RAJASTHAN RAJYA VIDYUT UTPADAN NIGAM LTD.

KOTA SUPER THERMAL POWER STATION

LOCATION :
Kota Super Thermal Power Station is located on the left bank of river Chambal in Rajasthans principal industrial city Kota. Infrastructural facilities like adequate water availability in Kota Barrage throughout the year, availability of broad-gauge railway line, power load centre & existing transmission system for evacuation and distribution of power were some of the important factors responsible for selection of this location.

SANCTION OF SCHEMES (STAGE-I to V) :

Kota TPS Stage-I Unit 1 and 2 were sanctioned by the Planning Commission in Sept. 76 and commissioned on 17.1.83 and 13.7.83 respectively. Kota Thermal Power Station has celebrated it silver jubilee during 2008.

Stage I II III IV V

Unit 1 2 3 4 5 6 7

Capacity (MW) 110 110 210 210 210 195 195

Cost (Rs. Crore) 143 480 480 537 962

Synchronizing Date 17.1.83 13.7.83 25.9.88 01.5.89 26.3.94 30.7.03 30.5.09

SALIENT FEATURES :
(1) (2) (3) (a) (b) (c) (4) (a) (b) Location Installed Capacity Land Details : Plant Area Ash Dump Area Colony Area Cooling Water : Source Of Cooling Water Method Of Cooling: i) Unit # 1 to 5 ii) Unit # 6 & 7 (5) Coal : (a) Type (b) Linked Coal Mines (c) (6) (a) (b) (7) (8) (9) a) b) c) d) (10) Average Ash Content Fuel Oil : Type Available Storage Capacity Steam Generator Turbo Generator Coal Handling Plant Stock Yard Capacity Wagon Tipplers Coal Crushers Conveyor System Transmission Lines Kota (Rajasthan) 1240 MW
(2X110 MW + 3X210 MW + 2X195 MW)

204 Hectare 423 Hectare 31 Hectare Kota Barrage (Chambal River) Once through Cooling System (Open Cycle) - 1180 Cusecs Re-circulating through Cooling Tower - 18 Cusecs (Including Consumptive use) Bituminous Coal SECL (Korea-Rewa & Korba) & NCL (Singrauli) 28-32% Furnace Oil / HSD
HSD - 3100 KL & FO - 18600 KL

M/s. BHEL make M/s. BHEL make 5,00,000 MT 5 Nos. 10 Nos. 1.595 Kms. Power evacuation through 9 Nos. 220 KV outgoing feeders. Further 2 Nos. of new 220 KV feeders are under construction

RECORDS OF EXCELLENCE :
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Kota Super Thermal Power Station is reckoned as one of the best, efficient and prestigious power station of the country. KSTPS has established a record of excellence and has earned meritorious productivity awards from the Ministry of Power, Govt. of India during 1984, 1987, 1989, 1991 and every year since 1992-93 onwards. KSTPS has earned golden shield award from Union Ministry of Power ,Govt. of India , for Consistent outstanding performance during 2000-01 to 200304. The Golden Shield was presented by Honble President of India Dr. A.P.J. Abdul Kalam on 24.8.04. KSTPS was awarded Silver Shield for the year 2008-09, Golden Shield for the year 2009-10 & certificate of recognization for the year 2010-11 for Corporation Ltd. (RRECL), Jaipur. KSTPS has achieved the distinction of about 100% fly ash utilization. The utilization of Dry fly ash utilization over last three years is as under: Yr. 2008-09 - 99.12% Yr. 2009-10 - 99.40% Yr. 2010-11 - 95.19% Yr. 2011-12 - 99.52% (upto 20/12/11) An all time high generation level of 9891 MU at an annual PLF of 91.06% & annual availability of 94.23% was achieved during 2010-11. The achievements made by KSTPS during 2010-11 are as under:its contribution in field of Energy Conservation by Rajasthan Renewable Energy

RECORD ACHIEVEMENTS : 2010-11

TOTAL STATION GENERATION PLANT LOAD FACTOR STATION AVAILABILITY No. OF FORCED OUTAGES SP. OIL CONSUMPTION U#3 SP. OIL CONSUMPTION U#7 DRY FLY ASH UTILISATION BOILER TUBE LEAKAGE UNIT # 7 CONTINUOUS RUN

9891 MU (Highest since commissioning) 91.06 % 94.23 % 6 Nos. (Lowest since commissioning) 0.24 ml/Kwh (Lowest since commissioning) 0.76 ml/Kwh (Lowest since commissioning) 99.40% (Highest since commissioning) NIL (During Yr. 2010-11) 100 Days (Dt. 16.02.10 to 26.05.10) 30.895 MU (Highest in a day on 13.03.11) 937.274 MU (Highest in a month in Mar11)

210 MW Unit # 4 STATION GENERATION (in a day) STATION GENERATION (in a month) -

KSTPS units achieved record continuous run of more than 100 days by uninterrupted & stable operation during last three years detailed as below :-

Year
2009-10 2010-11 2011-12

Unit No.
Unit # 2 Unit # 4 Unit # 4 Unit # 2 Unit # 4 Unit # 7

No. of days run

137 days 100 days 100 days 134 days 121 days 115 days

Further, it is worthwhile to mention that KSTPS managed efficient unloading of coal rakes within the duration as prescribed by the Railways and thereby achieved unloading of about 234 coal rakes without any demurrage 4

charges since 19th April 2010 to 7th June, .2010. KSTPS achieved a record unloading of 705 coal wagons on 12th January 2010 , which is maximum in a day since commissioning of the plant in 1983. Though KSTPS Units 1 to 4 are very old (110 MW Unit No. 1 & 2 being 27 years old & 210 MW Units No. 3 & 4 being 21 years old), the station performance is consistently well above the National average as depicted in the operational parameters for last 5 years as under:-

YEAR

GEN (MU)

PLF (%)

SPCFC. OIL CONSUMP. (ml/kwh)

AUX. CONSUMP (%)

AVAIL. FACTOR (%)

FLY ASH UTILIZATION (%)

2005-06 2006-07 2007-08 2008-09 2009-10 2010-11 2011-12 (upto 20/12/11)

8294 8163 8395 8674 8584 9891 7051

90.60 89.17 91.46 94.76 89.65 91.06 89.75

0.48 0.57 0.50 0.43 0.70 0.52 0.58

9.27 9.36 9.37 9.37 9.54 9.67 9.67

91.51 89.86 94.27 95.34 90.41 94.23 91.17

79.45 88.51 98.12 99.14 99.40 97.31 99.52

ENVIRONMENTAL PROFILE :
Adequate