the pond and reduce the organic each hour parameters like L10, L50, L90 and Leq were
load and turbidity caused by the anthropogenic directly computed by the instrument based on the sound
activity. pressure. The monitoring was carried out at ‘A’ response
and fast mode.
Ø A separate pipeline directly from the Pench intake
channel should be established which will ensure The ambient noise level at location monitored during the
supply of good quality water directly to the plant. study period has been provided below in Table - 16.
This will also help reduce the quantity of chemical
used to treat the water there by reducing the cost As can be seen from the table, the ambient noise levels
on chemicals. The proposed scheme has been were monitored at the boundary of the plant, at the
provided as Plate - III. hospital in the colony and commercial complex at the
nearest village outside the plant boundary.
The perusal of the ambient noise level shows that the Lday
ranged between 43.5 dB (A) to 58.6 dB (A). The highest
was recorded at the plant boundary and the lowest at the
hospital. The Lnight ranged between 41.1 dB (A) to 52.1
dB (A). The highest again was recorded at the plant
boundary.

The noise levels at the station gate I & II are within the 4.7.1 Noise Control Measures
limits of the standards of 75 and 70 dB during day and
night respectively. The noise level at the hospital which is As mentioned in earlier section, the major sources of noise
in the KTPS colony is also within the limit of Silence Zone are the generators, boilers and turbines.
during the day time. However, the noise level is slightly
higher during night i.e. 41 dB against 40 dB. This can be KTPS has provided acoustic enclosures for turbine
attributed to the close proximity of the highway and also generators and boilers where possible to reduce the impact
activities in the colony. of the noise generated from generators. Preventive
maintenance is carried out regularly for auxiliary units like
TABLE – 16: AMBIENT NOISE LEVELS air compressors and ID Fans to maintain the noise levels
within the limits.
Location L10 L50 L90 Leq Lday Lnight Ldn
KTPS has provided acoustic enclosures to all the work
Station – 1 57.8 51.2 49.7 55.3 54.2 51.5 58.4
places in the turbine room to avoid noise levels to exceed
Gate
the work zone limit. Ear muffs and plugs have been
Station – 2 56.9 52.0 46.0 55.2 58.6 52.1 60.3 provided to all the workers who are exposed to high noise
Gate levels at places such as boiler and turbine area to avoid
Hospital 48.3 44.2 41.1 45.5 43.5 41.1 49.2 health hazards.
Commercial 50.4 46.3 42.8 47.5 48.9 42.4 50.6
Complex 4.8 DUST SUPRESSION SYSTEM
TABLE – 17: AMBIENT NOISE STANDARD The major source of fugitive dust is from the coal handling
plant (CHP). Coal is delivered to the CHP area through rail
Category of Area Day Night wagons and rope ways. The coal from the tippler is
transferred to the coal pile, crusher and to the bunkers by
Industrial Area 75 70
conveyors. Transfer points constitute the fugitive sources.
Commercial Area 65 55 Screens, sieves, crushers, dust on road are the typical
Residential Area 55 45 sources.
Silence Zone 50 40
KTPS has provided automatic water sprinkler system at the
wagon tipplers and advance fog system at conveyers to

minimize dust emissions. However no dust collection

system with dust suppressants is made available at CHP.
Also, water sprinkling / spraying is done on roads to reduce

the dust levels.
All the roads in the plant and colony are tar roads. The
movement of vehicles in the plant is restricted and hence
there in no dust from the roads.
KTPS had also carried out a study of air quality in the CHP
premises during May 2007. The study was carried out by an
independent consultant. Certain recommendations were
provided based on the study which includes:
Ø Improvement in the dust control system installed at

crushers;
Ø Sprinkling/spraying of water using neutrapit waste
which contains dissolved CaCl2 and MgCl2 which are
typical dust suppressants; and
Ø Tippers moving in the CHP should be covered.
The following recommendations to improve the air quality

in the plant premises are provided below for consideration
by KTPS management:
Ø Spraying / sprinkling of water in CHP area can be

done using dust suppressants for retention of
moisture for longer duration of time.

PART 5: RESOURCE EFFICIENCY ASSESSMENT In addition, the pattern pertaining to specific coal
consumption and specific water consumption were also
The key objectives of the resource efficiency assessment drawn and peak points were highlighted.
includes: The data related to the breakdown of the plant was
collected and analysis of the same was carried out.
Ø Historical performance of efficiency parameters
such as primary fuel use, auxiliary fuel use, specific The power generation, coal consumption, water
water consumption and auxiliary consumption; consumption and specific coal consumption data were
presented on year wise basis and the explanation of the
Ø Establishment of heat and energy balance of the graphs is presented in the following sections of the report.
major energy guzzlers in the plant; and
All the data collected from the plant is enclosed as
Ø Discuss and finalize the energy conservation annexure at the end of the report.
measures and best practices being followed by other
thermal power plants in India with the appointed
R&M consultant;
Our approach for resource efficiency assessment has been

provided in the subsequent pages of the report.
5.1 HISTORICAL ANALYSIS OF POWER, COAL AND

WATER
During the site visit, the data pertaining to historical

analysis of the plant (Unit-6) such as power generation,
water consumption and coal consumption have been
collected for the previous 2 years and the graphs were
drawn for the same.

APPROACH FOR RESOURCE EFFICIENCY ASSESSMENT
Primary data collection
Secondary data collection
Data analysis
Establishment of Historical analysis
Heat and Mass balance of the major energy guzzlers
Energy conservation measures and best practices being followed in

other thermal power plants

FIGURE - 19 : UNIT – 6 : POWER GENERATION PATTERN FOR THE YEAR 2005-06
Power Generation pattern for the year 2005-2006
160
140
42 %
120
100
Million kWh
80 Planned overhaul
maintenance
60
40
20
0
Apr-05 May-05 Jun-05 Jul-05 Aug-05 Sep-05 Oct-05 Nov-05 Dec-05 Jan-06 Feb-06 Mar-06
Month

FIGURE - 20 : UNIT – 6 : COAL CONSUMPTION PATTERN FOR THE YEAR 2005-06
Coal Consumption pattern for the financial year 2005-2006
140000
120000
100000 39 %
Consumption (MT)
80000
Planned overhaul
60000
maintenance
40000
20000
0
-20000
Month

FIGURE – 21 : UNIT : 6 SPECIFIC COAL CONSUMPTION PATTERN FOR THE YEAR 2005-06
Coal Consumption / Power

Specific Coal Generation
Consumption for the
Pattern forfinancial year 2005-2006
the year 2005-06
0.90
0.80
0.70
Kg of Coal / Kwh of Power
0.60
0.50
0.40
0.30 Planned overhaul

maintenance
0.20
0.10
0.00
-0.10
Month

FIGURE – 22 : UNIT – 6 : AUXILIARY POWER GENERATION PATTERN FOR THE YEAR 2005-06
Auxiliary consumption for the year 2005-06
16.00
14.00
12.00
55 %
% Auxiliary consumption
10.00
8.00
6.00
4.00
2.00
0.00
-2.00
Month

FIGURE – 23 : UNIT – 6 : SPECIFIC DM WATER CONSUMPTION FOR THE YEAR 2005-06
Specific DM water consumption for the financial year 2005-2006 for Unit - 6
0.60
0.50
Kg of water / kWh of Electricity
0.40
0.30 Planned overhaul

maintenance
0.20
0.10
0.00
Month

5.1.1 Analysis of Graphs November 2005 - 0 Hours

December 2005 - 147 Hours
Ø The total electricity generation in the year 2005-2006 January 2006 - 6.9 Hours
was 1,302.966 Million units. February 2006 - 2.35 Hours
Ø The total coal consumption in the year 2005-2006 was March 2006 - 53.57 Hours
984,994 Metric tonnes.
Ø The total DM water consumption in the year 2005-2006 The plant was under forced shutdown due to various
was 117,295,810 litres. reasons. Some of the main reasons are listed below:
Ø The average calorific value of the coal for is taken as
4,292 kcal/kg. • Fire at GCR
Ø During the site visit, KTPS break down records were • Boiler tube leakage
analyzed and some of the major observations are listed • High pressure in the furnace
below: • Boiler air ingress
• High drum pressure
Ø The plant was shutdown on 20 occasions, of which
19 were forced shutdowns and one was a planned Ø As per the analysis based on the records, the plant
shutdown. shutdown happened because of Boiler tube failure for
Ø The total number of hours for which the plant was nearly 75 % of 494 hours.
shut down is 1,843 hours, out of which, the plant
was shutdown for approximately 1349 hours during Ø On an average it takes 50-60 hours to arrest or retrofit
July and August and it was under forced shutdown the boiler tube leakage. The leakage of the boiler tubes
for the remaining 494 hours. was either in water tube / reheater tubes, etc. Because
of these stoppages, abnormalities were found in power
Monthly downtime of the plant are mentioned below and generation.
the peak portions are marked in the graphs above.
April 2005 – 4.25 Hours

May 2005 – 2.45 Hours
June– August 2005 - 1,534 Hours
September 2005 - 37.4 Hours
October 2005 - 55 Hours

FIGURE – 24 : UNIT 6 - POWER GENERATION PATTERN FOR THE YEAR 2006-07
Po we r Ge ne ratio n patte rn fo r the financial ye ar 20 0 6-2 00 7
160
140
20 %
120
100
Million kWh
58 %
80
60
40
20 Planned overhaul
maintenance
0
Apr-0 6 May-0 6 J un-0 6 J ul-0 6 Aug -0 6 S ep-0 6 O ct-0 6 Nov-0 6 Dec-0 6 J an-0 7 Feb-0 7 Mar-0 7
M o nth

FIGURE 25 : UNIT 6 : COAL CONSUMPTION PATTERN FOR THE YEAR 2006-07
Coal Consumption for the financial year 2006-2007
120000
16 %
100000
Consumption (MT)
80000
58 %
60000
40000
20000
0
Month

FIGURE – 26 : UNIT 6 : AUXILIARY POWER CONSUMPTION PATTERN FOR THE YEAR 2006-07
% Auxiliary consumption in the year 2006-07
12.00
14 %
10.00
9%
% Auxiliary consumption
8.00
6.00
4.00
2.00
0.00
May-06 Jun-06 Jul-06 Aug-06 Sep-06 Oct-06 Nov-06 Dec-06 Jan-07 Feb-07 Mar-07
Month

FIGURE – 27 : UNIT 6 : SPECIFIC COAL CONSUMPTION PATTERN FOR THE YEAR 2006-07
Specific Coal/Consumption
Coal Consumption pattern
Power Ge ne ration for for
the the Year Ye
financial 2006-07
ar 2006-2007
1.00
0.90
0.80
Kg of Coal / Kwh of Power
0.70
0.60
0.50
0.40
0.30
0.20
0.10
0.00
Month

FIGURE – 28 : Unit 6 - SPECIFIC DM WATER CONSUMPTION FOR THE YEAR 2006-07
Specific DM wate r consumption for the financial ye ar 2006-2007 for Unit - 6
0.2
0.18
0.16
Kg of Water / kWh of Electricity
52 %
0.14
0.12
0.1
52 %
0.08
0.06
0.04
0.02
0
Month

5.1.2 Analysis on Graphs

Downtime details are given below
Ø The total electricity generation in the year 2006-2007
was 1,446.381 Million units. Monthly downtime of the plant:
Ø The total coal consumption in the year 2006-2007 was
1,151,797 Metric tonnes. May 2006 – 85.16 Hours
Ø The total water consumption in the year 2006-2007 July 2006 – 51.47 Hours
was 131,859,000 litres. August 2006 - 50.19 Hours
Ø The average calorific value of the coal is taken as October 2006 - 106.3 Hours
4,121 kcal/kg. November 2006 - 36 Hours
Ø During the site visit, KTPS break down records were December 2006 - 571.5 Hours
analyzed and some of the major observations are listed January 2007 - 43.55 Hours
below: February 2007 - 1.59 Hours
March 2007 - 0 Hours
Ø The plant was shutdown on 11 occasions, of which
10 were forced shutdowns and one was a planned The plant was under forced shutdown due to various
shutdown for overhauling. reasons. Some of the main reasons are listed below:
Ø The total number of hours for which the plant was
shut down is 945.76 hours, out of which, the plant • Boiler tube leakage
was shutdown for approximately 571.5 hours during • System jerk
July and August and it was under forced shutdown • Electrical problems in the ESP
for the remaining 374 hours.
Ø The Unit 6 was under COH from 29/06/05 to Ø Out of 11 times, the plant was forced to shutdown
25/08/05 (57 days) and AOH from 27/11/06 to because of Boiler tube leakage for 9 times.
20/12/06 (23 days). Therefore, the planned Ø The main reasons established for boiler tube leakage is
shutdown time was higher in 2005-06. due to overheating, ash erosion, inflation in the bends
Ø There is an increase in power generation from etc.
1,302 Million units to 1,446 Million units (11%).
Ø There is an increase in the coal consumption by 11%.

5.2 COAL HANDLING PLANT AND MONITORING Rakewise receipts are maintained by KTPS and S E Nagpur.
KTPS prepares the bills and submits the same to the HO.
KTPS is facilitated with a centralized Coal Handling plant to
supply coal to both Stage I and Stage II. H.O. will release the payment on receipt of coal. The cost of
coal at the time of receipt includes basic charges, royalty
A conveyor is being operated to supply coal from the coal charges and sizing charges. Transit losses are allowed upto
yard to another conveyor from where coal is being fed into 0.8% of the total.
the bunkers. At present there is no measurement to weigh
the coal before feeding into bunkers. After the receipt of coal, the entire wagon is weighed with
and without coal. The tare weight of the wagon is deducted
5.2.1 Coal receipt – A Brief Introduction from the total weight of the coal to get the actual receipt of
the coal. The weighed coal is stored in the coal yard for
KTPS receives coal in two modes: supply. At present, there is no online weighment of coal
Ø Rope supply to the individual units.
Ø Rail
The typical ultimate or elemental analysis of coal is given
The road transport is used only in case of emergency. below:
The following companies supply coal to KTPS. TABLE 18 : ELEMENTAL ANALYSIS OF COAL
Ø Mahanadi coal fields Elements Value Unit

Ø Western coal fields Carbon 42.6 %
Ø South eastern coal fields Hydrogen 2.5 %
Nitrogen 0.9 %
The coal requirement for the plant is worked out
considering the previous coal factor. The coal factor is Sulphur 0.8 %
determined based on the expected generation and calorific Ash & Moisture 53.2 %
value of the coal. The anticipated coal requirement will be Total 100 %
compiled and will be submitted to Head Office (H.O.) for
approval.

The coal sample was taken at each mill and the proximate TABLE – 20 : SIEVE ANALYSIS OF COAL
analysis was carried out for the same on 10th November
2007. The results of the analysis are given below: Sieve Gradation Before Crusher % After Crusher %
+100 18 0
TABLE 19 : PROXIMATE ANALYSIS OF COAL +50 16 6
+20 20 32
Coal Moisture Ash VM FC GCV
Basis +2 38 46
Mill % % % % kcal/kg
-2 8 16
ADB 3.75 40.01 23.73 32.51 4244
A
AFB 10.51 37.2 22.06 30.23 3946
As per the analysis, 78% of the coal was crushed close to
ADB 3.04 39.29 23.25 34.42 4415 20 mm size before being fed into the coal mill and 16% of
B
AFB 12.36 35.51 21.02 31.11 3991 the coal size was less than 2 mm. Though 94% of the coal
ADB 3.1 39.6 23.87 33.43 4377 was of desired size, 6% of it was more than the required
D size. As the size of the coal is high, the power consumption
AFB 12.66 35.69 21.51 30.14 3945
in the coal mill will be high. Therefore, 6% of the coal will
ADB 3.14 38.97 22.65 35.24 4430
F have direct impact on the coal mill power consumption
AFB 12.02 35.4 20.57 32.01 4024 which requires immediate attention.
Belt ADB 3.04 36.1 26.6 34.26 4715
No. KTPS is equipped with six coal mills better known as Coal
AFB 12.94 32.41 23.88 30.77 4234
101 Mill A, B, C, D, E & F. Coal from the bunker is made to pass
Belt ADB 2.19 41.81 25.96 30.04 4301 through the feeders and is being fed into the coal mill. The
No. rate of coal fed into the mill is directly proportional to the
106 AFB 13.22 37.1 23.03 26.65 3816
speed of the feeders. The coal feeder is controlled with
Dynodrive by varying speed.
5.2.2 Sieve Analysis (Crusher)
Once the coal is crushed, primary air from the PA fan will
Sieve analysis of the coal is regularly carried out by KTPS carry the crushed coal to the boiler.
to find out the size of the coal. A sample of 1 kg or 2 kg
after crusher and after coal mill is taken out to carry out In order to carry out the sieve analysis, the coal sample
the sieve analysis. The sieve analysis results are given was taken after the crusher and before feeding to the
below:

boiler. The samples are taken from four sides and the Ø Higher flow rate of coal compared to the design
results are given in Table – 20. value
Ø Lower air flow rate
Two types of sieves are used by KTPS to conduct sieve Ø Improper design of boiler and furnace
analysis. Size of one sieve mesh is -200 mm and that of the
other is +50 mm. Based on the analysis, on an average 70% As per the analysis carried out by KTPS, the unburnts are
of the coal fed into the boiler is of required size as per the generated because of improper sizing of coal and higher
design. fuel input due to lower calorific value of coal.
But, specific to the coal mill A, 3.5% of the coal crushed On an average, 6.5% unburnts in the bottom ash and 1%
from the mill is more than 50 mm. This clearly envisages unburnts in the fly ash were measured which is significantly
not only the production of unburnt carbon during on the higher side. The general acceptable limits of
combustion in the boiler but also shows the poor unburnts are < 4% for bottom ash and < 1% for fly ash. This
performance of the mill. is one of main concern where immediate attention from
KTPS is required.
Even in other mills, 1.4 - 1.6% of the coal size was more
than 50 mm. As the size of the input coal is high, the
unburnt carbon generation during combustion will be high.
In order to analyze the same, unburnts testing are carried
out and the results are given below:
5.2.3 Unburnt carbon in the fly ash and bottom ash
The tests for unburnt carbon in the fly ash and bottom ash
were carried out during the site visit and the results of the
same are given in Table-21.
Unburnt carbon is being generated because of the following

reasons
Ø Improper sizing of coal before feeding into the boiler

TABLE – 21 : SIEVE ANALYSIS OF COAL AFTER COAL MILL
CM - A CM - B CM - E CM - F
Corner ( + 50 ) ( - 200 ) ( + 50 ) ( - 200 ) ( + 50 ) ( - 200 ) ( + 50 ) ( - 200 )
1 4 62.9 1.6 67.8 0.9 75.8 1 76
2 4.4 64.5 0.9 72.8 3 69.6 1.1 76.8
3 0.8 73.1 1.7 69.8 1.6 64.8 1.6 65.8
4 4.8 65.4 1.4 71.8 0.8 76.4 1.8 76.1
Average 3.5 66.48 1.4 70.55 1.58 71.65 1.38 73.68
During the site visit, Mills C&D were not in operation
TABLE - 22 : UNBURNTS IN BOTTOM AND FLY ASH
DATE FLY ASH BOTTOM

ASH
10/10/2007 0.51 4.56
10/11/2007 0.96 6.21
10/12/2007 1 7.15
10/13/2007 1.04 7.34
10/14/2007 1.56 6.36
10/15/2007 1.58 4.96
10/16/2007 0.4 6.76
10/17/2007 0.46 6.9
Unburnts more than

5%

5.2.4 Auxiliary Systems Auxiliary Current Voltage PF Power

A kV kW
During the site visit, the power consumption of the COAL MILL F 30 6.65 0.81 279.9
individual auxiliary units was made available by KTPS.
There are two types of auxiliaries in the power plant. CEP A 20 6.9 0.81 193.6
CEP B Not in service
Ø Auxiliary systems exclusively for Unit 6 CEP C 21 6.65 0.81 195.9
Ø Common auxiliary for stage II (Unit 5, 6 & 7)
CW PUMP A 94 6.9 0.667 749.3
The power consumption, voltage, current and power factor CW PUMP B 87 6.65 0.81 811.7
of the equipments which were under operation were given. BFP A Not in service
The data exclusively for Unit 6 is given below:
BFP B 255 6.9 0.81 2468.4
TABLE - 23 : AUXILIARY POWER CONSUMPTION DATA BFP C 250 6.65 0.81 2332
Auxiliary Current Voltage PF Power The total auxiliary power consumption is around 15 MW.
A kV kW The total auxiliary consumption of the Unit 6 works out to
ID FAN A 142 6.9 0.81 1374.6 10.1%. During the site visit, it was requested to perform an
ID FAN B 145 6.65 0.81 1352.8 exclusive study to measure coal consumption, power
FD FAN A 28 6.9 0.81 271.0 generation and auxiliary power consumption. The
FD FAN B Not in service measurements were carried out and based on the data,
heat rate, efficiency, % auxiliary consumption and plant
PA FAN A 110 6.9 0.81 1064.8
load factor are calculated. The results of the same are
PA FAN B 100 6.65 0.81 932.9 given below:
COAL MILL A Not in service
COAL MILL B 25.5 6.9 0.81 246.8
COAL MILL C 25 6.65 0.81 233.2
COAL MILL D Not in service
COAL MILL E 29 6.9 0.81 280.7

TABLE – 24 : AUXILIARY CONSUMPTION AND PLF DURING THE AUDIT PERIOD
Maximum
Heat Plant
Aux. Coal Output power
Generation input in Overall Heat % auxiliary load
Date Consumption Consumption 106 generation
in mU 106 efficiency rate consumption factor
in mU in MT kCal/d possible in
kCal/d in %
MU
10/10/2007 3.894 0.4328 3310 3348.8 12846.1 26.07 3298.9 11.1 5.04 77
10/11/2007 4.05 0.4395 3442 3483.0 13358.4 26.07 3298.4 10.9 5.04 80
10/12/2007 4.282 0.4403 3635 3682.5 14107.4 26.10 3294.6 10.3 5.04 85
10/13/2007 3.628 0.4253 3084 3120.1 11969.0 26.07 3299.1 11.7 5.04 72
10/14/2007 3.888 0.4367 3305 3343.7 12826.7 26.07 3299.0 11.2 5.04 77
10/15/2007 3.862 0.431 3283 3321.3 12741.3 26.07 3299.2 11.2 5.04 77
10/16/2007 3.846 0.4303 3269 3307.6 12687.0 26.07 3298.7 11.2 5.04 76
10/17/2007 4.222 0.4373 3589 3630.9 13928.9 26.07 3299.1 10.4 5.04 84

5.3 STOCHIOMETRIC AIR REQUIREMENT AND FLUE KTPS feeds blended coal into the boiler for steam and
GAS ANALYSIS electricity generation. Therefore, the stochiometric
calculation using elemental analysis may not be
The stochiometric air requirement, total air requirement appropriate. Therefore, the entire stochiometric air and flue
and flue gas quantity of Unit – 6 Boiler is calculated using gas generation calculation is based on the flue gas analysis.
molar volume method.
KTPS monitors the flue gas analysis every shift / day. Flue
The primary data to calculate the air requirement is gas analysis at various loads and timings has been collated
collected from the plant and the same is used for and average data for similar load at different timings are
calculation. Ultimate analysis of the fuel collected from the used to calculate the flue gas flow rate from the plant.
plant given below is used for the calculation:
TABLE – 26 : FLUE GAS ANALYSIS
TABLE – 25 : ELEMENTAL (ULTIMATE) ANALYSIS OF Flue gas analysis
COAL O2 5.1 %
Ultimate analysis of the fuel CO2 13.9 %
C 38.86 % N2 81 %
H 3.655 %
N 1.235 % The flue gas flow rate of Unit – 6 is calculated as 6.77 kg of
S 0.49 % flue gas / kg of coal
O 8.715 %
Moisture 15 % The excess air (inclusive of air ingress from furnace
draught till the end of the chimney and excess being fed
Ash 32.05 %
through primary and secondary system) is calculated and
Total 100 % found to be 1.53 kg of air / kg of coal
Though the theoretical air and total air can be calculated The excess air percent is 26.5%
based on the elemental analysis, the same was not carried
out because the elemental analysis is carried out once in 6 Theoretical air requirement based on flue gas analysis is
months. 4.24 kg of air / kg of coal
In addition, the elemental analysis was given by the supplier
for specific quality of coal (homogenous composition). But, Total air requirement is 5.77 kg of air / kg of coal

5.4 THERMAL EFFICIENCY OF UNIT – 6 BOILER TABLE - 27 : EFFICIENCY OF BOILER
The thermal efficiency of the boiler has been calculated Total heat supplied 100 %
using Indirect Method i.e., loss deduction method. Heat Lost due to flue gas 6.34 %
Heat loss due to hydrogen in
In this method, losses from the boiler are identified and the
fuel 5.26 %
same is deducted from 100% to calculate the efficiency. It
is one of the best methods recommended by Bureau of Loss due to moisture in fuel 2.40 %
Energy Efficiency to calculate the efficiency of the boiler. Loss due to moisture in air 0.2948 %
Loss due to radiation
The secondary and primary data required to calculate the assumed 1 %
efficiency were collected from the plant. The following Unburnt losses in bottom ash 1.22 %
losses are calculated using the data collected from the Unburnt losses in Fly ash 0.76 %
plant. Heat loss due to partial
conversion of C to CO 0.09 %
Ø Heat loss in flue gas
Heat losses in bottom ash 1.13 %
Ø Heat loss due to moisture in fuel
Ø Heat loss due to moisture in air Heat losses in Fly ash 0.47 %
Ø Heat loss due to H2 in fuel Efficiency 81.04 %
Ø Heat loss due to radiation
Ø Heat loss due to partial conversion of C to CO The efficiency of the boiler is calculated and found to be
Ø Heat loss due to bottom ash 81.04%
Ø Heat loss due to fly ash
Ø Heat loss due to unburnts in fly ash
Ø Heat loss due to unburnts in bottom ash

FIGURE – 29 : HEAT DISTRIBUTION CHART
Heat Distribution chart
81.0%
6.3%
0.5% 0.1% 1.2% 1.0% 2.4% 5.3%
1.1% 0.8% 0.3%
Heat Lost due to flue gas Heat loss due to hydrogen in fuel
Loss due to moisture in fuel Loss due to moisture in air
Loss due to radiation assumed Unburnt losses in bottom ash
Unburnt losses in Fly ash Heat loss due to partial conversion of C to CO
Heat losses in bottom ash Heat losses in Fly ash
Useful heat

FIGURE - 30 : LOSS DISTRIBUTION CHART
Loss distribution chart
5.26, 28%
6.34, 34%
0.47, 2% 2.40, 13%

1.13, 6%
0.09, 0%
0.76, 4% 0.2948, 2%
1.22, 6% 1, 5%
Heat Lost due to flue gas Heat loss due to hydrogen in fuel
Loss due to moisture in fuel Loss due to moisture in air
Loss due to radiation assumed Unburnt losses in bottom ash
Unburnt losses in Fly ash Heat loss due to partial conversion of C to CO
Heat losses in bottom ash Heat losses in Fly ash

5.5 HEAT ADDITION DUE TO SUPER HEATER, FIGURE - 31: HEAT ADDITION BY ACCESSORIES
ECONOMISER AND AIR PREHEATER
Superheaters, economiser and air preheater are used to Heat addition by accessories
increase the useful heat by recovering the waste heat from
the flue gas. The flue gas temperature at the boiler exit is
close to 900oC. The flue gas at 900oC is made to pass 13.4%
11.9%
through series of heat exchangers to extract heat from the

flue gas. Superheater is used to increase heat of the steam
coming out from the boiler.
Economiser is used to increase the temperature of the 7.5%

water entering into the boiler after the water is heated
through heaters. Heat addition by Super heater Heat addition by Economiser
Heat addition by Air preheater

Air preheater, as the name indicates is used to preheat the
air entering into the boiler.
Though there is a significant heat addition by accessories,
TABLE -28 : HEAT ADDITION BY ACCESSORIES there is a considerable loss in the air preheater circuit. In
order to determine the losses in the air preheater, flue gas
Total heat supplied 11010 kJ/kg of coal analysis is carried out before and after air preheater. The
Heat addition by Super heater 1307 kJ/kg of coal result of the same is given below:
Heat addition in % 11.9 %
Heat addition by Economiser 827 kJ/kg of coal O2 % at Air preheater inlet 4.4 %
Heat addition in % 7.5 % O2 % at Air preheater Outlet 5.1 %
Heat addition by Air
preheater 1235.2 kJ/kg of coal As per the analysis, it is found that there is an increase in
O2 in the flue gas. This clearly indicates that there is air
Heat addition in % 11.25 %
ingress in air preheater. Immediate measures needs to be
taken to arrest this leakage, if the leak is lesser than the
design.

FIGURE - 32: TURBINE LAYOUT
Boiler / Reheater
HP Turbine IP Turbine LP Turbine
S
Condenser
HP LP Extraction
Extraction

The energy balance across the LP heaters, HP heaters, and LP inlet are not functioning properly. It is
condensers and reheaters were evaluated with the help of recommended to replace the sensor immediately. LP
the following details: cylinder efficiency and the overall efficiency are not
established due to the non-availability of dryness fraction at
Ø Pressure across each heaters the LP exhaust.
Ø Temperature across each heaters
Ø Pressure and temperature across condensers 5.5.2 Heat addition due to reheater
Ø Pressure and temperature across reheaters KTPS is equipped with a single stage reheating system
which reheats the steam coming out from the HP turbine to
Currently, the steam flow rate across each heater is not 535˚C. The reheat pressure during the audit period was 22
measured or monitored by KTPS. Due to unavailability of kg/cm2. The steam flow in the reheater is calculated by
instruments at the site, the same was not included in the deducting the steam extracted in the HP heaters to the
report. total steam supplied to the HP cylinder inlet. Steam
extracted in each HP heater is calculated using the
Steam flow rate is used to evaluate the overall following formula :
performance of the boiler and turbine.
Heat gained by Feed water = Heat lost by the steam.
5.5.1 Turbine Efficiency The drip temperature measured physically at various
Based on the pressure and temperature across each points, steam pressure across the heater and feed water
cylinder, the efficiency of the individual cylinders and the flow is used to calculate the steam extracted in each
overall efficiency of the turbine are calculated. The heater.
efficiency details are given below:
TABLE - 30 : REHEATER EFFICIENCY
Heat addition due to reheater 81494 kW
TABLE - 29: TURBINE EFFICIENCY Heat addition in percent compared to
HP turbine efficiency 82.14 % 21.7 %
the useful heat output per kg of fuel
IP cylinder efficiency 96.9 %
5.5.3 Condenser
The efficiency of the IP cylinder is more than the design Condenser is one of the pertinent equipment in any power
value. This is due to the fact that the temperature sensors plant. The condenser will always be maintained in vacuum
displaying the temperature of the steam leaving the IP exit and the performance of the condenser is based on the

altitude of the plant and the temperature of the water 5.6 HEAT RATE AND EFFICIENCY OF PLANT
available in the near-by location.
Heat rate is one of the most important parameter which
The following parameters are monitored by the plant on a reflects the performance of the plant with the assistance of
regular basis. major equipments, auxiliaries and accessories.
Pressure in the condenser = 665 mm of Hg or Lower the heat rate, better will be the performance of the
Absolute pressure = 75 mm of Hg plant and vice versa. Heat rate can be calculated
Temperature of the condenser = 48.9 C exclusively for major individual equipments and also for
Cooling water inlet temperature = 33.4 C combination of equipments.
Cooling water exit temperature = 42.9 C
Heat rate is calculated based on the fuel flow rate, quality
Based on the above parameters, the heat rejected and of the steam generated in the boiler and power generated
effectiveness of the condenser are calculated and the by the turbine.
details of the same are furnished below:
In this report, three different heat rates are derived with
The heat rejected from the condenser are cross-checked the help of the instantaneous data and secondary data
with cooling water pump flow rate and the temperature collected from the plant. They are:
difference across cooling water system.
• Boiler heat rate
TABLE - 31 : CONDENSER EFFICIENCY • Gross turbine heat rate
Main steam flow 663 TPH • Gross unit heat rate
Range of the cooling water 8.5 ˚C
Temperature being maintained in As these three rates are very important to find out the
48.9 ˚C performance of the plant, the same are calculated and
the condenser
furnished below
Effectiveness of the condenser 58.6 %
Maximum possible effectiveness 70 % Boiler heat rate = (Heat supplied by the fuel)/(Heat
Rated flow rate of the pumps 28560 m3/h generated in the boiler + heat added in the reheater)
Heat rejected in the condenser
282343 kW
based on water flow rate

Turbine heat rate = (Heat generated in the boiler + heat Ø Power generated by the boiler = 175000 kW
added in the reheater) / Power generated by the turbine or 150 Million kCal/h
Ø Heat supplied by the fuel = 542 Million kCal/h
Unit heat rate = Heat supplied by the fuel / Power
generated by the turbine The overall efficiency calculation of the plant is given below
The heat rates are also used to calculate the efficiency of TABLE - 33 : OVERALL EFFICIENCY OF THE PLANT
the plant. Parameters Values Units
Main steam flow 663 TPH
TABLE - 32 : HEAT RATE Main steam flow 184.2 kg/s
Main steam pressure 130 kg/cm2
Heat supplied 2330 Million kJ/h
Main steam temperature 533 C
Heat generated 1579 Million kJ/h
Main steam enthalpy 3425.3 kJ/kg
Heat added in the reheater 279 Million kJ/h
Main steam entropy 6.5531 kJ/kg K
Boiler heat rate 1078 kCal/kWh
Heat inlet to the turbine 630826 kW
Power generated by the
175000 kW Power output 175000 kW
turbine
Instantaneous Gross Power output 150500000 kCal/h
2535 kCal/kWh Heat inlet to the turbine 542386888 kCal/h
turbine heat rate
Instantaneous Unit heat Instantaneous Overall
3180 kCal/kWh Efficiency 27.75 %
rate
5.6.1 Efficiency of the plant 5.6.2 Benchmarking of KTPS
In general, the efficiency of any equipment will be CEA along with CII carried out energy efficiency study in 19
calculated as output upon input. As per formula, the power thermal units. The comparison of best figures in each
generated by the turbine upon the heat supplied by the parameter achieved by Indian thermal power plant over last
boiler will give the efficiency of the plant. five years (2001-2005) have been collected and the same
are compared with KTPS.

TABLE - 34: BENCHMARKING KTPS WITH OTHER same can be improved. Some of the suggestions are given
POWER PLANTS below to improve the monitoring and recording system:
Average Average Performance of Ø Online power measurement of BFP pumps, ID and

parameters parameter KTPS FD fans, CEPs and Coal mills. At present, total
of the best of all Indian auxiliary consumption is monitored but by
performing power 2005- 2006- measuring individual power consumption, the exact
Description unit plants 06 07 loading of the equipments can be found out.
Forced outage Therefore measurement of power can be included in
% 4.44 8.84 6.67 4.57 the log book as a part of regular practice
Planned
Ø Online power measurement of coal feeders. At
maintenance % NA 8.23 15.40 6.52 present, feeders are operated with the help of RPM
Operating and Amps which is an old practice. Though
availability measurement of amperage suffices the purpose, it
factor% 93.6 82.93 84.60 93.48 will have direct impact on the efficiency of the
Plant load motor as it is inversely proportional to the power
factor 93.18 74.82 70.77 78.6 factor. Therefore, power measurement can be
Specific fuel oil included in the log book.
consumption in
ml/kWh 1.2 1.37 3.06 2.23 Ø Arresting of steam leakages. The steam leakage
Auxiliary checks can be carried out regular intervals. Steam
consumption 7.53 8.57 9.42 9.82 leakage arrest the same as much as possible to save
energy.
Ø Measurement of boiler surface temperature at
During the site visit, the observations were made in terms regular intervals. It is recommended to measure the
of log book maintenance practices, operational practices, temperature of the boiler at regular intervals to
data retrieved from DCS system, availability of water flow check whether the surface temperature is well
and steam flow meters etc. Based on the observations, within the limits. In case of abnormalities, the
majority of the places had relevant instrumentation but the quality of insulation in the area can be improvised.

Ø Measurement of coal consumption. Though it is well

known that very few power plants in India have the 5.6.3.1.2 Continuous usage of attemperation
facility to measure the coal, but online monitoring of
the bunkered quantity of coal shall be carried out by During the visit, it was observed that there is a continuous
installation of the belt weigher to the conveyor belts attemperation. Attemperation or de-superheating of the
going to the bunker. steam will be carried out to reduce the inlet temperature of
the steam to the turbine when it is higher than the designed
5.6.3.1 Major observation for Energy Savings: temperature. Though attemperation is a regular practice in
power plants and as it does not lead to loss of steam or
5.6.3.1.1 Quality of coal water, it is not necessary to increase the temperature of
The boiler installed in KTPS is designed to handle the coal the steam to such a high temperature and reduce it to the
with a calorific value (CV) of 5000 kcal/kg. But the coal design temperature.
received by the plant has a calorific value of 3800 - 4200
kcal/kg. The receipt of low CV coal has a direct impact on In order to achieve high temperature, it is necessary to
the electricity generated by the plant. As per the elemental feed more fuel and during de-superheating, there is
analysis, this coal has nearly 15% moisture and 33% Ash. As reduction in temperature of the superheated steam which
there is high moisture and ash quantity, KTPS plant is a loss of energy. Attemperation on an intermittent
personnel are utilizing higher quantity of coal compared to interval is healthy but not when done continuously.
the rated capacity to maintain the load factor. Due to Therefore, during R&M, consideration should be given to
higher coal feed rate, incomplete combustion takes place address this issue.
inside the boiler. Due of this, the unburnts are produced
and is observed in the ash analysis. The unburnts in the 5.6.3.1.3 Oxygen level in the flue gas and flue gas
bottom ash are around 6 – 7%. During R&M, this issue temperature
should be considered. During the site visit, the flue gas analysis was carried out
to identify the oxygen level in the flue gas to determine the
The alternative option for KTPS is to avail the usage of excess air level. Based on the flue gas analysis, the
washed coal in the boiler. The washed coal has nitrogen balance was carried out to determine the excess
comparatively higher calorific value and lesser ash content air & air ingress and it was calculated and found to be 20%.
compared to that of conventional coal. Therefore, it is Further, flue gas analysis was also carried out before and
recommended to expedite available washed coal and use after Air preheater. There is a difference of 0.7% observed
the same in the boiler. across the Air preheater. Though it is less than the design

as mentioned by the plant personnel, reduction in air Sieve Gradation Before Crusher % After Crusher %
ingress will reduce the power consumption of ID fan. +100 18 0
Therefore necessary measures can be carried out to arrest +50 16 6
the air ingress.
+20 20 32
In addition, the flue gas temperature was also observed to +2 38 46
be higher than the desired value. On an average, the flue -2 8 16
gas temperature of the thermal power plant lies in between
145 - 150˚C. But the flue gas temperature was measured In practice, KTPS is monitoring and recording the analysis
as 169˚C. It is anticipated that the flue gas temperature of the coal before the crusher. During the visit, it was
will be much high compared to 169˚C as there is an air requested to carry out the sieve analysis before and after
ingress in the flue gas path and even in the air preheater. the crusher.
Because of the addtion of fresh air having low temperature, · As per the analysis after crusher, it is observed that
temperature of the flue gas was observed to be lower. nearly 80% of the size of the coal after crushing lies
Otherwise, the actual flue gas temperature will be close to between 2 mm to 50 mm and
200˚C which is very high compared to the normal standard · only 16% of the size of the coal lies between -2 mm
of any thermal power plant. to 2 mm.
But before crusher, it is observed that nearly
Therefore, it is highly recommended to take immediate · 58% of the size of the coal lies between 2 mm to 50
measures to reduce the flue gas temperature. mm,
· 8% of the size of the coal lies between -2 mm to 2
5.6.3.1.4 Sieve analysis mm and
The sieve analysis is carried out by the plant personnel · 34% of coal is having size higher than the 50 mm.
after crusher and before coal mill. During the site visit,
different types of sieves were observed and the plant 16% fines would be possible because of two main reasons:
personnel were requested to undergo sieve analysis for a 1. Coal would have been received with lot of fines or
maximum range before crusher, after crusher and after smaller size
coal mill. Based on the analysis for a specific sample, the 2. Improper functioning of Crusher
following results were observed.
Therefore, if the sieve analysis was conducted before
crushing, nearly 64% of the coal in that particular rake

would have been directly sent to the bunker without to ensure 100% size of the coal to be less than the desired
crushing. This not only saves the power consumption in the size for the boiler.
crusher but also increases coal crushing rate.
Therefore, it is recommended to carry out sieve analysis 5.6.3.2 Install Smart Wall Blowing System for
before crusher and to install a classifier to separate fines or Optimizing Wall Blowing and Improving Heat Rate
required size of the coal before feeding into the crusher.
The boiler performance including its ability to meet full
In addition to this, sieve analysis has been conducted after load, auxiliary power consumption, net plant heat rate,
coal mill. It is observed in the coal mill A that nearly 3.5% of availability of the unit, operation and maintenance cost etc.
the size of the coal lies above 50 mm and 67% of the size of are significantly affected by the fuel characteristics. Coal
the coal is less than -200mm and rest of the % size lies firing in the furnace forms different kinds of deposits on the
between -200mm and +50mm. Because of feeding higher boiler tubes.
size coal in the boiler, unburnts are coming out in the
bottom and fly ash. To improve the performance and thermal efficiency of the
boiler, it is important to remove these deposits periodically
The discharge of higher size from the coal mill is mainly due and maintain a clean heating surface.
to two reasons:
Boilers are designed such that the radiation and convective
1. Inefficiency of coal mill zone heat transfer surfaces absorb the released heat
2. Receipt of higher size coal from the crusher proportionately. Any deviation in heat transfer in radiation
and convection zone will affect the function of feed water
Both the issues are possible, therefore necessary measures preheating in the economiser, steam super heating in
needs to be carried out to maintain 100% size of the coal to LTSH, platen super heater and final super heater. This will
be less than -200 mm. result in reduction in boiler operating efficiency.
Because of the unburnts in the ash, nearly 2% loss in the Smart wall blowing system (SWBS) is a selective wall
efficiency is observed. In addition, there is a subsequent blowing system, operating on auto mode. The operation is
loss in the power consumption in the coal mill. Therefore, it controlled based on super heater spray flow and furnace
is highly recommended to install a classifier before crusher heat absorption at different zones. The system helps to
maintain the furnace heat absorption at optimum level

thereby maintaining the super heater and reheater sprays sensors in each wall and totally 32 sensors are mounted on
within limits. four sides of the water wall. The arrangement of heat flux
sensor is shown in Figure - .
5.6.3.2.1 Present Status
The two ends of the sensors are exposed to the flame
The conventional wall blowing systems are operated radiation and the stable cooling water side respectively.
sequentially once in 8 hrs. All soot blowers will be operated Sensors continuously give output proportional to the
3 times a day. absorbed heat flux.
In conventional blowing system, the furnace condition is The sensors are connected to the remote SWBS control
not taken into consideration. The changes in fuel panel positioned in the control room through transmitters.
characteristics and boiler load are also not taken into The SWBS control panel is connected to the conventional
account for controlling the soot blowing. soot blowing system. It is an add on facility to the existing
soot blowing system.
Periodical operation of the soot blowing system leads to
significant variation in super heater and reheater spray.
Soot blowing requires about 3.3 tons of steam per cycle.
In addition operating blowing system on a clean boiler tube

surfaces leads to increase in erosion rate. This leads to
increase in boiler tube failures.
5.6.3.2.2 Project Recommended:
SWBS consists of an electronic logic system interfaced with

existing normal blowing system. The system consists of
water wall heat flux sensors installed in between the wall
blowers. The sensors have built in thermo couples.
The heat flux sensors are installed in between the wall

blowers in four elevations. There are eight heat flux

FIGURE - 33: HEAT FLUX SENSOR the spray crosses the highest / lowest set points
respectively.
When there is a reduction in the heat flux below the

dynamic set value of a particular sensor the adjacent two
blowers are actuated automatically. The sequence of heat
flux comparison with the set values and the blower by
passing/ blowing continues in a sequential manner from
wall to wall till the SH spray flow reaches the low set point.
The blowing operation resumes in auto mode when the SH

spray flow crosses the high set point with a comparison of
heat flux with the set point. The system maintains super
heater spray flow within a narrow band.
The trend of super heater spray control with conventional

blowing system and SWBS is shown in Figure –
Each blower operates once / twice or thrice in a day

depending on the heat flux value. Blowers, which are not
operated in the first two cycles, are operated compulsorily
5.6.3.3 Operation of SWBS in the third cycle, irrespective of their heat flux value.
Hence each blower operates atleast once in a day and
The heat flux changes continuously depending upon the avoids permanent adherence of the deposits on water wall
thickness and heat transfer properties of the deposits. The surface.
actual heat flux is measured continuously by the heat flux
sensor and monitored with the dynamic set point.
The super heater spray requirement triggers the operation.

The High and low SH sprays are set to desired values. The
system either starts or stops the blowing sequence when

FIGURE - 34: SUPER HEATER SPRAY CONTROL WITH Reduction in tube erosion due to selective and reduced
CONVENTIONAL BLOWING SYSTEM AND SWBS steam blowing
5.6.3.3.2 Financial Analysis
Annual energy saving of Rs 52.50 Lakhs was achieved. The

break up of savings achieved is as below.
RH spray reduction - Rs 43.50 Lakhs

Reduction in steam consumption - Rs 7.50 Lakhs
Material saving due to reduction
in erosion - Rs 1.50 Lakhs
5.6.3.4 Introduction Of Super Cleaning Of Turbine

Oil
5.6.3.4.1 Background
5.6.3.3.1 Benefits
Lubrication oils are being used in various equipments, out
Installation of SWBS results in following benefits. of which turbine lubrication system is very important and
critical application. Servo prime-46 of M/s. IOC make is
Reduced variation in SH/RH spray. Hence steady SH / RH used for turbine bearing lubrication and governing system.
steam temperature. This results in improved efficiency of The major parameters of the lube oil like viscosity,
boiler and heat rate of overall cycle. moisture, and mechanical impurities, TAN etc. Are being
Reduced superheated steam consumption due to reduced maintained within limits, by inbuilt centrifuging and top-up.
number of wall blowing.
However the oil in use picks up contamination from wearing
The soot blower operation is reduces by about 55 - 60% parts and the wear debris further pass through the system
compared to conventional wall blowing system. and in turn generate more contaminants, which can be
described as a self-escalating snow balling process.

Smaller contaminant particles are larger in number than 5.6.3.4.3 Project Recommended
larger contaminant particles. Only these smaller particles
can enter clearances and cause damage to mating parts. Electrostatic Liquid cleaner-ELC-100LP is been
recommended to each Main oil Tank (MOT) to super clean
The super-cleaning initiated to reduce wear tear of the Turbine oil. The oil supply is taken from MOT and outlet
equipment components and increase the life of lubricating is connected back to MOT.
oil by keeping check on contamination by dedicating two
units of electrostatic liquid cleaner –elc 100lp. 5.6.3.4.4 Principle of Operation Of Electrostatic
Liquid Cleaner
5.6.3.4.2 Present Status
ELC is an Electro static liquid cleaner and works similar to
The Filtration particle size of Duplex filter element & Main the principle of ESP (Electro Static Precipitator),
oil tank filter element is 37 μm and 250 μm respectively. Contaminants in oil such as magnetic / nonmagnetic,
This indicates that particles size up to 37 μm can onlybe organic/ inorganic, resinous matter or sludge etc are either
filtered on line. positively or negatively charged due to the contact
potential difference with oil.
Turbine oil is supposed to maintain ISO 11/9 to 13/10 level
of cleanliness, which is equivalent to ‘NAS 7’ and below. When oil is passed through an electric field, positively
However it was observed that NAS level of oil in use is 12+ charged particles are drawn to the negative pole and vice
with present on line cleaning system. versa. Neutral contaminants are drawn and deposited by
gradient force to the edge of the die electric media where
Ø The frequent chocking of Duplex Filter was noticed the intensity of the deformed electric field is highest.
with the existing on line filtration & centrifuging
system. When corrugated die electric media (collectors) are
Ø The thick sludge of observed at the bottom of Main inserted between electrodes, the electric field is deformed
Oil Tank during overhauls. and die electric polarisation occurs at the tips of the
Ø Governing problem faced resulting in two tripping of corrugation. The electric field is the strongest at the tips
the unit. and particles are drawn and deposited on opposite electric
Ø Scratching and scouring marks were observed on poles and removed from oil.
the turbine and generator bearings and journals
during overhauls.

FIGURE - 35: WORKING PRINCIPLE 5.6.3.4.5 Benefits
Two nos of ELC-100LP Machines are dedicated for the

cleaning of Turbine oil. The oil cleanliness level of NAS 7
has been maintained. This has resulted in following
benefits.
§ Duplex Filter chocking has been reduced

considerably. Loss of oil from the system has
reduced due to reduced cleaning of Duplex Filter,
there by less draining of oil from the filter.
§ Average Oil consumption has been reduced to 76
barrels from 145 per year.
§ Reduction in sludge formation at the bottom of Main
Oil Tank.
§ No Governing problems are faced due to chocking of
governing components.
5.6.3.4.6 Cost Saving Due To Saving In Spares

(Turbine Bearings & Duplex Filter Strainer) and Oil
Conservation of oil and better environment due to lesser

need for disposal of used oil. The reduction in oil
consumption pattern is shown in the graph:

FIGURE - 36: OIL CONSUMPTION PATTERN 5.6.4 ENVIRONMENT AND ENERGY
Any resource efficiency assessment leads to increase in

efficiency of the power plant and it will have direct impact
on the environment. An exercise has been carried out to
arrive at the impact of R&M activity over the environment.
The main objective of carrying out this exercise is to
establish the month wise baseline emissions and what
would have happened after the R&M activity. In order to
arrive the same, the resources have been identified and
emissions because of utilizing the resources have been
calculated based on the data received, emissions measured
during the site visit and some assumptions.
The following resources have been identified:

5.6.3.4.7 Financial Analysis 1. Coal
2. Light Diesel Oil
Installation of super cleaning system has resulted in many 3. Furnace oil
tangible and intangible benefits. 4. Water
5. Chemicals for water treatment
Total cost saving of Rs. 71.96 Lakhs has been achieved
.The break up of saving is as below. The major emissions from the plant are:
1. CO2
Cost saving due to Turbine spares - Rs 38.00 Lakhs. 2. CO
Cost saving due to reduction in oil top up - Rs 14.21 Lakhs. 3. SOx
Cost saving due to tripping of unit due to chocking of 4. NOx
governing components - Rs 19.75 Lakhs 5. SPM
6. Industrial effluents
The mapping of the resources and emissions chart is given

below:

Coal CO2 5.6.4.1 Monthly Baseline emissions
The following parameters have been calculated to establish

LDO CO the baseline emissions.
1. Efficiency of the plant : The efficiency of the plant have

FO NOx been calculated with the help of coal consumption,
calorific value and electricity generation
SOx
2. CO2 emissions: CO2 emissions are calculated with the
use of percent carbon and coal consumption
SPM 3. SOx emissions: SOx emissions are calculated with the

use of SOx measured, Flue gas temperature (180 C),
flue gas flow rate and Coal consumption
Water & Effluents
chemicals 4. NOx emissions: NOx emissions are calculated with the
use of NOx measured, Flue gas temperature (180 C),
Since the consumption Light Diesel Oil and Furnace oil is flue gas flow rate and Coal consumption
comparatively much lower than the consumption of coal the
same has not been included in the calculation. 5. CO emissions: CO emissions are calculated with the use
of CO measured in PPM (18-21 ppm and 19.5 ppm is
The major water consumption areas in the power plant are assumed for calculation), flue gas temperature (180
cooling towers, Boiler feed and ash (bottom ash) slurry C), flue gas flow rate and coal consumption
mixing. Since the make up water consumption in the
cooling tower and boiler feed are comparatively lesser than 6. SPM emissions: SPM emissions are calculated with the
the water being used for Ash slurry mixing, the water use of SPM measured in mg/m3, Ash % in coal, Ratio of
consumption cooling tower and boiler feed have not been Bottom ash to Fly ash (20:80), flue gas flow rate and
considered for calculations. Coal consumption

7. Water consumption: It is assumed that in order to generated in the last financial year would be
dispose one tonne of ash three tonnes of water shall be generated in the future.
used.
For these above mentioned scenarios, coal consumption
Based on the calculations, the graphs were drawn to and other emissions pattern have been calculated. The
identify the pattern of the emissions in month wise. emissions pattern of the KTPS before R&M activity is given
below:
It is assumed as well as anticipated that because of the
R&M activity, there would increase or decrease in the FIGURE - 37: CO2 Emission Levels before R&M
emissions based on the type of activities which would have
carried out R&M. The following two scenarios have been
CO2 Emissions in MT
identified and emissions patterns have been forecasted for
the unit 6. 180000
160000
Scenario 1. 140000
120000
100000
The scenario one possess has adopted two conditions: 80000
60000
1. If the efficiency of the unit 6 is increases by 1% after 40000
R&M activity. 20000
2. If KTPS would operate the unit in such a manner so 0
that the monthly maximum electricity that had been Apr-06 May-06 Jun-06 Jul-06 Aug-06 Sep-06 Oct-06 Nov-06 Dec-06 Jan-07 Feb-07 Mar-07
Month
generated in the last financial year would be
generated in the future.
Scenario 2
1. If the efficiency of the unit 6 is increases by 1% after

R&M activity.
2. If KTPS would operate the unit in such a manner so
that the monthly average electricity that had been

FIGURE - 38: CO Emission Levels before R&M FIGURE - 40: SO2 Emission Levels before R&M
CO Emissions in MT SO2 Emissions in MT
9 400
8 350
7 300
6
250
5
200
4
150
3
100
2
1 50
0 0
Apr-06 May-06 Jun-06 Jul-06 Aug-06 Sep-06 Oct-06 Nov-06 Dec-06 Jan-07 Feb-07 Mar-07 Apr-06 May-06 Jun-06 Jul-06 Aug-06 Sep-06 Oct-06 Nov-06 Dec-06 Jan-07 Feb-07 Mar-07
Month Month
FIGURE - 39: SPM Emission Levels before R&M FIGURE - 41: NOx Emission Levels before R&M
SPM Emissions in MT NOX Emissions in MT
80.00 50
45
70.00
40
60.00
35
50.00 30
40.00 25
20
30.00
15
20.00
10
10.00 5
0.00 0
Apr-06 May-06 Jun-06 Jul-06 Aug-06 Sep-06 Oct-06 Nov-06 Dec-06 Jan-07 Feb-07 Mar-07 Apr-06 May-06 Jun-06 Jul-06 Aug-06 Sep-06 Oct-06 Nov-06 Dec-06 Jan-07 Feb-07 Mar-07
Month Month

FIGURE - 42: Water Consumption Levels before R&M FIGURE - 44: CO Emission Levels after R&M
Water consumption for Ash Slurry Preparation in MT CO Emissions in MT
10
30000
9
25000 8
7
20000 6
5
15000
4
3
10000
2
5000 1
0
0 Apr-06 May-06 Jun-06 Jul-06 Aug-06 Sep-06 Oct-06 Nov-06 Dec-06 Jan-07 Feb-07 Mar-07
Apr-06 May-06 Jun-06 Jul-06 Aug-06 Sep-06 Oct-06 Nov-06 Dec-06 Jan-07 Feb-07 Mar-07 Month
Month Actual electricity generated Maximum electricity generated Average electricity generated
The following patterns show the emissions level after FIGURE - 45: SPM Emission Levels after R&M
carrying out the R&M activity.
SPM Emissions in MT
FIGURE - 43: CO2 Emission Levels after R&M 90.00
80.00
70.00
CO2 Emissions in MT
60.00
200000
50.00
180000
160000 40.00
140000
30.00
120000
100000
20.00
80000 10.00
60000
0.00
40000
20000
Month
0
Apr-06 May-06 Jun-06 Jul-06 Aug-06 Sep-06 Oct-06 Nov-06 Dec-06 Jan-07 Feb-07 Mar-07 Actual electricity generated Maximum electricity generated Average electricity generated
Month
Actual electricity generated Maximum electricity generation Average e le ctricity generated

FIGURE - 46: SO2 Emission Levels after R&M FIGURE - 48: Water Consumption Levels after R&M
SO2 Emissions in MT Water consumption for Ash Slurry preparation
450 3 5000
400
3 0000
350
2 5000
300
250 2 0000
200
1 5000
150
1 0000
100
50 5000
0 0
Apr-06 May-06 Jun-06 Jul-06 Aug-06 Se p-06 Oct-06 Nov-06 De c-06 Jan-07 Feb-07 Mar-07 Apr-06 M ay-06 Jun-06 Jul-06 Aug-06 Se p-06 Oct-06 Nov -06 De c-06 Jan-07 Fe b-07 Mar-07
Month Month
Actual e missions Maximum e le ctricity ge ne rate d Ave rage e le ctricity ge ne rate d Actual emissions Maximum electricity generated Average electricity generated
FIGURE - 47: NOx Emission Levels after R&M From the above emission pattern it is observed that if the
efficiency of the increased by 1% and average electricity
NOX Emissions in MT generated that had been generated in last financial year
60 would have been generated in the future the emissions are
50 lower than the present emissions.
40
30
If actual electricity generation in the future is equal to the
monthly maximum electricity that had been generated in
20
the last financial year than the emissions are slightly higher
10
than the actual emissions
0
Month The comparison table is given below:
Actual electricity generated Maximum electricity generated Average electricity generated

CO2 emissions SOx

SOx emissions with
Percent in
Months average electricity
emissions emissions
generation
CO2 emissions with
CO2 Percent in 9 Data not taken for calculation
emissions emissions 10 363.4 308.8 -15
generation
MT MT % 11 341.2 305.5 -10
1 149706 128881 -14 12 365.1 306.8 -16
2 133307 127665 -4 Total 3658 3449 -5.725
3 150143 130324 -13
4 139568 135622 -3 NOx emissions with
NOx Percent in
5 142148 150374 6 Months average electricity
emissions emissions
6 140479 145902 4 generation
7 141981 138858 -2 MT MT %
8 122371 136065 11 1 43 37 -14
9 Data not taken for calculation 2 36 35 -4
3 41 36 -13
10 157594 133916 -15
4 40 39 -3
11 147764 132288 -10
5 39 42 6
12 159301 133845 -16
6 39 40 4
Total 1584360 1493740 -5.720
7 37 36 -2
8 30 33 11
SOx emissions with 9 Data not taken for calculation
SOx Percent in
emissions emissions 10 40 34 -15
generation
MT MT % 11 36 32 -10
1 347.2 298.9 -14 12 37 31 -16
2 310.1 296.9 -4 Total 420 396 -5.626
3 346.7 300.9 -13
4 325.1 315.9 -3
5 329.7 348.7 6
6 320.6 332.9 4
7 328.8 321.6 -2
8 280.5 311.9 11

CO emissions with SPM emissions with

CO Percent in SPM Percent in
Months average electricity Months average electricity
emissions emissions emissions emissions
generation generation
MT MT % 11 62.22 55.70 -10
1 8 7 -14 12 71.94 60.45 -16
2 7 7 -4 Total 621 585 -5.844
3 8 7 -13
4 7 7 -3 Water
5 7 8 6 consumption Water would have
Percent in
6 7 7 4 Months for Ash consumed for Ash
emissions
7 7 7 -2 slurry preparation
8 6 7 11 preparation
9 Data not taken for calculation MT MT %
1 23236 20004 -14
10 8 7 -15
2 20775 19896 -4
11 8 7 -10
3 23058 20014 -13
12 8 7 -16
4 20535 19954 -3
Total 81 76 -5.720
5 23266 24613 6
6 22680 23555 4
SPM emissions with 7
SPM Percent in 22982 22477 -2
emissions emissions 8 19452 21629 11
generation
MT MT % 9 Data not taken for calculation
1 64.56 55.58 -14 10 24388 20724 -15
2 36.21 34.68 -4 11 23159 20734 -10
3 50.98 44.25 -13 12 24303 20420 -16
4 44.55 43.29 -3 Total 247835 234020 -5.575
5 53.58 56.68 6
6 51.99 54.00 4 In nut shell, if the unit generates maintain average
7 70.87 69.31 -2 electricity that had been generated in the last financial
8 52.77 58.68 11 year, there is an emission reduction of more than 5%.
9 Data not taken for calculation
10 61.54 52.29 -15

Sl no Parameters Percent decrease

1 CO2 5.720
2 CO 5.720
3 SOx 5.725
4 NOx 5.626
5 SPM 5.844
6 Water consumption 5.575
The emission pattern calculation and scenario 1 calculation

have been given in the annexure.

PART 6: OCCUPATIONAL HEALTH & SAFETY Ø Review of the protocols for safety of workers
ASSESSMENT working in hazardous work place
Ø Review of the accidents and emergency responses;
MAHAGENCO is committed to achieving its Environmental, and
Health and Safety Mission statement and has established a Ø Review of the monitoring and maintenance of health
Corporate Environmental, Health and Safety Unit (CEHSU) records.
to be responsible for the implementation of its EHS policy.
In this regard, MAHAGENCO has instituted a dedicated The areas covered during the study included fire fighting
Safety department at the KTPS, which is responsible for systems, personal protective equipment, safety drills,
addressing the policy, undertaking and implementing periodic health check up for workers, rotation of work and
measures for achieving the set targets with regard to minimisation of exposure and emergency management
safety and reporting its performance to the higher plans.
management.
Our approach for OH&S assessment has been provided in
The OH&S assessment was carried out to review and Figure.
assess the adequacy and effectiveness of the existing
Occupational Health and Safety (OH&S) and to suggest A list of documents that have been reviewed and personnel
necessary measures to improve the safety performance of interviewed during the audit has been provided in Table 1
the plant. and Table 2, respectively.
The key objectives of the OH&S assessment included:

Ø Examining the plant’s capacity and record with
respect to workers’ safety and occupational health;
Ø Evaluating the readiness and capacity of the plant’s
emergency management systems to cope with
incidents varying from small spills to major
accidents;
Ø Assessing plant’s overall performance vis-à-vis
applicable national and state level laws and
regulations on OH&S and emergency preparedness;

APPROACH FOR OH&S ASSESSMENT
Understand the existing system in place for OH&S Management
Review of plant’s safety performance
Review of compliance status with applicable national and state laws and
regulations
Review of documents to understand the adequacy of the existing

management system
Site reconnaissance for physical verification and understanding the

effectiveness of the existing system through visual observations
Workers interviews to understand the level of awareness and gauging the

effectiveness of the existing system

6.1 Safety Analysis FIGURE - 50: SAFETY PERFORMANCE OF KTPS PLANT

6.1.1. Safety Performance (SOURCE: KTPS)
The performance of the plant with regard to safety has

been analyzed for a five year period between 2002 and
2006. Table 35 provides a summary of the number of
accidents and fatal accidents as against the total number of
workers (permanent & contract) employed in the plant.
From Figure 50, it may be observed that the number of

accidents has risen from 2002 to 2004. Since 2004, a
declining trend has been observed in the number of
accidents in spite of including minor accidents such as pin
prick, sprained back or foot, slip on plain road. In the year
2006, the plant, on an average, witnessed one accident
every second week.
TABLE - 35: SAFETY PERFORMANCE OF KTPS PLANT TABLE – 36: SAFETY STATISTICS OF KTPS PLANT
(SOURCE: KTPS) (SOURCE: KTPS)
No of Man Man days

Frequency Severity Incidence
Accidents/ Year days lost
Total no of No of No of fatal Rate Rate Rate
Year Total Worked
Employees accidents accidents 2002 2.14 51.05 0.49 1596145 643
employees
(%) 2003 3.96 635.57 1.08 1343200 6736
2002 4373 27 0 0.617 2004 4.96 1400.2 1.07 1687760 18646
2003 3680 33 1 0.896 2005 2.79 74.14 0.77 1318015 771
2004 4624 39 3 0.843 2006 2.37 62.24 0.63 1371670 683
2005 3611 29 0 0.803
2006 3758 26 0 0.691

6.1.2 Predominant Cause-wise Accident workers are concentrated at one particular area and
monitoring for safety related issues is more effective.
Table 37 categorizes the cause of the accidents based on Also, detailed safety instruction are given to the
Unsafe Act and Unsafe Condition. Unsafe Acts may be contractors employed during the over haul along with the
defined as the actions of a worker in a manner which vary contract document. This makes it mandatory for all
from the accepted or legislated safe practice and create a contract workers to follow safety procedures during the
hazard to themselves, another person, or equipment. maintenance work. It was also informed that such kind of
Unsafe Condition is a condition in which something exists vigilance / monitoring is not possible during the regular
that varies from a normal accepted safe condition and, if work as the workers / employees are scattered and
not corrected, could cause injury, death, or property checking each individual would be a tedious task.
damage.
From the above, it may be concluded that the performance
On perusal of Table - 39, it may be observed that unsafe of the plant with regard to safety has been consistently
acts have contributed to more than half of the accidents improving since the past three years. However, unsafe
that have occurred in the plant since 2004. Although the acts, the cause for majority of such accidents in the plant
number of accidents has been declining, the number of premises have not shown a declining trend.
unsafe acts has not declined. The number of unsafe
conditions, leading to accidents has however constantly
decreased since 2004.
It was observed that the there were no accidents reported

during the over haul. On further investigation it was
informed that, the same was due to the increased vigilance
of the safety department during the over haul as all the

TABLE - 37: CAUSE-WISE ACCIDENT STATISTICS OF KTPS PLANT (SOURCE: KTPS)
Particular 2002 2003 2004 2005 2006

No % No % No % No % No %
Total No of Accidents 27 - 33 - 39 - 29 - 26 -
Unsafe Act - - - - 21 53.8 15 51.7 15 57.7
Unsafe Condition - - - - 14 35.9 9 31.0 5 19.2
Combined - - - - 4 10.3 5 17.2 6 23.1
Total Number of - - - - 25 64.1 20 68.9 21 80.7
Unsafe Acts
6.2 Occupational Health & Safety System Recommendations
The following section details the observations made with The EHS policy should be updated and endorsed by the top
regard to the existing OH&S system of the plant and management of MAHAGENCO as it conveys the
recommendations suggested to improve the performance commitment and attitude of the management towards
for each of those aspects. ensuring safe and healthy work environment in the plant
premises.
6.2.1. Environment, Health and Safety (EHS) Policy
It was informed by KTPS that the EHS policy is being
Background amended as per the requirement and same shall be part of
the health and safety management once it is approved by
The EHS policy of the erstwhile MSEB has been displayed at the corporate EHS Unit.
multiple locations within the plant premises in English as
well as local language. 6.2.2. EHS Audit
Observation The EHS policy makes a commitment towards carrying out

annual audits for its EHS performance to determine
MAHAGENCO, has not revised the policy since the compliance with the policy. However, it was observed that
restructuring of MSEB in 2004. the audits pertaining to the Health and Safety performance

of the plant, as committed in the policy, are not being Ø Assess the likelihood of each of the hazardous
carried out on an annual basis. OH & S audit by an external situations occurring (Risk Assessment);
agency has not been carried out since November / Ø Identify and effectively implement appropriate
December 2002. The latest EHS internal audit was carried control measures to prevent the occurrence of such
out in the September 2005 but the report is yet to be hazardous situations (Risk control); and finally
shared with KTPS personnel. Ø Review measures continually to ensure their
effectiveness
Recommendations
Observation
OH&S audit should be carried out at the frequency
committed in the policy. Regular audits would help in KTPS has conducted a Risk Analysis study at the plant and
tracking and improving the performance of the existing OH detailed action plan is prepared and implemented through
& S system. OHSAS.
6.2.3 Hazard Identification & Risk Assessment Recommendations
Background While planning for control measures the Hierarchy of

Control indicated in the Figure 51 below should be
A hazard identification and risk assessment study helps an considered. Controls closer to the top of the hierarchy are
organization in identifying, evaluating and controlling of preferable to those lower down the hierarchy such as PPE
OH&S risks on an ongoing basis, hence contributing to as they are less dependent on human behavior. Elimination
making the work place safer. Hazard Identification, risk should be given priority in controlling hazards, wherever
assessment and risk control processes are identified as key possible and practical. Isolation and engineering controls
components of such a study. To effectively manage the should be next considered. Administrative controls and
health and safety of its employees, it is essential for an PPE may be useful in addition to other control methods.
organization to:
Ø Identify any potentially hazardous situations (which

may cause injury, illness or disease) in workplace on
an ongoing basis (Hazard Identification);

FIGURE – 51: HIERARCHY OF RISK CONTROL 6.2.4. Personal Protective Equipment
Background
HAZARD
PPE are useful in eliminating and reducing injuries to
workers due to hazards, which cannot be controlled
ELIMINATE adequately through other control methods such as
elimination, substitution, and engineering.
Observations
SUBSTITUE
PPE such as shoes, helmets, goggles, belts and masks have
been provided to the workers in KTPS. The appropriateness
ENGINEERING and specification for the PPE to be used for performing
various work activities is decided in consultation with the
safety officer. The list of PPE to be used in the plant is
maintained with the safety department. The workers and
ADMINISTRATIVE
contractors have been communicated about the type of
PPE to be used based on the nature of the work activity.
The safety department and sectional heads are reportedly
PPE responsible for ensuring that workers are provided and use
appropriate PPE.
ACCIDENT / The management has initiated efforts for ensuring

LOSS increased use of PPE by the workers by denying entry to
workers without safety shoes and helmets. During the site
visit, however, multiple workers were observed working
without using basic PPE.

Root Cause Ø Efforts should be initiated to understand the

negligence of the workers towards the usage of PPE.
Further investigation revealed the non-adherence to use of For effective use of the PPE, the first line
PPE is due to the following reasons: supervisory personnel should also be imparted
training and such personnel may be held
Ø Discomfort (in carrying out certain tasks while accountable for effective use of the PPE. These
wearing PPE) supervisors need to set an example by wearing PPE
Ø Lack of awareness of potential hazards and PPE to themselves and ensure effective use of the PPE by
be used specific to minimizing risk due to those others as well. Awards and recognition should
hazards complement on-going training and awareness
Ø Behavioral issues such as carelessness and lack of programs.
motivation -“A few workers indicated that they have
been doing the same job for several years and do 6.2.5 Near Miss Incident Reporting
not require PPE”
Background
Recommendations
A near miss is an unplanned event that does not result in
Ø Selecting the right PPE requires careful evaluation injury, illness, or damage - but has the potential to do so.
of the hazards associated with each task being Near-miss reporting helps in tracking as well as correcting
performed at KTPS. While performing Hazard situations / circumstances that could potentially lead to
Identification & Risk Assessment, individual serious accidents.
employee tasks should be studied to determine the
duration and frequency of the task, the degree of Observation
dexterity required and the worker’s exposure to
various hazards. KTPS has put in place a near miss incident reporting
system. The same has been communicated to various
Ø Training and awareness program may be arranged departments. KTPS is also taking steps to increase the
for unskilled workers and contract labor on the workers participation in the system. The near miss incident
hazards associated with regard to why, how, when reporting format has been provided as Annexure - V.
and which PPE is to be used.

6.2.6 Safety Committee Root Cause
Background Ø Further investigation revealed lack of interest from

workers is due to behavioral issues such as lack of
KTPS has three numbers of apex safety committees i.e, self-motivation.
one each for Stage-I, Stage-II and CHP. Each safety Ø Further investigation revealed safety committee
committee is chaired by General Manager from the meetings and decisions could not reach all workers
corresponding section and consists of management due to the following reasons:
representative, workers representatives and safety
monitors. There is a Sectional Safety Committee in the 1. Lack of direct representation of workers in
Maintenance Section. The workers’ representatives are not safety committee meetings
nominated by the workers but are nominated by the 2. Behavioral issues such as lack of motivation –
Sectional Heads. Limited efforts from employees end to
exchange safety related information
Safety department indicated that Minutes of safety communicated to them
committee meetings (MOMs) are circulated to all members 3. Lack of contract labor representation in
of the committee and section heads, who in turn safety committee meetings
communicate the key safety decisions to the workers
Recommendations
Observations
Ø The number of safety committee members, as
Ø It was reported that the workers have not evinced compared to the number of workers is low and
interest in either being a member of the safety hence the communication of key safety initiatives,
committee or in nominating a colleague for the measures and interventions to all levels may be
membership to the safety committee. impeded. Appropriate number of sub-safety
Ø Some of the workers (including contract workers) committees may be formed at departmental levels
indicated that that they are not aware of safety with the sub-safety committee heads representing
committee meetings and the decisions taken by the those departments in the Safety Committee. The
committee. sub-safety committee representatives can be
entrusted with the responsibility of facilitating
communication between the management and the

workers. Floor level safety meetings should also be Manager (Stage-I). GM (Stage-I) reports to Chief General
institutionalized. Manager.
Ø Initiatives such as institutionalizing of a near miss
incident reporting system, encouraging worker Observations
participation in safety management, accident
investigation and training need identification can be No deviations from scheduled standard test and
driven through the sub-safety committees examination of fire service equipment and fire protection
Ø These committees may be extended to include system were observed during the site visit. However, some
contract labor representation. This may help deviations were noticed with reference to the
communication of key safety decisions to contract recommendations by The Fire Advisor & Chief Fire Officer.
laborers also. The same are already been informed to and accepted /
Ø The formation of the sub-safety committees would approved by the FA & CFO.
also help in involvement of higher number of
workers in the safety initiative of the plant Root Cause
6.2.7 Safety & Fire Fighting Department Reportedly, these deviations have been due to the shortage
of manpower.
Background
Recommendations
The structure of the safety and fire-fighting department
has been provided as Figure – 4. The plant employs over Staff-strength of the safety and fire-fighting department
2000 workers in three shifts but has only one Safety may be increased for improving the efficiency and
Officer with two subordinates. Safety Management at the effectiveness of the safety department.
CHP is handled by an Executive Engineer who reports to
the Safety Officer. Additionally, there are twelve members 6.2.8. Housekeeping, Lighting and Ventilation
in the fire fighting department. Eight firemen are
outsourced through an external agency. Observation
Currently, the Safety Officer reports to the Superintendent During the site visit, housekeeping, lighting and ventilation
Engineer (Operations), who in turn reports to General were observed to be poor in the plant for safe working of
occupant, specifically in the CHP area. At the time of site

visit, the dust suppression system and fresh air system in 6.2.9. Training
CHP were found to be out of order. Several gas cylinders
were found to be stored without caps. Background
Root Cause In-house Annual Training Calendar indicating annual

training & awareness programs schedule is maintained by
Ø Some of the workers indicated that poor the HRD. OH&S specific programs included in the annual
housekeeping, lighting and ventilation issues have calendar for the year 2007-08 are: Disaster Management
been brought to the management’s notice several Plan, Awareness about Heart Disease, Awareness about
times but have received a slow response from the Hypertension, Stress Management, Awareness about
management Diabetes, Awareness about Asthama, Awareness about
Ø Behavioral issues such as thefts and negligence in Occupational Diseases and Health, Use of Safety and Fire
housekeeping, are also being faced from the Fighting Equipment. The participants’ profiles for these
workers and contract labor with regard to programs as indicated in the calendar consisted of
maintaining the system Engineers, Chemist and Technicians. In addition, as
informed, a few other safety specific training and
Recommendations awareness programs are conducted by the safety
department on a need-basis.
Ø Specific team comprising of individuals from each
section could be formed for supervising proper It was also informed that the following activities have been
housekeeping and ensuring lighting and ventilation taken up since the initial site visit for EA-DDA:
systems are operational at all times.
Ø Measures such as training and awareness programs Ø 28 Employees were sent to Koradi Training Center
on good housekeeping practices, safety and health for training programme from 16 to 19 Oct 2007.
impacts of poor housekeeping, may help in
addressing the behavioral aspects of workers. Ø About 80 employees and contract workers attended
a seminar on ‘Safety’ held at Hotel Tuli International
Nagpur on 16th and 17th Nov 2007.
It was also informed that the training for use of Portable

Fire Extinguisher is imparted to staff at their location by

actually making use of extinguisher. This goes on 6.2.10. Periodic Health Checkup of Workers
throughout year. In the year April 2006 – March 2007
about 1204 persons were imparted this training Observations
Observation Medical check-up of plant employees have been carried out

periodically. The records of medical examinations are
Ø Contract worker participation is very limited in maintained by Medical Superintendent and his team.
safety specific training and awareness programmes
Root Cause The health records indicated that such medical check-ups
are carried out once in a year. Pre-employment medical
Ø Further investigation revealed that for the scale of check ups are being carried out for the permanent
operation at KTPS, it is difficult to train provide employees. However, it was not evidenced if similar check
hands-on training to all workers. However, to check ups are made prior to employment of contract labor.
the effectiveness of the training, workers are picked
up on a random basis during the training session to Twenty three (23) workers have been imparted training in
demonstrate the use of the same. first-aid and are designated as Trained First Aiders.
Documentation was not made available to conclude if
Ø Lack of self-motivation and carelessness towards refresher training courses have been organized for Trained
safety is reportedly the primary cause for limited First Aiders. No documentation was available on how many
participation of contract workers in safety specific of the Trained First Aiders are available in each shift. First
training and awareness programmes aid boxes are placed at various sections and are inspected /
refilled periodically. The relevant records for periodic
Recommendations check-up and supplies refilling are being maintained in the
Dispensary. Two ambulances are provided with basic first-
Ø Safety specific training and awareness programs aid supplies. One of the ambulances is kept available round
should be made mandatory for contract labor the clock at the main entrance of the plant.
Comprehensive documentation with regard to classification

of diseases based on occupational exposure was not found
in place. It was also informed that the dispensary, with its
limited staff, has been facing shortage of manpower.

Recommendations Root Cause
Classification of diseases based on occupational exposure Further investigation revealed workers resist such
should be documented. programs due to the following reasons:
6.2.11. Rotation of Work and Minimisation of Exposure Ø Reluctance in adapting to change

Ø Unwilling for medical check-ups thinking that if
Observations diagnosed with a disease, they may become unfit for
the job
Comprehensive procedures for administrative controls such
as rotating employees and imparting trainings on Recommendations
performing tasks in ways that reduce exposure to work
place hazards were not found in place. At present, rotation The workers and worker unions should be sensitized
of work is only considered in cases where workers towards the need and benefits of rotation of work. A
specifically request for it. It was informed that based on the rotation of work policy could be framed and workers at the
medical condition and willingness of the worker, the doctor time of recruitment should be informed about the policy
may recommend rotation of work for consideration by the and the probability of inter departmental transfers.
top management. The final decision lies with the top
management. However, no comprehensive documents with 6.2.12. Safety Drills
regard to the same were available.
Observations
It was informed that despite having medical problems,
which may be aggravated due to occupational exposure, Safety / mock drills with regard to acid leak, chlorine leak,
workers have not been keen on rotation of work. fire and Disaster Management Plan (DMP) are conducted
Reportedly, the workers have resisted attempts by the top periodically to check the preparedness of the emergency
management to transfer workers from one department to response system, records of which are being maintained by
the other. Workers interviewed during the site visits have the safety department.
also indicated their preference to continue working in the
same department. Observations and recommendations made during mock drill
that required corrective measures have not been addressed
promptly. For instance, a few observations that were

recommended by the safety officer in August 2005 mock spray system for cable galleries and boiler burners, high
drill for chlorine leak were not addressed and have been velocity water spray for main oil tanks, foam pouring
carried over to February 2007 mock drill. system for fuel oil tanks, and fire alarm and smoke
detection system.
Further, it was observed the responsibility of implementing
these observations was not clearly assigned to any Mobile facilities cover fire tender units and portable fire
individual. Also, no comprehensive documentation was extinguishers. On receipt of information, fire fighting staff
found in place with regard to action points / measures on duty responds to the situation. Fire report forms are
taken to address observations made during mock drills. documented by the fire officer.
Recommendations Fire drills are carried out periodically by fire fighting officer
under the guidance of safety officer. List of fire fighting
Observations made during mock drill, which require equipment is maintained by fire-fighting station in-charge.
corrective measures, should be given priority and Fire fighting station in-charge is also responsible for
addressed immediately for improving the efficiency of the inspection and testing of portable fire extinguisher.
emergency preparedness and response. Specific individuals
should be assigned the responsibility of ensuring these Pumps, size of mains, no. of hydrants, hose pipes and
action points are addressed as and when identified. Action medium velocity water spray system maintained with in the
points taken and status of the observations requiring plant premises meet or exceed the minimum regulatory
corrective measures should be documented to keep track requirements. For Stage-I oil handling plant, foam pouring
of the performance of the system. system has not been provided for storage tanks. Only fire
hydrants and water monitors have been provided.
6.2.13. Fire Fighting System
Observation
Background
Frequent incidents of minor fire occurrences on turbine
The firefighting system in the plant consists of fixed floor have been reported. Oil leakage and turbine heat were
installations and mobile facilities. Fixed installations informed to be the prime causes for these incidents.
consist of fire hydrant system, automatic high velocity However, the response times to such fire alarms were
water spray system (for oil storage tank and coal observed to be good and the fire was brought under control
conveyors), manually operated medium velocity water within reasonable time during all such alarms raised. Fire

extinguishers are being maintained as per the requirement. audit, a sample accident case was taken and suggestions
Fire blankets are also reportedly due for replacement. were provided on how a RCA should be carried out and
provided to the safety department. The same is provided
Recommendations below for reference.
Ø Steps should be taken to address the recurrence of Case Study:

turbine floor fire incidences.
Ø The planned schedule for standard testing and An accident was reported at the CHP area during maintenance
examination of fire fighting equipment should be work which involved a contract worker. It was reported that the
accident led to fracture of the lower leg and the patient was
strictly adhered to and on completion should be
rushed to the hospital for further treatment.
promptly updated
The accident report reviewed during the audit showed that only
6.2.14. Accident Investigation the cause of the accident was reported along with the
recommendations to avoid such accidents. However, no detailed
Observations RCA was carried out.
As discussed earlier, the number of accidents in the plant An RCA should be carried out in these lines:
has shown a declining trend since 2004. However, the
number of accidents occurring the plant may still be Ø Was there a proper work permit for the work to be carried
out
considered high as the plant on an average witnessed one
Ø Was the worker aware of the hazardous condition and was
accident every second week in the year 2006. Accidents he trained for such maintenance work
are investigated and recorded. However, a comprehensive Ø Is a SOP available for the maintenance work and was the
Root Cause Analysis (RCA) of all the accidents is not worker aware of the procedures
carried out. Ø Was the supervisor available during the maintenance
work?
Recommendations Ø Was he provided with the appropriate PPE before
entering the work and was the same checked by a
A comprehensive Root Cause Analysis (RCA) by the supervisor
Safety Department would help in identifying the root cause Ø Was the worker using the PPE during the work?
Ø How often is such maintenance work carried out?
for the accident and placing systemic controls and for
ensuring avoidance of similar mishaps in future. During the

Based on the outcome of the RCA, recommendations Recommendations

should be provided to prevent such accidents in future. The
accident report has been provided as Annexure - 6 for The workers should be sensitized about the importance of
reference. adhering to the Work Permit System. The first line
supervisory personnel should also be held accountable for
6.2.15. Work Permit System adherence to the system. Use of technology and better
communication facilities, wherever possible, will help in
Background expediting the process of obtaining the permit from the
authorized personnel.
The Work Permit is a formal written statement used to
control certain type of potentially hazardous activities. It is 6.2.16. Standard Operating Procedures
also a means of communication between site management,
supervisors, operators and the workers enabling co- Observation
ordination among various activities to ensure safe working
environment. The Work Permit itself does not make the job It was informed that standard operating procedures (SOP)
safe, but helps in ensuring that proper consideration is with regard to safe working conditions have been in place
given to the risks and that they are dealt with prior to but were not made available with the exception of that for
commencement of the work. KTPS has instituted a Work bunker scrapping. Reportedly, comprehensive standard
Permit System for working in various hazardous operating procedures with regard to working from heights
workplaces in the plant including the CHP. were not available.
Observation Recommendations
It was observed during documentation review that an SOPs for working from heights should be developed
instance of non-adherence to the Permit System by one of
the workers had led to a fatal accident. A comprehensive
RCA was not carried for the accident and impatience on the
part of the worker was attributed as the reason for his non-
adherence to the set operating procedure.

6.2.17. HAZMAT and Management 6.2.18. Emergency Management Plan / Disaster

Management Plan
KTPS has part of the water treatment plant and hydrogen
generation plant uses various chemicals such as listed Observation
below:
Emergency preparedness and response plan has been
S. No. Chemicals displayed at several locations. Emergency telephone
1 Chlorine Cylinders numbers have been displayed at several locations and have
2 Caustic Soda been tested on a random sample basis. During interviews
3 Poly Aluminum Chloride with workers, the awareness on emergency telephone
4 Acids and Bases numbers and muster points was found to be poor.
5 Hydrogen Cylinders
Recommendations
KTPS also stores fuel oils such as FO, LDO, lubricating oil
which is used in the plant operations. Measures should be adopted to increase awareness on
emergency preparedness and response among employees
Chlorine and Hydrogen cylinders and fuel oils are and contract labor
considered to be the most hazardous materials with a
potential to cause damage both on-site and off-site. The 6.2.19. Worker Awareness and Involvement
quantities of the aforementioned chemicals and fuel oils
and their storage areas are provided as Annexure – 8. Observation
KTPS has displayed the Material Safety Data Sheets at all While the top management is ultimately accountable for
the storage locations and has also prepared a Disaster health and safety issues the workers also play an important
Management Plan which identifies the potential risks due to role in ensuring successful implementation of the EHS
storage of hazardous materials and the action plan to be policy. It is important for all levels of employees to
taken during a disaster such as Chlorine Gas Leak, understand the dangers existing in the workplace, build the
Explosion of Oil Tankers, etc. The DMP also identifies the right attitude, always maintain a ‘safety first’ approach and
key individuals responsible for the smooth implementation obey the rules.
of DMP.
The EHS policy recognizes awareness building through

training and other means of communication as an important formation of safety sub committees or smaller
contribution towards the successful implementation of the safety groups.
safety policy.
Ø Efforts should be made to institute programs which
A review of the accident statistics between the years 2004 promote two way communications between the
and 2006 indicates that unsafe acts have been responsible management and the workers. Such efforts may
for majority of the accidents. Although the number of include organization of competition at unit level or
accidents at KTPS has been declining since 2004, the departmental level, encouraging and inviting
number of accidents due to unsafe acts have not suggestions for improving working conditions in
decreased. their individual workplaces.
Ø Multidisciplinary team of workers evincing interest
It has been understood through the interaction with the in safety initiatives may be formed and given
plant personnel and workers that the level of awareness intensive training inputs. These teams, post
and the degree of involvement of the workers in issues education and empowerment should be encouraged
pertaining to safety is low to drive safety initiatives in their respective
departments.
It was observed during the review of the areas pertaining to
use of PPE, effectiveness of Work Permit Systems, worker Ø The workers making a contribution towards safety
involvement in Safety Committees, participation in safety initiative should be given due recognition. Such
drills and the Emergency Management Plan that the recognition may be provided at an individual, group
workers’ involvement, co-operation and awareness with and/or sectional level.
regards to safety related issues has been low. The workers
have also shown resistance to health related programs
such as rotation of work and minimization of exposure and
have not participated in the plant’s medical check up
programs.
Recommendations
Ø Measures should be taken to involve higher number

of workers in the safety initiatives through

PART 7: INSTITUTIONAL CAPACITY ASSESSMENT Our approach for institutional capacity assessment has
been provided in subsequent slides.
MAHAGENCO is committed to sound environmental
management at all its power plants with KTPS as no
exception. In order to achieve its mission and vision,
MAHAGENCO has established a Corporate Environmental,
Health and Safety Unit (CEHSU) to be responsible for the
implementation of its EHS policy.
The objective of the study was to review and assess the

adequacy and effectiveness of the existing institutional
setup and resource availability at KTPS to ensure sound
environmental performance and management after the
proposed R&M of Unit – 6.
The assessment includes review of the strengths and

weaknesses of the existing institutional capacity to manage
environmental issues of the plant and implement
interventions proposed as part of the EA-DDA and to
sustain the improved environmental performance. Based on
the assessment improvement measures to enhance the
institutional capacity will be suggested.
As part of the study, the following were assessed.
Ø Institutional setup for environmental management

Ø Systems and procedures
Ø Training
Ø Mechanisms for addressing public concerns

APPROACH FOR INSTITUTIONAL CAPACITY ASSESSMENT
Understand the existing management system in place at KTPS
Review of existence of the environmental management system and

procedures
Review of existence of training as part of the overall capacity building

activity of the department based on record review
Existence and maintenance of records of communication received from

stakeholders
Interviews with key plant personnel to understand the effectiveness of the

existing system in place
Stakeholders interviews to understand the level of awareness and gauging

the effectiveness of the existing system for addressing public concerns

7.1 INSTITUTIONAL SETUP FOR ENVIRONMENTAL 7.1.2. Recommendations

MANAGEMENT
Ø KTPS may bring the sectional heads of EMC and
The institutional setup for Environmental Management Cell safety department under one supervisor which
(EMC) at KTPS along with the reporting structure is would enable to integrate environmental issues with
provided as Figures – 52 and 53 of the report. The major safety and health issues at the plant level leading a
observations pertaining to the institutional setup has been comprehensive EHS system.
detailed below: Ø The same was agreed in principle by KTPS
management and MAHAGENCO for change in the
7.1.1. Observations: organizational structure.
Ø A sample management structure has been provided
Ø Environmental Management cell is a separate as Figure – 54 for reference.
department of the plant, which is commonly, headed Ø All the required posts may be filled to avoid
by Executive Chemist along with Water Treatment problems pertaining to staff strength for proper
Plant (WTP). It is a separate department with environmental management.
completely separate office and premises but the
head is common for Environment and WTP. 7.2 SYSTEMS AND PROCEDURES
Ø The Section Head does not report to the Chief
General Manager (i.e. the plant head). Instead the KTPS has implemented Environmental Management System
reporting is done to the Superintendent Engineer as per the ISO standard 14001. The plant has developed
Ø The Corporate Environmental Health & Safety Unit procedures as per the management system requirements.
(CEHSU) which is based in Mumbai (Ex: Bombay) The EMS is regularly audited by the certifying agency for
is not part of the organization structure or the correctness and completeness.
reporting structure of the Environmental
Management Cell of KTPS.

FIGURE - 52: EXISTING REPORTING STRUCTURE – WTP- II, KTPS (ENVIRONMENTAL MANAGEMENT CELL)
Executive
Chemist
(SH)
Sr. Chemist Sr. Chemist Sr. Chemist

EMC
Department
Chemist / SWAS Lab DM Plant Gravity Lift Pump ETP Lab Chemist
Lab Chemist Filter /
Chemist 4 LC/JLC 4 Art 4 Art 1 Jr. Lab
LC 4 Art to SSA 8 Chemist
Art to SSA 7 SSA 8 SSA 4 Art to SSA 6

FIGURE - 53: EXISTING REPORTING STRUCTURE – ENVIRONMENTAL MANGEMENT CELL, KTPS
Chief
General
Manager
General General General

Manager - I Manager - II Manager - III
SE – (O) I SE (M) - I MS (Disp) SE (O) - II SE (M) - II SE (Co – SE SHs

Ord) CHP R&M
SH SH’s SH SH’s SH’s SH

(Safety) (WTP – II) CHP
(Env. Cell)
SH
(WTP – I)

FIGURE - 54: PROPOSED REPORTING STRUCTURE – EHS MANAGEMENT, KTPS (SAMPLE)
Chief
General
Manager
General General General

Manager - Manager - Manager
I II III
SE – (O) I SE (M) - I MS SH SH SE (O) - SE (M) - SE (Co – SE - CHP SH

(Disp) (Safety) (WTP – I) II II Ord) R&M
Env. Cell
SHs SH’s SH SH’s SH’s SHs

WTP II CHP

7.2.1. System and Procedure for Budget Allocation Ø There is no fixed percentage for fund allocation for
Environmental Management Cell and is done based
As per the legal procedure, all the budget allocations for on the need assessment.
individual plants, which are part of MAHAGENCO, are done
by Maharashtra Electricity Regulatory Commission 7.3 TRAINING
(MERC).
Training on the environmental management has been
Individual plant first assesses the requirements of funds identified as one of the key performance indicators as part
and prepares a budget for the financial year, which is sent of the Environmental Management System (ISO 14001) at
to the HO. HO submits the total budget for all the power KTPS. All the staff members including the section heads
stations to MERC for approval. The total budget is finalised and regular employees are trained on environmental
by MERC and the allotment of budget to the individual TPS management including aspects, legal requirements and
is communicated to the plant by HO. Based on the allotted management system implementation.
funds, the plant head, i.e. CGM, would again revisit the
budget prepared and on the priority basis the funds are Training calendar is prepared by the HR department for the
disbursed to each department / section (s). The final entire year. The training calendar is circulated to the
decision on the distribution of funds is taken by CGM. Superintendent Engineers (SE’s) and General Managers
(GM’s) for the approval and finalization.
For Eq: If the plant assesses the fund requirement as 100
crores and prepares a budget for the same. MERC may only Upon receiving the approval, the training calendar is
allocate 80 crores. Based on the priority of the department circulated to the respective Section Heads (SH’s) of each
/section (s) requirement, the budget is redrafted and department to nominate the participants as per the training
funds are accordingly distributed. needs and requirements.
7.2.1.1 Observations Training needs are identified by the SH’s for their
employees and a list is sent to the HR department for the
Ø The final allocation of funds at the plant level is the concerned training programme which has been prepared for
decision of the CGM. Corporate EHS Unit has no hold the year. Training on environmental management is part of
on the fund allocation at the plant level for the induction training programme. Trainings are mostly
environmental management. provided in-house. The faculty members are the SHs / SEs.

Feedback on the training sessions are taken from the 7.3.2. Recommendations
respective SH’s.
Ø KTPS should invite experts from other plants
KTPS as part of the management system has circulated (either belonging to MAHAGENCO or other state
booklets on environmental policy and awareness to the owned generation companies) for conducting
educational institutions, industries and local governing training programmes along with in-house faculty.
bodies in the surrounding villages. This would enhance the training module as well as
improve the knowledge sharing process. HRD should
7.3.1. Observations also take initiatives to send plant personnel to
external training programmes.
Ø MAHAGENCO has independent training department Ø Feedback on the training sessions is being taken
with two institutes situated at Nasik and Koradi to from the people attending the training at the end of
cater training needs of MAHAGENCO. The the training session. However, the feedback should
employees are also deputed for trainings outside the be concealed and the same should be directly
organization by MAHAGENCO HR Department. submitted to the HR department for further action.
Ø KTPS has started taking feed back on the training
sessions from the people attending the training at 7.4 MECHANISM FOR ADDRESSING PUBLIC
the end of the training session following the CONCERNS
comments made by E&Y in this regards during the
course of the initial reports. KTPS as part of their environmental management system
Ø The participants’ profiles for these programmes as has a written procedure to address the external
indicated in the calendar consist of Engineers, communication on concerns / issues with respect to
Chemist and Technicians (including unskilled environmental performance or management of KTPS.
labourers). No documentation was made available
to validate if such trainings are imparted to, As per the procedure, the stakeholder with his concern /
contract labors. However, documentation related to issue shall contact the SE (Co-ordination) at the CGM’s
safety trainings for Contract Laborers are available. office, who upon receiving the stakeholders comments
would direct the person to the concerned department /
section of the plant to get appropriate reply.

If the stakeholder requested the plant to provide any 7.4.2. Recommendations

information within the purview of the Right To Information
(RTI) Act, an application shall be deposited with the SE Ø KTPS should also inform the village panchayat office
(Co-ordination) who would collected the information from the procedure for lodging written complaints with KTPS
the concerned department and submit to the stakeholder. or the concerned authorities responsible for
environmental management.
Stakeholder can also write letters directly to the CGM’s
office to get information from the plant on the concerns Ø KTPS may also provide a drop box at the entrance
raised. (near security cabin), which is easily accessible by the
local residents. It will be used to submit concerns in
7.4.1. Observations writing. The drop box would be under the jurisdiction of
PRO of KTPS.
Ø During the stakeholder consultation process, the gram
sarpanch (village head) of Koradi village informed that
their office does not have the proper guidance/
information as to whom to approach within the KTPS to
communicate the view or concerns of the villagers. It
was also informed that the lack of knowledge leads
them to raise their issues with the local elected member
of the Legislature who in turn communicates the same
with the plant.
Ø It was informed by KTPS that a Public Relations Officer

(PRO) has been appointed and same was
communicated to the villagers so that they can meet
the PRO to put forth their grievances. A board has also
been displayed at the entrance of the plant regarding
the same.

PART 8: POTENTIAL LIABILITY/RISK 8.1.1. Resettlement and Rehabilitation Program

ASSESSMENT
The first unit of Koradi TPS was commissioned in 1974. For
8.1 STAKEHOLDER ENGAGEMENT the setting up of the power plant, land was acquired from
the local residents. In order to compensate them for the
KTPS was commissioned in the year 1974. Subsequently 6 loss, the erstwhile MSEB had instituted a rehabilitation and
more units have been added to the plant resulting in resettlement program, as a part of which the local
increased pollution load and increased demand for the residents who lost land were provided alternative land
natural resources. These may result in in potential and/or were provided with employment.
environmental liabilities, impact on the local residing in the
vicinity of the plant. In order to identify, any such potential The Sarpanch and the villagers interviewed during the visit,
risks or liabilities and to understand its extent, a local indicated their satisfaction with the resettlement and
stakeholder engagement was undertaken during the site rehabilitation program of the erstwhile MSEB. The
visit. interviewed villagers indicated that they were amply
compensated for their loss and were provided with land in
The local stakeholders were identified as the following lieu of their land acquired by MSEB and were provided with
employment opportunity at the plant as well.
Ø Plant Management
Ø People residing around the plant area. 8.1.2. Water Pollution & Access to Potable water
Ø People affected by the project activity.
Water pollution and non availability of potable water to
Five villages were visited during the site visit viz., Suradevi, other competing users is one of the concerns when industry
Mhasala, Khasala, Koradi and Naanda. The Sarpanch of is established in a locality. Interviews were carried out in
Koradi Gram Panchayat, which includes Panjra, Koradi, the villages surrounding the power plant to understand the
Naanda, Kapri, Adarsh Nagar, and Shriyas Nagar, was also aforementioned concern.
interviewed during the site visit. The details of the villagers
interviewed are provided in Annexure - 9. During the interview it was informed that the villages have
access to potable water and do not face any problem in
terms of water pollution due to the activities of the power
plant.

However, the resident of Mhasala village, which is located Ground water sample was analyzed and compared with the
adjacent to the Khasara ash bund, indicated that during IS : 10500 Limit. The ground water sample showed that the
summer, due to scarcity of potable water they are forced turbidity was 32 NTU as against the standard of 5 NTU with
to drink the river water which has ash supernatant. a relaxation up to 10 NTU. Sulphates was recorded as 449
mg/l which was found to be higher than the prescribed limit
It was also informed during the interview that diseases of 400 mg/l. Fluoride was recorded as 1.29 mg/l which was
such as Jaundice, Diahorrea and Dysentery were prevalent higher than 1 mg/l but less than the 1.5 mg/l which is the
in the area. This was due to non availability of potable permissible limit. Nitrate content in the water was recorded
water during summer season. The residents of Naanda and as 7.5 mg/l.
Mhasala interviewed during the visit indicated that there
were no dispensaries in their village and they either visited 8.1.3. Air Pollution
the neighboring villages or travelled to Nagpur for
accessing medical facilities. Residents of the other villages None of the other residents interviewed indicated any
also indicated that they visited Nagpur city for the problems on account of air pollution.
treatment of major ailments.
8.1.4. Community Engagement
In order to cross check the interviewees comments, the
water quality of ground water and surface water was In order to gauge the effectiveness of the interaction with
sampled and tested. Ground water sample was collected the community by KTPS, a sample number of villagers were
from Mashala village on the downstream of the ash pond at interviewed during the audit. During the interview, the
Khasara. Surface water samples were collected from water sarpanch (head of the village) was also interviewed.
bodies receiving ETP discharge and ash pond discharge
near railway station. The details of the analysis are During the interaction it was mentioned by the sarpanch
provided as Table – 38. that KTPS does not have in place a structured process to
engage with the community. It was also informed during
The surface water analyzed was compared with the the interview that the village panchayat is not aware of a
drinking water standard IS:2296 Class ‘C’ Limits for any concerned person whom they can approach for assistance
variations. It was observed that the surface water drains with issues related to the community and KTPS.
were meeting the prescribed standards and all the
parameters monitored were found to be well within the In order to substantiate the claim, officials from KTPS were
limits. interview, who informed that a Public Relations Officer

(PRO) has been appointed by KTPS to collect grievances

from the villagers and provide appropriate response. A
board has also been displayed at the entrance of the plant
which indicates whom one can meet to discuss their
grievances. The same was also verified during the site visit.
Considering that the sarpanch (village head) is unaware of

the existing process, it is recommended that KTPS may
engage with the community to inform about the existing
process more often.

TABLE - 38 : SURFACE WATER ANALYSIS
S. No Parameters Unit IS:2296 Class ‘C’ Limits SW 1 SW 2

1 PH - 6.5 to 8.5 7.6 7.9
2 Colour Hazen 300 2 <1
3 Conductivity μS/cm $ 805 1202
4 TDS mg/l 1500 430 706
5 DO mg/l 4 Min. 6.1 5.9
6 BOD mg/l 3 <3 <3
7 COD mg/l $ 11.8 15.6
8 Total Hardness as CaCO3 mg/l $ 295 325
9 Total Alkalinity as CaCO3 mg/l $ 216 212
10 Calcium as Ca mg/l $ 88 84
11 Magnesium as Mg mg/l $ 18.2 27.9
12 Chlorides as Cl mg/l 600 80.8 249.2
13 Sulphates as SO4 mg/l 400 47.3 16.9
14 Fluorides as F mg/l 1.5 1.2 0.6
15 Nitrates as NO3 mg/l 50 0.7 1.6
16 Sodium as Na mg/l $ 46.5 123.0
17 Potassium as K mg/l $ 6.1 58.0
18 Total Boron as B mg/l $ 0.58 0.03
19 Cyanides mg/l 0.05 <0.02 <0.02
20 Phenolic Compounds mg/l 0.005 <0.001 <0.001
21 Oil and Grease mg/l 0.1 <0.1 <0.1
22 Cadmium as Cd mg/l 0.01 <0.01 <0.01
23 Arsenic as As mg/l 0.2 0.04 <0.01
24 Copper as Cu mg/l 1.5 <0.01 <0.01

S. No Parameters Unit IS:2296 Class ‘C’ Limits SW 1 SW 2

25 Lead as Pb mg/l 0.1 <0.01 <0.01
26 Iron as Fe mg/l 50 0.01 0.01
27 Chromium as Cr+6 mg/l 0.05 <0.05 <0.05
28 Selenium as Se mg/l 0.05 0.01 <0.01
29 Zinc as Zn mg/l 15 <0.01 <0.01
30 Aluminium as Al mg/l $ <0.01 0.01
31 Mercury as Hg mg/l $ 0.002 <0.001
32 Insecticides mg/l Absent Absent Absent
33 Anionic detergents as MBAS mg/l 1 <0.1 <0.1
34 Total Coliforms MPN/100ml 5000 <2 <2

TABLE - 39: GROUND WATER ANALYSIS
S. No Parameters Unit IS:10500 limits GW 1

1 PH - 6.5-8.5 (NR) 7.3
2 Colour Hazen 5 (25) 3
3 Taste - Agreeable Agreeable
4 Odour - U.O U.O
5 Conductivity μS/cm $ 4890
6 Turbidity NTU 5 (10) 32
7 TDS mg/l 500 (2000) 2420
8 Total Hardness as CaCO3 mg/l 300 (600) 1380
9 Total Alkalinity mg/l 200 (600) 520
10 Calcium as Ca mg/l 75 (200) 324
11 Magnesium as Mg mg/l 30 (100) 138.5
12 Residual Chlorine mg/l 0.2 Min <0.1
13 Boron mg/l 1 0.09
14 Chlorides as Cl mg/l 250 (1000) 471.5
15 Sulphates as SO4 mg/l 200 (400) 449.5
16 Fluorides as F mg/l 1.0 (1.5) 1.0
17 Nitrates as NO3 mg/l 45 (NR) 7.5
18 Sodium as Na mg/l $ 259.0
19 Potassium as K mg/l $ 3.5
20 Phenolic compounds mg/l 0.001 (0.002) <0.001
21 Cyanides mg/l 0.05 (NR) <0.02
22 Anionic Detergents mg/l 0.2 (1.0) <0.2
23 Mineral Oil mg/l 0.01 (0.03) <0.01
24 Cadmium as Cd mg/l 0.01 (NR) <0.01

25 Arsenic as As mg/l 0.01 (NR) <0.01

26 Copper as Cu mg/l 0.05 (1.5) <0.01
27 Lead as Pb mg/l 0.05 (NR) <0.01
28 Manganese as Mn mg/l 0.1 (0.3) 0.03
29 Iron as Fe mg/l 0.3 (1.0) 0.02
30 Chromium as Cr+6 mg/l 0.05 (NR) <0.05
31 Selenium as Se mg/l 0.01 (NR) <0.01
32 Zinc as Zn mg/l 5 (15) 0.13
33 Aluminium as Al mg/l 0.03 (0.2) <0.01
34 Mercury as Hg mg/l 0.001 (NR) <0.001
35 Pesticides mg/l Absent Absent
36 E. Coli - Absent Absent
37 Total Coliform MPN/100 ml 10 <2

8.2 MERCURY (Hg) MASS BALANCE consecutive days i.e. 2nd January 2008 to 4th January
2008. The analysis report showed that the average Hg
As part of the overall risk and liability assessment, Hg mass content in coal was 0.81 mg/kg for stage – I and 0.83
balance was carried to gauge the risk to the community due mg/kg for stage – II.
to the presence of Hg in the environment.
Coal after burning is converted into ash. Bottom ash and fly
The main source of mercury at KTPS is the raw material ash samples were collected and analyzed for Hg content.
‘coal’. After the coal is fed into the boiler, Hg is released The average Hg content in bottom ash was 0.40 and 0.48
into the environment in the form of air emissions, trade mg/kg in stage – I and stage – II respectively. The average
effluent and bottom and fly ash. A schematic Diagram of Hg content in fly ash was 0.38 & 0.33 mg/kg in stage – I
the flow of Hg in the system is presented in Annexure – II. and stage – II respectively.
At KTPS, the bottom and fly ash are mixed with the treated The Table – 40 below provides the total Hg balance.
trade effluent prepare ash slurry. The ash slurry thus
formed in sent to the Booster Pump House (BPH) from TABLE -40 : Hg Balance
where it is sent to the ash pond. The supernatant from the
ash pond is collected in the Ash Water Recovery (AWR) Stage Input Output Unaccounted
unit which is then pumped back into the plant to use for ash
slurry preparation along with treated effluent.
Coal Fly Ash Bottom Ash Total
In order to carry out a mass balance of Hg at KTPS, and
considering the aforementioned cycle of Hg, samples were I 0.81 0.38 0.40 0.78 0.03
collected for analysis. II 0.83 0.33 0.48 0.80 0.03
8.2.1. Analysis for Hg 8.2.2. Recommendations
Coal, being the source of Hg, was analyzed. Bunkered coal Ø KTPS to continue monitoring of Hg in air emissions
was collected and analysis was carried out which showed and ash (both bottom and fly ash) to estimate the
that there was presence of Hg in coal being used by KTPS. quantity of Hg not being accounted and take further
Bunkered coal was collected from both the stages of the action to reduce the impact of Hg on the
plant i.e. I & II separately and analyzed for three environment.

PART 9: ENVIRONMENTAL HEALTH & SAFETY options will be confirmed as part of the design
MANAGEMENT ACTION PLAN configuration of R&M activities (especially considering the
operational difficulties of current arrangement of
This part of the report consolidates the analysis of EHS combination of ESP and bag filters).
issues and recommendations of EADD in the form of EHS
Management Action Plan (EMAP). The EMAP includes brief The proposed measures for institutional strengthening and
on EHS issues, agreed mitigation measures with Koradi capacity building, and measures for overall station level
TPS/MAHAGENCO, estimated cost for implementation of improvements are focused to: (a) enhance overall
the mitigation measure, and the implementation schedule environmental performance and thereby minimize potential
of each measure. For ease of implementation, the EMAP is environmental risks and liabilities; (b) achieve 100%
segregated in to three levels of actions, including: (a) regulatory compliance; and (c) achieve better
mitigation measures to be implemented as part of R&M performance on Occupation Health and Safety aspects.
activities for the 6 th Unit (210 MW); (b) measures
proposed to be integrated as part of Institutional The Table below provides the EMAP details.
strengthening and capacity building for Koradi TPS; and
(c) measures to be taken up by Koradi TPS for the power
station as a whole. The EMAP has explicitly integrated the
action plans committed by Koradi TPS to Maharashtra
Pollution Control Board (MPCB) for complying with the
conditions of “Consent to Operate”. The EMAP also
specifies the environmental monitoring requirements
(including monitoring specified by MPCB) and the
reporting mechanism. The final EADD, including EMAP has
been disclosed for public by MAHAGENCO at their
corporate office in Mumbai and on their website, and at
Koradi TPS.
In case of 6th Unit, the proposed measures will be

integrated as part of the R&M design specifications and the
costing. In this regard, it is important to highlight that
certain measures such as choice of pollution control

Sr. Environmental Issue Agreed Mitigation Measure Estimated Time Frame

No. (EADD analysis reference in pranthesis)¥ Cost (Rs.
Mil.)*
Environmental Management Measures to be Integrated as Part of R&M Designs/Activities for Unit – 6, Koradi Thermal Power
Station
1 Particulate emissions from the Unit VI of Ø Pollution Control measures for Unit - 6 ESP to be 250.00 Coterminous
the plant are above the prescribed either retrofitted by moving to either complete (in case of with
swithing over to
standards as the current pollution control ESP system or maintain the current combination ESPs) implementat
system of combination of ESP and Bag of ESP + Bag filters with necessary Operation and ion of R&M
filters is not efficient (Ref No. 4.3) maintenance mechanism to achieve design PM 40.00 activities
emission standard of 100 mg/Nm3 but not (in case of
refurbishing bags
exceeding 150 mg/Nm3.. As may be applicable, and ESP + Ammonia
these measures shall explicitly consider current dosing)
MPCB consent conditions.

Design
Ø Ammonia injection in ESP to use as additional PM
Specs. to
control measure
be
Above measures to be reconfirmed as part of design
confirmed
details for the R&M activities
2 KTPS currently employs a soot blower Ø A Smart wall blowing system, is to be installed to 10.00 - As Above -
system for soot removal which is not maintain the furnace heat absorption at optimum (Design
energy efficient. (Ref No. 5.2) level thereby maintaining the super heater and Specs. and
reheater sprays within limits, helping in cost to be
conservation of energy confirmed)
3 No oil cleaning system has been employed Ø A Turbine oil super cleaning system is to be 2.50 - As Above -
at the plant resulting in deposition of small introduced to reduce chocking of governing (to be
particle contaminants into clearances in the components. confirmed as
turbine and causing damage to the mating part of design
parts (Ref No. 5.2) specs.)

Measures to be integrated as part of Institutional Strengthening and Capacity Building

4 Pending revision of EHS Policy in line with Ø The EHS policy to be revised in the context of No cost March, 2009
reorganization of MSEB in 2004 (Ref. No. KTPS operations and to be endorsed by implications
6.2) MAHAGENCO
5. Limitations on decision making process Ø Streamline EHS functions and decision making No Cost March 2009
related to Environment, Health, and Safety process by modifying reporting structures of Head Implications
(EHS) Management due to divergence of EMC and Safety manager to single supervisor
reporting mechanism for Health and Safety
Manager and Head of Environment
Management Cell (EMC) – (Ref. No.7.1) .
6. Training of KTPS Medical Officer for Ø Formal training of the KTPS medical officer for 0.10 To be
industrial health and safety management Industrial Worker Health and Safety Management (lumpsum) completed
through certificate course on Industrial through 3 month Certificate course, accredited by by March,
Health and Safety Management would Maharastra State Government 2009
further facilitate the worker health
management aspects (Ref. No. 3.3)
7. Awareness amongst workers on importance Ø KTPS to conduct regular (at least once in 6 Cost to be First
of Occupation Health and Safety (OHS) months) awareness generation programs for internalized in awreness
measures including Personal Protective imparting practical know how on OHS. Awareness ongoing safety program to
Equipment (PPE). This aspects also lacks to include cross section of workers from managers awareness complete
integration of awareness for contract to floor level employees. programs before
labour (Ref. 6.2) Ø Mandatory compliance with OHS requirements for March 2009
all the works contracts as well as temporary labour
hiring
8. Sustained hazard exposure for section of Ø Awareness program for workers and their unions Cost, if any to Policy Plan
workers in the plant. No existing policy on to sensitize on importance of job oration on be estimated by March
job rotation (Ref. No. 6.2) regular basis by Personnel 2009.
Ø Job rotation Policy Plan to be developed by KTPS Dept. of KTPS Implementat
based on skill requirement and feasibility of ion June
manpower rotation. Job rotation shall be on 2009
regular basis.

9. Currently there is no system established for Ø A comprehensive Root Cause Analysis (RCA) No Cost RCA
Root Cause Analysis to analyse accident function with specific protocols to be internalized Implication Formats and
cases. Lack of such systems could lead to as part of the job responsibility of EHS supervisor Protocols by
increased chance of recurrence of similar referred under point 5 above. March, 2009
accidents (Ref. No. 6.2)
Agreed Plant Level Environmental Management Measures (including units 1, 2, 3, 4, 5, and 7) for Implementation by KTPS
10. Compliance with Air pollution control Summary of actions already taken (during 2007-08) Cost incurred Completed
requirements as per Mharashtra Pollution include: and
Control Board’s (MPCB) consent Ø Unit-5: complete replacement of bags in bag filter implemented
conditions for Units 1-5 and Unit 7 (Ref. system as part of
No. 3.3) Ø Unit 7: (a) AFGC system has been installed and regular plant
currently under testing and commissioning; O&M costs
Ø All units: (a) Replacement of faulty collecting
electrodoes; (b) Replancement of faulty emitting
electrodes; and (c) Periodic inspection of ESP’s
for alignment of fields for 100% availability.
Further Actions:,
Ø Commissioning of AFGC and Ammonia dosing for
Unit 7 Cost incurred Nov. 2009
Ø Periodic inspection of ESP’s on continual basis for as part of On regular
100% availability of fields regular basis
Ø Thorough assessment of ESP performance and plant O&M
necessary refurbishment for Unit-3 during capital costs Feb. 2009
overhaul
Ø Decommissioning of Unit 1-4 Dec 2012
11. Fugitive Dust Emissions from Coal Handling Ø Implementation of dry fog system (to be supported 1.40 Completed
Plant (Ref. No 4.8). This is also one of the by regular maintenance for effective functioning) June 2008
consent conditions by MPCB. Ø Installation of Dust Suppression system at Wagon 2.50 April, 2009
Tiplers and Coal Handling area (work order placed
by KTPS)
Ø Revamping dust extraction system at impact 3.80 June 2009
crusher of CHP (KTPS is negotiating with M/s
Aerovent Proj. Pvt. Ltd.)

Ø Use of dust suppressants/chemicals as part of water O&M Costs March, 2009

sprinkling to retain moisture during summer season.
Feasibility to be ascertained by KTPS
12. Continuous Ambient Air Quality Monitoring KTPS has placed Work order with Enviro Tech Pvt. Ltd., 8.00 CAAQMS by
(CAAQMS) complying with consent New Delhi for installation, testing, commissioning of March 2009.
conditions of MPCB (Ref. No. 3.3) CAAQMS. Till such time, KTPS to continue AAQM AAQM to
complying with NAAQS continue
13. Compliance with utilization with dry fly ash Ø KTPS to comply with Flyash notification Buyers to June 2009
as per Fly Ash Utilization Notification, April requirements through relevant agreements with incur cost as
3, 2007 is not achieved. (Ref. No. 4.4). cement manufacturers by entering in to relevant per
Compliance with this requirement is also offtake agreements. agreements
one of the consent conditions of MPCB Ø Establishing dry ash silo scroew conveyer system in 1.00 May 2009
Unit-3
Ø Awareness generation in villages around KTPS for Cost by KTPS Ongoing and
utilization of fly ash for different purposes continual
basis
14. Currently water consumption is assessed Water flow meters are to be installed at all major inlet 7.02 March, 2009
based on pumps capacities. Thus there is no and outlet points. The points where the flow meters are
precise mechanism to assess water balance to be installed are detailed in Plate-II B of the EADD
and there by limited opportunity for report. KTPS has already placed work orders: (a)
efficiency improvements in water savings. KTPS/PUR/2008-09/I&C-II/296 dt. Sept 04, 2008; and (b)
KTPS/PUR/2008-09/I&C-II/391, dtd. Sept 29, 2008
MPCB consent condition for installation of
flow meters for monitoring plant water
balance under Water (Prevention and
Control) Act, 1974 (Ref. No. 3.3).
15. Water discharges from Khasara Ash pond is Ø The ongoing works for raising Khasara Ash bund will Costs already December
partly recycled and partly discharged in to be completed on priority budgeted and 2008
stream, causing pollution in monsoon Ø Replacement of couplings by welding of the joints to under
season. Further, the bund overflows and be completed on priority implementatio
failure of slurry pipelines causes pollution Ø Further, maintenance of the pipelines to be made n
of local streams. Similarly, CHP toe drain effective based on the completed study on “Slurry
discharges are causing pollution (Ref. No. Thikness”

4.5). Referred water pollution abatement is Ø KTPS issued work order (KTPS/Civil.2G/015/WR-75 dtd. 0.36 January
also one of the MPCB consent conditions 08/26/08 ) for rearranging of stone filters at 2009
(Ref. No. 4.5) percolation wells and bund drains
Ø Ongoing work for recovery of CHP toe drain as well 0.97 January
as Booster Pumping House (BPH) to ash water 2009
recovery scheme and subsequent reuse through
settling tank to be completed on priority (Ref:
KTPS/Civil.02G/011/PUR-5642/WO/498/7381 dtd. 09/15/08)
Ø The current water recycling to be extended for rest Estimates and January
of the discharges from ash pond for ash slurry implementatio 2010
preparation and/or any other plant housekeeping n due by KTPS
purposes
16. The Raw Water from Pench Dam is In view of the EADD analysis and preliminary feasibility, 30.-00 December
conveyed to Intake Pond No.3 through open KTPS has agreed to for the option of construction of a 2010
channel. This results on higher levels of separate pipeline from Pench Dam to the Raw Water
chlorides leading to higher chemical Pumping (RWP) sump. Detailed feasibility of this
consumption for treatment in WTP-I and II. option will be established and implemented by KTPS
(Ref No. 4.6)
17. Intake pond No. 3 is infested with aquatic Capital investment for cleaning of Pond No. 3 and 7.50 August 2009
weed and high organic load and turbidity securing bunds with subsequent measures to establish
resulting in high chemical consumption for regular cleaning mechanism
water treatment (Ref. No. 4.6)
18. Disposal of Hazardous Waste (Ref. No. Based on MPCB consent conditions and EADD Cost has been Compliance
3.3) observations, KTPS has made an agreement with M/s V budgeted and Review by
EPL, Nagpur for Hazardous waste disposal at Common incurred by Envt. Cell of
Hazardous Waste Treatment Storage and Disposal KTPS KTPS on
Facility (CHWTSDF) located at Buttibori. The Monthly
arrangement is valid up to 07/25/2012 basis
19. Annual Occupation Health and Safety Mandatory Annual OHS audit as committed in EHS Internal Audit First OHS
(OHS) internal audits as per EHS policy are policy to be complied by KTPS regularly on Annual -cost audit by
currently not conducted (Ref. No. 6.2) basis internalized – March 2009
OHS function
20. Only Annual medical checkups are Regular biannual medical checkups for permanent as 3.2 First
conducted for workers as against biannual well as contract workers complying with the (Annum) compliance

checkups as per Maharastra Factories Maharashtra Factories Rules by March

Rules. Also the checkups are not conducted 2009
for contract labour (Ref. No. 3.3.)
21. Poor housekeeping, lighting and ventilation Adoption of good practices especially housekeeping, ------------- Regular
in the plant (Ref. No. 6.2) lighting in CHP area; and ventilation and lighting basis
facilities in the plant area, complying with the factories
act
*Estimates are subject to review by design consultant

ANNEXURE – I
List of Monitoring Parameters and Locations

S. No. Environmental Attribute No. of Samples Location Details

1 Stack Emission 5 Stack 2, 3, 5, 6 & 7 (1&4 not operational)
2 Ambient Air Quality 5 Time Office Stage – 2
Club – 2
Railway Siding
STP – Colony
KTC Koradi
3 Process Effluent 4 Condenser Cooling
Cooling tower blow down
Boiler blow down
Ash Slurry BPH
4 Treated Process Effluent 2 ETP Outlet
Ash Pond Overflow
5 Sewage Effluent from Plant and Colony 2 Plant
Colony
6 Treated Sewage 1 STP Outlet
7 Surface Water Quality 2 Ash Pond Discharge (Rly. Station)
Water body receiving STP/ETP Discharge
8 Ground Water 1 Borewell at Mashala Village near GP School
9 Source Noise Generator Noise
DG Sets (1- 5)
TF (1 & 2)
10 Ambient Noise 5 Stage 1 Gate
Stage 2 Gate
Hospital
Commercial Complex
Shivaji Nagar
11 Coal Quality 2 Bunkered Coal (Stage 1&2)

ANNEXURE – II
Unit Wise Stack Monitoring Report

Unit – 1 (105 MW): FIGURE – 3: STACK EMISSION (NOx) – UNIT 1
During the review of the monthly data for Unit 1, it was

NOx Emission (Unit 1)
found that the stack emission were within the prescribed
norms over a period of 4 years. However, during June 160
2004-05, the SPM level in the stack emission was recorded 140
NOx Level (PPM)

2003-04
120
as 170 mg/Nm3 and a second highest level was recorded 100 2004-05
80 2005-06
during March 2005-06 which was 151 mg/Nm3. 60 2006-07
40
20 Standard
NOx emissions were also recorded to be with in the 0
prescribed limit of 150 PPM.
r
ne
ly
r il
ry
ch
r
st
er
ay
be
ar
be
be
Ju
Ap
ua
gu
Ju
ob
ar
M
nu
em
br
Au
M
ct
ve
ce
Ja
Fe
O
pt
No
De
Figures 2 and 3 show the trend in the stack emission of
Se
Months
Unit 1 for the year 2003-04 to 2006-07. The unit was shut
down during July – August 2003-04 and August 2004-05.
Unit – 2 (105 MW):
FIGURE – 2: STACK EMISSION (SPM) – UNIT 1
Particulate Matter (PM) emission of Unit – 2 was found to
PM Emission (Unit 1)
be within the prescribed norm except for the months of
August 2004-05 and October 2006-07 where the PM was
180 recorded as 159 and 161 mg/Nm3 respectively.
PM Value (mg/Nm3)
160 2003-04
140 2004-05
120
100
80
2005-06 NOx emissions for Unit 2 were within the limit of 150 PPM.
60 2006-07
40 Standard
20
0 Figures 4 and 5 show the trend in the stack emission of
Unit 2 for the year 2003-04 to 2006-07. The unit was shit
r
ry
r
ne
ry
ri l
ly
ch
t
er
ay
be
be
us
be
Ju
Ap
ua
a
ob
ar
Ju
down during January – March 2004, September to

M
nu
ug
em
br
M
ct
ve
te
Ja
A
ec
Fe
O
ep
No
November 2005 and February – March 2006.

S
Months

FIGURE – 4: STACK EMISSION (SPM) – UNIT 2 Unit – 3 (105 MW):
Particulate Matter (PM) emission of Unit – 3 was

PM Emissions (Unit 2)
exceeding the standard mostly during the year 2004-05. It
180 was observed that the PM levels were higher than the limit
PM Value (mg/Nm 3)
160
140
2003-04 over a period of 8 months during the year 2004-05. The
2004-05
120
100 highest was recorded during the month of June 2004-05
2005-06
80
60
which was 189 mg/Nm3. The PM emission during the year
2006-07
40
Standard
2005-06 was recorded below the limit except for the month
20
0 of December when the PM level was recorded as 168
mg/Nm3.
r
ne
ly
F e ry
ry
ch
ril
Ja r
ay
st
er
r
be
be
be
Ju
Ap
ua
gu
ob
Ju
ar
M
nu
m
em
Au
M
br
ct
ve
ce
O
pt
No
De
Se
Months
NOx emissions for Unit 3 were within the limit of 150 PPM.
Figures 6 and 7 show the trend in the stack emission of
Unit 2 for the year 2003-04 to 2006-07.
FIGURE – 5: STACK EMISSION (NOx) – UNIT 2
The unit was shout down during Oct – Dec 2003 and Feb’
04 and during July 2005.
160 FIGURE – 6: STACK EMISSION (PM) – UNIT 3

140
NOx Level (PPM)
2003-04
120
100 2004-05
80 2005-06 PM Emissions (Unit 3)
60 2006-07
40
20 Standard 200
PM Value (mg/Nm3)
0 2003-04
150
2004-05
De be r
ne
ly
ry
ri l
F e ry
ch
t
Ja r
ay
er
r
s
be
be
Ju
Ap
ua
a
gu
ob
Ju
ar
M
100 2005-06
m
nu
m
M
br
Au
ct
ve
ce
e
O
pt
No
2006-07
Se
50
Months Standard
0
r
ne
ly
Fe ry
ry
ch
ril
r
t
ay
er
be
us
be
be
Ju
Ap
ua
ob
Ju
ar
M
nu
ug
m
em
M
br
ct
ve
ce
Ja
A
O
pt
No
De
Se
Months

FIGURE – 7: STACK EMISSION (NOx) – UNIT 3 Figures 7 and 8 shows the trend in the stack emission of
FIGURE – 8: STACK EMISSION (PM) – UNIT 4
160
140
NOx Level (P P M )
2003-04
120
2004-05 PM Emissions (Unit 4)
100
80 2005-06
60 2006-07 200
PM Value (mg/Nm3)
40 2003-04
20 Standard 150
2004-05
0
100 2005-06
r
ne
ly
ri l
F e ry
ry
ch
Ja r
ay
st
er
r
De b e
2006-07
be
be
Ju
Ap
ua
gu
a
Ju
ob
ar
M
50
nu
em
m
Au
M
br
ct
ve
ce
Standard
O
pt
No
Se
0
Months
r
ne
ly
ry
ch
il
r
st
er
ay
be
be
be
pr
ar
Ju
ua
gu
ob
Ju
ar
M
m
A
nu
m
em
br
M
Au
ct
ve
ce
Ja
Fe
O
pt
No
De
Se
Unit – 4 (105 MW): Months
Particulate Matter (PM) emission of Unit – 4 was recorded

higher than the limit during the months of January, March, FIGURE – 9: STACK EMISSION (NOx) – UNIT 4
July and August 2005-06. The highest was recorded during
the month of January 2005-06 which was 180 mg/Nm3.
The PM emission was recorded below the limit in all the
other years for which the data was reviewed. 160
140
NOx Level (PPM)

2003-04
120
2004-05
NOx emissions for Unit 4 were mostly within the limit of 100
80 2005-06
150 PPM. 60 2006-07
40
20 Standard
The unit was shut down during May 2004 and February 0
2005.
D e be r
ne
ly
F e ry
ry
ri l
ch
Ja r
st
er
ay
be
be
Ju
Ap
ua
gu
ob
Ju
ar
M
nu
em
m
Au
M
br
ct
ve
ce
O
pt
No
Se
Months

Unit – 5 (200 MW):

FIGURE – 10: STACK EMISSION (PM) – UNIT 5
Particulate Matter (PM) emission of Unit – 5 was found to
be higher than the statutory limit of 150 mg/Nm3. During PM Emissions (Unit 5)
the years 2003-04 and 2004-05 the PM emissions were at 900
PM Value (mg/Nm3)
the peak and the emissions ranged between 400 and 700 800
700
2003-04
2004-05
mg/Nm3. The emissions were 4 to 5 times higher than the 600
500
2005-06
400
prescribed limit. The unit went through a shutdown period 300 2006-07
200
of 7 months starting from December 2004-05 till June 100 Standard
0
2005-06. The emission level recorded after this period was
ry
r
y
r
ne
h
il
er
ly
st
be
ay
be
be
found to be within the prescribed limit.
ar
pr
c
Ju
ua
gu
ob
ar
Ju
M
m
A
nu
em
em
br
Au
M
ct
ve
Ja
c
Fe
pt
No
De
Se
Months
The PM levels were found to be less than 100 mg/Nm3
which is also the prescribed limit according to PPAH. The
high levels of particulate matter during the years 2003-04 FIGURE – 11: STACK EMISSION (NOx) – UNIT 5
and 2004-05 is due to non functioning of the ESP. During
the 7 months shut down period, KTPS had installed the bag
filter in addition to the existing ESP for Unit – 5. This NOx Emission (Unit 5)
contributed in the reduction of the PM emissions from the 160

140
NOx Level (PPM)

unit. 120
2003-04
2004-05
100
80 2005-06
60
SO2 emissions were also found to be within the prescribed 40
2006-07
Standard
20
limit. NOx emissions for Unit 5 were also found to be within 0
the prescribed limit.
ry
r
ne
h
t
er
ly
be
il
ay
be
be
ar
us
pr
c
Ju
ua
ob
ar
Ju
em
M
nu
ug
A
em
em
br
M
ct
Ja
ov
A
ec
t
Fe
O
ep
D
S
Months

Unit – 6 (210 MW):
Unit – 6 of the KTPS has been chosen for the R&M. FIGURE – 12: STACK EMISSION (PM) – UNIT 6
Therefore, special emphasis has been laid to review the
existing data for Unit – 6 of the plant.
Review of the data on stack emission for Particulate Matter 600
P M V alue (m g/Nm 3)
(PM) of Unit – 6 has shown that the PM emission has 500 2003-04
400 2004-05
increased from February 2003 till June 2005. The highest
300 2005-06
during this period was recorded in June 2005 when the PM 200 2006-07
level went has high as 549 mg/Nm3. During the year 2004- 100 Standard
05, the PM emission level was recorded in the range of 180 0
to 220 mg/Nm3 which was higher than the limit of 150
r
ne
ly
ri l
F e ry
ry
ch
Ja r
ay
st
er
r
De b e
be
be
Ju
Ap
ua
gu
a
Ju
ob
ar
M
mg/Nm3. The PM level decreased after a shutdown period
nu
em
m
Au
M
br
ct
ve
ce
O
pt
No
Se
of July 2005. The highest PM level recorded after this Months
period was in the month of October 2006.
The decrease in the PM emission of Unit – 6 is attributed to FIGURE – 13: STACK EMISSION (NOx) – UNIT 6
the partial replacement of bag filters during the shut down
period.
SO2 emissions were also found to be within the prescribed 160

140
limit. NOx emissions for Unit 6 across the years for which
NOx Level (PPM)

2003-04
120
2004-05
the data was reviewed showed that the emission levels 100
80 2005-06
were within the prescribed limit of 150 PPM. 60 2006-07
40
20 Standard
Figures 12 and 13 shows the trend in the stack emission of 0
r
ne
ly
ri l
F e ry
ry
ch
Ja r
ay
st
r
r
De be
be
be
be
Ju
Ap
ua
gu
Ju
ar
M
nu
m
em
c to
Au
M
br
ve
ce
O
pt
No
Se
Months

Unit – 7 (210 MW): FIGURE – 14: STACK EMISSION (PM) – UNIT 7
Particulate Matter (PM) emission of Unit – 7 recorded the

highest emission level compared to any other unit within
KTPS. The PM emission level from the year 2003-04 to 1200
PM Value (m g/Nm 3)
2006-07 was found to be in the range of 304 to 1001 1000 2003-04
mg/Nm3 with the highest being recorded in the month of 800 2004-05
600 2005-06
June 2005 and the lowest in the month of May 2006. 400 2006-07
200 Standard
The high level of PM emissions is attributed to the 0
inefficiency of the existing ESP for the Unit. At present, the
er
ne
ly
ry
ch
ril
Fe ry
ay
st
Ja r
r
r
be
be
be
Ju
Ap
ua
gu
Ju
ar
ESP has 20 fields and all the twenty fields are operated
nu
c to
m
em
M
Au
br
ve
ce
O
pt
No
De
Se
during the unit operation. However, due to high ash content Months
in the coal procured from local a colliery (which is about 35
– 38%), the particulate matter emission is high. The
present ESP is not capable to handling such high FIGURE – 15: STACK EMISSION (NOx) – UNIT 7
particulate matter emission. KTPS has requested the state
pollution control board to relax the norms for this
particular unit till 2008 after which KTPS is planning to
change/modify the existing ESP. 160
140
NOx V alue (P P M )
2003-04
120
NOx emissions for Unit 7 are within the limit of 150 PPM. 100 2004-05
80 2005-06
60 2006-07
Figures 14 and 15 shows the trend in the stack emission of 40
20 Standard
Unit 7 for the year 2003-04 to 2006-07. 0
r
ne
ly
ri l
F e ry
ry
ch
Ja r
ay
st
er
r
D e be
be
be
Ju
Ap
ua
gu
Ju
ob
ar
M
nu
m
em
Au
M
br
ct
ve
ce
O
pt
No
Se
Months

ANNEXURE – III
ETP and STP (Waste Water Analysis)

PROCESS EFFLUENT ANALYSIS
S. No. Test Parameters UOM Condenser cooling Boiler blow Cooling tower Ash slurry-BPH
down blow down
1 PH - 8.1 - 8.7 6.9
2 Temp. oC 32.0 30.0 30.0 33.0
3 Chlorine mg/l <0.1 <0.1 <0.1 <0.1
4 Suspended solids at mg/l 2.0 1.0 2.0 32050
105oC
5 Oil &Grease mg/l 2.0 2.0 <1.0 10.0
6 Chromium mg/l <0.01 0.01 <0.01 <0.01
7 Total copper mg/l 0.02 0.02 0.01 0.02
8 Total Iron mg/l 0.07 0.01 0.05 0.06
9 Zinc mg/l 0.09 0.25 0.11 0.26
10 Phosphate mg/l 0.1 <0.1 0.7 0.7
11 Mercury mg/l 0.002 <0.001 0.002 0.005

TREATED EFFLUENT ANALYSIS
S. No Test parameters UOM ETP Outlet Ash pond overflow

1 PH - 8.2 8.0
2 Temp. 0c 28.0 32.0
3 Chlorine mg/l <0.01 <0.1
4 Suspended solids at 1800c mg/l 106 39.0
5 Oil & Grease mg/l 5.0 5.0
6 Chromium mg/l <0.01 <0.01
7 Total copper mg/l 0.01 0.01
8 Total Iron mg/l 0.02 0.048
9 Zinc mg/l 0.22 0.2
10 Phosphate mg/l 1.0 0.8
11 Mercury mg/l <0.001 0.001
SEWAGE WATER ANALYSIS
S. No Test parameters UOM Plant Colony STP outlet

1 pH 7.2 7.3 7.4
2 Temperature oC 26 30 28
3 Suspended Solids at 1050c mg/l 13 9 4.0
4 Total dissolved solids at 1800c mg/l 324 368 316
5 Oil &Grease mg/l 4.0 9.0 3.0
6 COD mg/l 325.3 35.3 23.5
7 BOD mg/l 40.0 5.0 <5.0

ANNEXURE – IV
Data analyzed during REA

Historical Analysis for the Year 2005-06
Un-burnt Un-burnt in
Power Generation Coal Consumption Water consumption Calorific in Fly Bottom Ash
Month (Million Kwh) (MT) (L) value of coal Ash % %
Apr-05 126.325 387783 737393 3921 1.21 3.29
May-05 133.662 409210 793117 3922 1.23 3.78
Jun-05 103.242 386806 1324741 3908 1.2 3.89
Jul-05 0 309377 1342092 3815 1.47 5.57
Aug-05 19.065 350895 1574821 3813 1.51 6.24
Sep-05 123.192 372808 1557926 3885 1.41 7.46
Oct-05 130.733 416524 1612567 3810 1.16 6.05
Nov-05 138.188 466209 1760780 3795 0.95 4.92
Dec-05 111.923 486506 1892191 3840 1 4.2
Jan-06 154.55 479559 1723224 3995 1.31 3.88
Feb-06 132.604 388122 1794722 3902 1.04 3.77
Mar-06 129.482 460322 2570813 3917 1.23 4.48

Historic Analysis for the Year 2006-07
Un-burnt Un-burnt in
Power Generation Coal Consumption Water consumption Calorific value in Fly Bottom Ash
Month (Million Kwh) (MT) (L) of coal Ash % %
Apr-06 138.251 401576 1344615 3883 1.14 4.47
May-06 124.141 411142 1644882 3906 1.07 4.58
Jun-06 137.534 429056 1494258 3830 1.27 4.15
Jul-06 123.909 459073 1641949 3681 1.42 4.55
Aug-06 115.036 469439 1573467 3326 1.11 5.44
Sep-06 114.581 488947 1577781 3401 1.09 4.53
Oct-06 121.91 472304 1741951 3600 0.98 4.88
Nov-06 107.163 480746 1548756 3665 0.94 5.44
Dec-06 50.457 443545 1738353 3712 1.12 5.66
Jan-07 137.026 522533 1714936 3731 0.97 4.87
Feb-07 131.177 450851 1564609 3770 0.84 4.96
Mar-07 145.196 450440 1593383 3737 0.85 4.7

UNIT VI – THERMAL EFFICIENCY OF BOILER heater
Total Heat content of steam Thermal energy transfer

at 141 kg/cm2 & 535 C 3418.6 kJ/kg from Flue gas to the
Feed water temperature 240 C steam 1307 kJ/kg of coal
Feed water enthalpy 1037 kJ/kg Percentage heat addition
Net heat transferred to the in superheater 11.88 %
steam 2382 kJ/kg
Steam Flow rate 663 TPH Air preheater
coal consumption 3442 Tonnes/day Volume of air charged into the kg of air / kg of
boiler 5.77 coal
coal consumption 143 TPH
Cp of air 1.005 kJ/kg K
kg of steam / Cp of flue gas assumed 1.08 kJ/kg K
Rate of steam generation 4.62 kg of coal kg of flue
Net heat transferred to Mass flow rate of flue gas 6.77 gas/kg of coal
steam / kg of coal burnt 11010 kJ/kg of coal Outlet temperature of Flue gas
from APH 169 C
Super Heater Inlet temperature of Flue gas
to APH 338.5 C
kg of steam / kg
1238.
Rate of steam generation 4.62 of coal
Transfer in thermal energy 9 kJ/kg of coal
Cp of super heated steam 2.095 kJ/kg K
1238.
Inlet temperature of the Net transfer in thermal energy 9 kJ/kg of coal
steam (assumed it as Thermal efficiency of Air
saturated) into the preheater 11.25 %
superheater 400 C
Outlet temperature of
steam from the super 535 C

gas of coal
Air preheater Inlet temperature of

Volume of air charged into the kg of air / kg of Feed water 238 C
boiler 5.77 coal Outlet temperature of
Cp of air 1.005 kJ/kg K Feed water 283 C
Cp of flue gas assumed 1.08 kJ/kg K
Transfer in thermal
kg of flue gas/kg
energy 827.67 kJ/kg of coal
Mass flow rate of flue gas 6.77 of coal
Outlet temperature of Flue gas Percentage heat
from APH 169 C addition in economiser 7.52 %
Inlet temperature of Flue gas
to APH 338.5 C Heat Lost due to flue gas
1238. kg of flue
Transfer in thermal energy 9 kJ/kg of coal gas / kg
Weight of the dry flue gas 6.77 of coal
1238. Cp of flue gas assumed 1.08 kJ/kg K
Net transfer in thermal energy 9 kJ/kg of coal Exit temperature of flue gas 169 C
Thermal efficiency of Air Ambient temperature 28 C
preheater 11.25 % kJ/kg of
Thermal energy loss in Flue gas 1030.581253 coal
Economiser Energy loss in Flue gas 6.34 %

Feed water flow into the
economiser 630.00 tonnes per hour Loss due to moisture in fuel
Cp of water 4.187 kJ/kg K Moisture in Fuel 15 %
Cp of flue gas assumed 0.257941247 kCal/kg K
Feed water flow per kg of water / kg
Flue gas temperature 169 C
tonne coal 4.39 of coal
Ambient dry bulb 28 C
Mass flow rate of flue 8.15 kg of flue gas/kg temperature

GCV of coal 3881 kCal/kg of coal assumed

Loss due to Hydrogen 2.40 % Unburnt losses in bottom ash
Ash
Loss due to moisture in air percent in
Actual mass of air 5.77 kg of air / kg coal 32.05 kg of Ash / 100 kg of coal
supplied of coal Unburnt
Humidity factor 0.014 kg of water / carbon in
kg of dry air bottom
ash 6.21 kg of C / 100 kg of bottom ash
Flue gas temperature 169 C
Ratio of
Ambient dry bulb 28 C Bottom to
temperature Fly ash 20:80
GCV of coal 3881 kCal/kg of coal I kg of
Loss due to Hydrogen 0.2948 % Carbon 33820 kJ/kg of carbon
Unburnt
Heat loss due to hydrogen in fuel carbon 0.00398061 kg of Carbon/kg of coal
Hydrogen in Fuel 3.655 % Heat value
Cp of flue gas assumed 0.257941247 kCal/kg by burning
of 1 kg of
K
carbon 135 kJ/kg of coal
Flue gas temperature 169 C Loss due
Ambient dry bulb 28 C to bottom
temperature ash 1.22 %
GCV of coal 3881 kCal/kg
of coal Unburnt losses in Fly ash
Loss due to Hydrogen 5.26 % Ash
percent in
coal 32.05 kg of Ash / 100 kg of coal
Loss due to Unburnt
radiation 1 % carbon in 0.96 kg of C / 100 kg of fly ash

Fly ash
Ratio of Cp of Silica 0.5 kCal/kg C
Bottom to Temperature of the
Fly ash 20:80 ash 1400 C
I kg of Ambient temperature 28 C
Carbon 33820 kJ/kg of carbon Heat loss 43.97 kCal/kg of coal
Unburnt Heat loss % 1.13 %
carbon 0.00246144 kg of Carbon/kg of coal
Heat value Heat losses in Fly ash
by burning Ash percent in coal 32.05 kg of Ash / 100 kg of coal
of 1 kg of Ratio of Bottom to
carbon 83 kJ/kg of coal Fly ash 20:80
Loss due
to fly ash 0.76 % Botton ash 0.2564 kg of ash/ kg of coal
Cp of Silica 0.5 kCal/kg C
Temperature of the
Heat loss due to partial conversion of C to CO ash 169 C
CO % in flue gas 21.00 ppm Ambient
Mass flow rate of fuel 143000 kg/h temperature 28 C
Loss due to CO 482978 kCal/h Heat loss 18.08 kCal/kg of coal
Heat loss % 0.47 %
Heat input 554983000 kCal/h
Loss due to CO in % 0.087 %
Indirect Thermal efficiency of the
Heat losses in bottom ash boiler 81.04 %
kg of Ash / 100 kg of
Ash percent in coal 32.05 coal REHEATERS AND CONDENSERS
Ratio of Bottom to Fly
ash 20:80 Heat addition in the reheater
Bottom ash 0.0641 kg of ash/ kg of coal Parameters Values Unit

Cold reheat pressure 22 kg/cm2 mm of HG

Condenser pressure 665 guage
Hot reheat pressure 20 kg/cm2 LP exhaust temperature 47 C
Cold reheat temperature 300 C LP exhaust enthalpy 2589.8 kJ/kg
Hot reheat temperature 530 C Altitude of KTPS 305 M
kg of steam/kg Barometric pressure 732 mm of Hg
Steam to Fuel ratio 4.62 of coal
Absolute pressure in the
Main steam flow 663.00 TPH condenser 63.5 mm of Hg
Total HP extraction Enthalpy at 0.101925
quantity 96.19 TPH kg/cm2 617.8 kcal/kg
Reheater steam flow 566.81 TPH 2586.7 kJ/kg
Main steam flow 157.45 kg/s temperature at 0.12
Cold reheat enthalpy 3015.3 kJ/kg kg/cm2 49.1 C
Hot reheat enthalpy 3532.9 kJ/kg Temperature at 0.1 kg/cm2 45.5 C
Saturated temperature at Temperature at 0.101925 48.9 C
20 kg/cm2 213.92 C temperature of liquid 46 C
Saturated temperature at
22 kg/cm2 218.59 C
Heat added in the reheat Effectiveness of the condenser
per kg of coal 2393 kJ / kg of coal Cooling water exit temperature 42.9 C
Heat added in the reheat 81494 kW Cooling water inlet temperature 34.4 C
Heat addition in the Temperature corresponding to
reheater 21.7 % vaccum in the condenser 48.9 C
Range 8.5 C
Heat rejection in the condensers
Maximum possible temperature
Parameters Values Unit difference 14.51 C

Effectivness of the condenser 58.6 %

Maximum possible effectiveness 70 % HP Heater 6
Parameters Values Units
REGENERATION Inlet enthalpy to the heater at
The calculation is carried out based on the data made 21 kg/cm2 2797 kJ/kg
available during the visit Outlet enthalpy at 21 kg/cm2 926.1 kJ/kg
Enthalpy at drip temperature 680.43 kJ/kg
HP Heater 7
Net latent heat transfer 1870.9 kJ/kg
Net sensible heat transfer 245.67 kJ/kg
Inlet enthalpy to the heater at
33 kg/cm2 Net heat transferred to Feed
2800 kJ/kg
water 2116.57 kJ/kg
Outlet enthalpy at 33 kg/cm2 1036 kJ/kg
Inlet feed water temperature
Enthalpy at drip temperature 768.4 kJ/kg
to the heater 168 C
Net latent heat transfer 1764 kJ/kg
Outlet feed water temperature
Net sensible heat transfer 267.6 kJ/kg from the heater 183 C
Net heat transferred to Feed Feed water flow rate 663 TPH
water 2031.6 kJ/kg
Feed water flow rate 184.1667 kg/s
Inlet feed water temperature
Net heat taken away by feed
to the heater 183 C
water 11566.59 kW
Outlet feed water
Therefore steam flow rate 5.46 kg/s
temperature from the heater 239 C
Extracted steam 19.67 TPH
Feed water flow rate 663 TPH
Total HP extraction quantity 2797 kJ/kg
Net heat taken away by feed HP Heater 5
water 43181.93 kW
Therefore steam flow rate 21.25513 kg/s
Inlet enthalpy to the heater at 2776.1 kJ/kg
Extracted steam 76.52 TPH

9.5 kg/cm2 Main steam enthalpy 3425.3 kJ/kg

Outlet enthalpy at 9.5 kg/cm2 768.49 kJ/kg Main steam entropy 6.5531 kJ/kg K
Enthalpy at drip temperature 504.09 kJ/kg Heat inlet to the
Net latent heat transfer 2007.61 kJ/kg turbine 630826 kW
Net sensible heat transfer 264.4 kJ/kg Power output 175000 kW
Net heat transferred to Feed Power output 150500000 kCal/h
water 2272.01 kJ/kg Heat inlet to the
Inlet feed water temperature turbine 542386888 kCal/h
to the heater 140 C Overall unit
Outlet feed water temperature Efficiency 27.75 %
from the heater 168 C
Feed water flow rate 663 TPH TURBINE EFFICIENCY
Net heat taken away by feed HP Cylinder
water 21590.96 kW Efficiency (h1-h2)/(h1-h2')
Therefore steam flow rate 9.50 kg/s Inlet enthalpy to
Extracted steam h1 the turbine
34.21 TPH
Hp outlet enthalpy
OVERALL EFFICIENCY h2 at the turbine
Enthalpy at
Parameters Values Units h2' constant entropy
Main steam flow 663 TPH Inlet entropy of
Main steam flow 184.2 kg/s S1 the steam
Main steam pressure 130 kg/cm2 h1 at 131 kg/cm2 abs
and 533 C 3425.3 kJ/kg
Main steam
h2 at 23.01325 kg/cm2
temperature 533 C
abs and 300 C 3015.4 kJ/kg

THEORITICAL AIR REQUIREMENT AND FG

S1 6.5531 kJ/kg K
ANALYSIS
At 6.5531 kJ/kg K and Ultimate analysis of the fuel
23.01325 kg/cm2 abs 2926.3 kJ/kg
C 38.86 %
HP Cylinder efficiency 82.14 % H 3.655 %
N 1.235 %
IP Cylinder S 0.49 %
Efficiency (h1-h2)/(h1-h2')
Inlet enthalpy to the O 8.715
h1 turbine Moisture 15 %
IP outlet enthalpy at Ash 32.045 %
h2 the turbine Total 100 %
Enthalpy at constant
h2' entropy
O2 4.4 %
Inlet entropy of the
S1 steam CO2 14.6 %
Average flue N2 81 %
h1 at 23.013 kg/cm2 gas in at 175
abs and 533 C 3537.6 kJ/kg
MW
h2 at 1.59 kg/cm2 abs Total 100 %
and 179 C 2829.9 kJ/kg % by Molecular kmol kmol of O2
S1 7.4681 kJ/kg K weight weight required for
At 7.4677 kJ/kg K and complete
1.59 kg/cm2 abs 2807.6 kJ/kg combustion
C 38.86 12 3.238333 3.238333333
IP Cylinder efficiency 96.95 %
H 3.655 2 1.8275 0.91375
N 1.235 28 0.044107
S 0.49 32 0.015313 0.0153125

O 8.715 Total 4.167395833 Excess air supplied 1.53 kg of air / kg of

Moisture 15 coal
Ash 32.05
Total 100.0 FLUE GAS ANALYSIS
Flue kmol Molecular Weight Weight of unit LHS RHS LHS RHS
gas weight 23.2 kmol of O2 CO2 O2 CO2 O2 CO2 CO2
% % % % % % O2 % %
kmol flue gas
O2 4.4 32 140.8 31.23 10/11/2 15.30
007 Hrs 152 5.6 13.2 4 15 7 11.8 5.4 13.6
CO2 14.6 44 642.4 142.49
10/12/2 11.00
N2 81 28 2268 503.05
007 Hrs. 175 4.4 14.6 16 3 5.8 13.2 14.6 4.4
Total 100
676.77 100
Flue Gas
kg of Analysis 152 MW APH in RHS
coal
APH in LHS O2 5.6 % O2 4 %
CO2 13.2 % CO2 15 %
Quantity of flue gas 677 kg/100 kg of coal
N2 81.2 % N2 81 %
generated
Total 100 % Total 100 %
Quantity of flue gas 6.77 kg of air / kg of APH out LHS APH out RHS
generated coal O2 7 % O2 5.4 %
Total air would have 5.77 kg of air / kg of CO2 11.8 % CO2 14.6 %
supplied coal N2 81.2 % N2 80 %
Excess air percent 26.5 kg of air / kg of Total 100 % Total 100 %
coal
Thereoritical air 4.24 kg of air / kg of OPERATIONAL DATA given from the plant personnel
required coal

Dt. 31.10.2007 Freq. Unit CW inlet Temp 33 33 0C
49.58 CW O/L temp 40/41/ 40/41 0

C
Parameter AT AT LOAD O2 in FG at APH I/L % 3/'3 3/'3 %
LOAD 175 MW Wind Box Pr. 41 40 Kg/cm2
167 MW APH Gas I/L Temp 334/339 336/341 0C
BFP Disch Pr. 155 155 Kg/cm2 APH Gas O/L Temp 151/141 154/143 0C
Drum Pressure 140 141 Kg/cm2
ID Fan Amp 166/150 150/150 Amp
MS Pres. Blr 131 131 Kg/cm2
FD Fan Amp 32/20 32 Amp
MS Pres bef MSV 130 130 Kg/cm2 Deaerator Pressure 5 5.5 Kg/cm2
MS Pres aft MSV 130 130 Kg/cm2 Feed Tank Temp. 159 160 0C
0
MS Temp. Blr O/L 535 535 C
MS Temp bef MSV 532 533 0C
Cooling Tower Data
FW temp Eco I/L 236 238 0C
CW Outlet / Cooling tower inlet 42 C
FW temp Eco O/L 282 283 0C
water temp.
FW Flow 589 630 M3/h CW intlet / Cooling tower outlet 36 C
MS Flow T/hr 542 663 M3/h water temp.
CRH Pr.TG End 21 22 Kg/cm2 Dry Bulb Temp 28 C
HRH Pr. 19 20 Kg/cm2 Wet Bulb Temp 22 C
CRH Temp TG end 300 300 0
C C.T. Fan air flow rate Not available
0
HRH Temp R/H O/L 522 530 C
HRH Temp R/H I/L 520 528 0
C Range of the cooling tower 6 C
IPT O/L Pr. 0.53 0.58 Kg/cm2 Approach 14 C
IPT O/L Temp 171 179 0C Effectiveness 30 %
LPT Exhaust temp 46/44 46/45 0C
Hot well temp. 46/47 46/47 0

C BOILER SURFACE TEMPERATURE in 0C
Vacuum 667 665 Mm of hg

Elevation UNIT 7 SIDE CHIMNEY SIDE UNIT-5 SIDE PCR SIDE

LHS MIDDLE RHS LHS MIDDLE RHS LHS MIDDLE RHS LHS MIDDLE RHS
Elevation A 58 53 56 59 48 64 75 95 78 65 49 68
Elevation B 124 68 79 54 59 66 80 101 59 96 81 104
Elevation C 71 72 73 67 61 72 11 163 68 75 74 97
Elevation D 51 59 67 47 49 59 65 51 52 60 63 88
STEAM EXTRACTION
Parameter GC-II LPH2 LPH3 LPH4 HPH5 HPH6 HPH7

Extraction Inlet Temp 0C NA 155 260 NA NA NA NA
Extraction Inlet Press. Kg/cm2 0 0.25 1.5 5.4 9.5 21 33
0
Drip Temp. C 72 81 98 113 120 161 181
0
Feed Water Inlet C
Temp 65 75 100 122 140 168 183
Feed Water outlet 0C
Temp 75 100 122 140 168 183 239

Feed Water Inlet Kg/cm2

Press. 120
Feed Water outlet Kg/cm2
Press. 150

ANNEXURE – IV
Energy – Environment Comparison

Flue Gas Analysis (used for calculating emissions)
Ultimate analysis September 2007 November 2006 average

C 37.22 40.5 38.86
N 0.74 1.73 1.235
S 0.58 0.4 0.49
O 11.93 5.5 8.715
H 2.4 4.91 3.655
Mineral matter 47.13 46.96 47.045
% by weight Molecular weight kmol kmol of O2 required for complete combustion

C 38.86 12 3.2383 3.2383
H 3.655 2 1.8275 0.9138
N 1.235 28 0.0441 -
S 0.49 32 0.0153 0.0153
O 8.715 32 0.2723 -
A&M 14.1 Total 4.167
100 kg of coal gives 3.238 kmol of C

100 kmol of FG contains 15 kmol of CO2
Flue gas quantity 21.59 kmol / 100 kg of coal
1 kmol is 22.4 NM3 483.83 NM3/100 kg of coal
FG flow rate 4.84 Nm3/kg of coal
12 kg of carbon gives 44 kg of CO2
32 kg of sulphur gives 64 kg of SO2

Before R&M – Efficiency of Power Plant and Emission Levels
Coal Electricity Efficiency of the CO2 SO2 CO Particulate Water

Parameters consumption generated power plant emissions emissions emissions NOX matter emitted consumption
Million
Units MT kWh % MT MT/Month MT MT MT/month KL/month
Apr-06 105066 138.251 29.14 149706 347 8 43 64.56 23236
May-06 93557 124.141 29.11 133307 310 7 36 36.21 20775
Jun-06 105373 137.534 29.23 150143 347 8 41 50.98 23058
Jul-06 97951 123.909 29.48 139568 325 7 40 44.55 20535
Aug-06 99762 115.036 29.80 142148 330 7 39 53.58 23266
Sep-06 98591 114.581 29.14 140479 321 7 39 51.99 22680
Oct-06 99645 121.91 29.19 141981 329 7 37 70.87 22982
Nov-06 85883 107.163 29.18 122371 280 6 30 52.77 19452
Dec-06 39861 50.457 29.24 56797 131 3 15 25.26 8751
Jan-07 110603 137.026 28.51 157594 363 8 40 61.54 24388
Feb-07 103704 131.177 28.76 147764 341 8 36 62.22 23159
Mar-07 111801 145.196 29.87 159301 365 8 37 71.94 24303

After R&M – Efficiency of Power Plant and Emission Levels
Revised coal Revised electricity Revised efficiency CO2 SO2 CO Particulate Water
Month consumption generation of the plant emissions emissions emissions NOX matter emitted consumption
MT Million kWh % MT MT MT MT MT/month MT/month
Apr-06 90451 121 29.51 128881 299 7 37 55.58 20004
May-06 89598 121 29.51 127665 297 7 35 34.68 19896
Jun-06 91464 121 29.51 130324 301 7 36 44.25 20014
Jul-06 95182 121 29.51 135622 316 7 39 43.29 19954
Aug-06 105536 121 29.51 150374 349 8 42 56.68 24613
Sep-06 102397 121 29.51 145902 333 7 40 54.00 23555
Oct-06 97454 121 29.51 138858 322 7 36 69.31 22477
Nov-06 95493 121 29.51 136065 312 7 33 58.68 21629
Dec-06 94339 121 29.51 134420 309 7 35 59.79 20711
Jan-07 93985 121 29.51 133916 309 7 34 52.29 20724
Feb-07 92842 121 29.51 132288 305 7 32 55.70 20734
Mar-07 93935 121 29.51 133845 307 7 31 60.45 20420

ANNEXURE – V
Format for Near Miss Reporting


ANNEXURE – VI
Sample Accident Report




ANNEXURE – VII
Details of Chemicals and Fuel Oil Storages
(Occupational Health and Safety)

Chlorine
Location Quantity Type

Domestic Water Plant St I 1 Cylinder Cylinder of 100 Kg
Domestic Pre-Treatment Plant St-I 1 Cylinder Cylinder of 100 Kg
Soft water pre treatment plant St-I 3 Cylinder Cylinder of 100 Kg
Cooling tower St I 3 Tonner Tonner of 900 Kg
Hydrogen Cylinders

H 2 generating plant St I 350 Nos Cylinder of 5.4 & 5.94M 3
H 2 generating plant St II 500 Nos Cylinder of 5.4 & 5.94 M 3
FO and LDO

Oil handling plant St I 3440 KL Furnace Oil
1720 KL Low Diesel Oil
Oil handling plant St II 3600 KL Furnace Oil
1800 KL Low Diesel Oil
CHP Vehicle Maintenance 140 KL High Speed Diesel
Lubricant Oil and Transformer Oil

Boiler Maint. Oil Store St I 1 Barrel Servo Gem-2 Grease
15 Barrels Servo Mesh SP 320
13 Barrels Servo Mesh SP 257
1 Barrel Servo premium XHP 15W-40

19 Barrels Servo Prime 46

49 Barrels Total
Boiler Maint. Oil Store St II 1 Barrel Servo Gem-2 Grease

2 Barrel Servo System 320
20 Barrel Servo Mesh SP 257
2 Barrel Servo System 150
3 Barrel Servo Prime 46
1 Barrel Servo Cycle C-800
1 Barrel Servo 20W40
30 Barrel Total
Turbine Maint. Oil Store St I 1 Barrel Servo Friz F 57

20 Barrel Servo Prime 46
1 Barrel Servo Gear HO 90
14 Barrel Servo System HLP 32
1 Barrel Servo Torque 10
37 Barrel Total
Turbine Maint. Oil Store St II 20 Barrel Servo Prime 46

20 Barrel Total
Electrical Maint Oil Store St I 10 Barrels Transformer Oil

Electrical Maint Oil Store St I 25 Barrels Transformer Oil

ANNEXURE – VIII
Details of Person Interviewed
(Potential Liability & Risk Assessment)

Name of the Name of the person Residence of the

village interviewed Occupation village since Relation with MSEB
Suradevi Ramdas Farming 58 years Neither he nor anybody else from his
family is employed with the state utility.
Mhasala Pyarelal Ladke Farming 50 years Neither he nor anybody else from his
Khasar Mahadev Shambarkar Farming 50 years 2 sons of Mr. Mahadev Shambarkar
Bandu Shambarkar including Mr. Bandu were provided
Employed employment by MSEB. They were also
provided land as a part of the
rehabilitation program.
Koradi Neha Vasudev Bhoyar Sarpanch of Koradi Gram 20 years Her parents were provided land during
Panchayat (includes the rehabilitation program and her
Paanjra, Koradi, Naanda, brother was provided employment.
Khapri, Adarsh Nagar &
Shriyas Nagar)
Naanda Rajesh Mishra Laborer 20 years Neither he nor anybody else from his

ANNEXURE – IX
WATER CONSUMPTION & DISCHARGE DETAILS (2007-08)

Month Raw Water Blr Feed C.W. Effluent Gen. Effluent Recovered Discharged Ash Disposal Effluent
Intake m3 Cons.(m3) Cons.(m 3) (m 3) (m3) to Pond-3 Cons. m3 Gen.m3
(Recovered)
1 2 3 4 5 6 7 8
Apr-07 27668523 85091 2338582 472694 472694 0 1227628 1227628
May-07 25567133 85275 2229097 483600 439725 43875 1247894 1247894
Jun-07 15229364 67833 1611435 468000 456300 11700 1199564 1199564
Jul-07 26567566 80662 2066040 531300 493350 37950 1220666 1220666
Aug-07 28130961 74611 2083321 531300 494325 36975 1248630 1248630
Sep-07 29630570 68849 2241743 486000 469300 16700 1202113 1202113
Oct-07 27079739 76358 2109465 500774 463840 36934 1245509 1245509
Nov-07 24782535 76024 1911322 486000 465400 20600 1202460 1202460
Dec-07 25570240 68785 1923837 520219 475800 44419 1224410 1224410
Jan-08 26686196 67960 1924770 286124 271050 15074 1236555 1236555
Feb-08 25435827 65278 1982054 485100 445250 39850 1152509 1152509
Mar-08 27386938 68960 1998794 520800 468845 51955 1226774 1226774
Total 309735592 885686 24420460 5771911 5415879 356032 14634712 14634712

Month Effluent Recovery Discharge m3 Domestic Cons. Effluent Gen. Effluent Discharge m3 Loss m3
m3 (Unrecovered) m3 m3 Recovery m3 (Recovered)
9 10 11 12 13 14 15
Apr-07 685519 542109 306498 54000 37800 16200 542109
May-07 679739 568155 327300 50282 32683 17599 568155
Jun-07 672431 527133 324171 59820 32901 26919 527133
Jul-07 659610 561056 316877 68448 30802 37646 561056
Aug-07 679285 569345 305808 69068 27627 41441 569345
Sep-07 643942 558171 296318 64080 22428 41652 558171
Oct-07 665954 579555 304367 74338 33452 40886 579555
Nov-07 639896 562564 320756 71250 39188 32062 562564
Dec-07 451263 773147 323676 72912 36456 36456 773147
Jan-08 427148 809407 309559 69874 31443 38431 809407
Feb-08 623514 528995 289605 63974 29552 34422 528995
Mar-08 664225 562549 300798 72013 36673 35340 562549
Total 7492526 7142186 3725733 790059 391005 399054 7142186
Note: Apart from the unrecovered water of 7142186 m3 as mentioned in the cess recoreds, it was also observed that 18326431 m 3 (from Stream 2 of
Khasara ash bund (12251736 m3) and CHP&BPH outlet (6074695 m3)) is also unrecovered and unaccounted for in the cess records. Therefore, the
water recovered would not match with the cess records and the water balance statement.

Plate – I
Monitoring Locations

Colour Coding for Monitoring Locations on the Layout Map
Stack Monitoring Locations (1, 2, 3, 4, 5, 6 & 7)

Ambient Air Quality
Ambient Noise
Noise (DG Sets + TG)
STP Inlet (Colony & Plant)
STP Outlet
Cooling Water Blowdown
Boiler Blowdown
Ash Slurry BPH
ETP Outlet
Ash Pond Overflow
Surface Water (1)
Surface Water (2)
Note: Ground Water Location cannot be identified on the layout as it is out of the boundary


Plate – II A
Water Flow Schematic
[Flow measurements taken during the audit period have been represented. The flow schematic is not conclusive as measurements were not possible at
all inlet and outlet points]

Supernatant (not joining AWR) 33566.4 cu.m /day

10703.76 cu.m/day Ash Bund (khasara)
Open stream
(river) AWR ( Khasara )
16643.1 cu.m/day CHP +BPH FFPH
OVERFLOW
Koradi Ash Bund
Outside Booster PH AHP - I
AWR (Koradi)
open 704.85 cu.m/hr
drain
Stage I and II surface runoffs and Pre-
AHP - II ETP treatment effluents and boiler blow downs
461.5 cu.m/hr
Ash Slurry Line (U 5)
Lift Unit 5, 6 & 7 (U 6)
(U5) 287719 cu.m/day
Pump (U 7)
(U6) 326021 cu.m/day
Cooling tower
294645 cu.m/day
WTP - I SW
Units 1,2,3 & 4
Cooling tower
cu.m/day
DM SW
cu.m/day
Square
Tank Ash Slurry Line
(U7)
1314.25
cu.m/hr
WTP - II Raw water tank

RWP - II RWP - I
Domestic (Colony &Plant) 566.86 cu.m/hr Junction Box
Over flow
Dalmia pump
house
Inflow
from Pench Pond No. 3 Pond No. 2
Dam
(963,964.29 cu.m/day) 40% Channel
60% Channel
Un – recovered from ETP
Over flow nalah

PLATE – II B
Proposed flow meter installation locations

Supernatant (not joining AWR)

Ash Bund (khasara)
Open stream
(river) AWR ( Khasara )
CHP +BPH FFPH
OVERFLOW
Koradi Ash Bund
Outside Booster PH AHP - I
AWR (Koradi)
open
drain
Stage I and II surface runoffs and Pre-
AHP - II ETP treatment effluents and boiler blow downs
Ash Slurry Line (U 5)
Lift Unit 5, 6 & 7 (U 6)
Pump (U 7)
Cooling tower
WTP - I
SW
Units 1,2,3 & 4
Cooling tower
DM SW
Square
Tank Ash Slurry Line
WTP - II Raw water tank

RWP - II RWP - I
Domestic (Colony &Plant) Junction Box
Over flow
Dalmia pump
house
Inflow
from Pench Pond No. 3 Pond No. 2
Dam
40% Channel
60% Channel
Un - recovered
Over flow nalah

Plate – III
Proposed pipeline from Pench feed


Plate – IV
ETP Schematic

Over flow
D. D. D.
C C
X
D. D.
D.C
Screen C C
chamber
Sump No.1 Pump
Settler Eff.
Inlet Settling Tank-1 sump Settler
No.2 Out
cham Effluent No.3
let Sludge
ber inlet Pump
Sump No.2 pump P.H house
Valve Settling Tank-2 Settler
Pump
cham No.1
house
Valve
chamber
Removed
Manually
X Ext
chambe
r
Effluent Ext Ext.
from stage-I
New cham
chamber New
cham AHP Stage II
Effluent Inlet Pump- 03 Nos Capacity 1000 M3/hr

Effluent Outlet Pump-03 Nos Capacity 800 M3/hr
Effluent from stage-II Settler-03 Nos Capacity 1000 M3

Plate – V
STP Schematic

Garden pumps
1,2,3
OUTLET Clarifier Tank

CHAMBER
Sludge sump Aeration

overflow
Grit
chamber ART-1
RSP-1 RSP-2 RSP-
SP-1 SP-2 AERATING TANK
PUMP HOUSE ART-2

INTAKE TANK
Inlet
Chamber
LABORATORY
SLUDGE DRYING BEDS
1 2 3 4
COLONY END
5 6 7 8

DISCLAIMER
As it is practically not possible to study all the required aspects in its entirety thoroughly during the limited time period of the study, based
on our methodology, we carried out the study through review of related documents provided by the management of MAHAGENCO,
discussions with the management personnel and other key people, physical observations at the site, which helped us in identifying issues
and concerns, if any, associated with KTPS. Consequently, this report may not necessarily address all related matters perceived as
important by the management.
The information provided in this report is based on site reconnaissance, data and information made available to Ernst & Young during the
site visit, interviews and investigations during the site visit, and therefore, the finding of this report are valid as of the time period of the
site visit. Conclusion drawn from information available from documents / information made available to Ernst & Young Pvt. Ltd., pertain to
the time of generation of the respective documents and significance or accuracy of the same at the time of the site reconnaissance has not
be verified. Ernst & Young Pvt. Ltd., does not own the responsibility of information collated from interviews or discussion in the course of
the environmental audit and due diligence assessment.
The assessment was performed with the degree of care and skill ordinarily exercised under similar conditions by reputable, qualified EHS
professionals practicing the same or similar locality. The conclusions and recommendations represent professional judgments and are
based on the interpretation of such data / information made available to Ernst & Young Pvt. Ltd.
Limitations on Use of Report
This report is solely for the information of MAHAGENCO and should not be used, circulated, quoted or otherwise referred to for any other
purpose, nor included or referred to in whole or in part in any document without our prior written consent.

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Environmental Audit and Due Diligence Assessment

For R&M of 210 MW, Unit – 6 at Koradi Thermal Power Station

è PART 1: INTRODUCTION 12-16

è PART 2: OBJECTIVE AND SCOPE OF WORK 17-19

è PART 3: COMPLIANCE ASSESSMENT 20-28

è PART 4: POLLUTION PREVENTION AND CONTROL ASSESSMENT 29-60

è PART 5: RESOURCE EFFICIENCY ASSESSMENT 61-107

è PART 6: OCCUPATIONAL HEALTH AND SAFETY ASSESSMENT 108-125

è PART 7: INSTITUTIONAL CAPACITY ASSESSMENT 126-134

è PART 8: POTENTIAL RISK AND LIABILITY ASSESSMENT 135-142

è PART 9: ENVIRONMENTAL HEALTH & SAFETY MANAGEMNT ACTION PLAN 143-149

Page 1 of 210 Confidential – For Internal Circulation Only

EXECUTIVE SUMMARY Compliance Assessment:

Page 2 of 210 Confidential – For Internal Circulation Only

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Some of the recommendations for the observation made

Ø KTPS may bring the sectional heads of EMC and

Page 10 of 210 Confidential – For Internal Circulation Only

Risk and Liability Assessment: Ø Community Engagement: During the interaction it

Page 11 of 210 Confidential – For Internal Circulation Only

Page 12 of 210 Confidential – For Internal Circulation Only

The E&Y team comprised of the following members:

Ø Mr. Sujeet Kishen

Page 13 of 210 Confidential – For Internal Circulation Only

TABLE 1: ENVIRONMENTAL SETTING

S. No. Particulars Details

Page 14 of 210 Confidential – For Internal Circulation Only

16. Villages within 1-km radius surrounding the Koradi

Page 15 of 210 Confidential – For Internal Circulation Only

FIGURE 1: DISTRICT MAP OF NAGPUR

Source: Maps of India

Page 16 of 210 Confidential – For Internal Circulation Only

PART 2.0: OBJECTIVE &SCOPE OF WORK w Assessment of environmental clearance /

2.2. SCOPE OF WORK Ø Pollution Prevention and Control Assessment: This

Ø Compliance Assessment: Regulatory compliance w Measures / systems to improve coal quality,

Page 17 of 210 Confidential – For Internal Circulation Only

w Noise control systems q Workers safety equipments

Ø Occupational Health, Safety Assessment (OHS): This w Plant management,

Page 18 of 210 Confidential – For Internal Circulation Only

Ø Identification of interventions: This includes

Page 19 of 210 Confidential – For Internal Circulation Only

Page 20 of 210 Confidential – For Internal Circulation Only

KTPS has been served Show Cause Notice thrice in the

Ø Show Cause Notice vide letter no.

Page 21 of 210 Confidential – For Internal Circulation Only

S. Compliance Requirement Observations

Page 22 of 210 Confidential – For Internal Circulation Only

S. Compliance Requirement Observations

Page 23 of 210 Confidential – For Internal Circulation Only

S. Compliance Requirement Observations

Page 24 of 210 Confidential – For Internal Circulation Only

S. Compliance Requirement Observations

Page 25 of 210 Confidential – For Internal Circulation Only

S. Compliance Requirement Observations

U/s 2 (l) of the Factories Act, 1948,

Page 26 of 210 Confidential – For Internal Circulation Only

S. Compliance Requirement Observations

Page 27 of 210 Confidential – For Internal Circulation Only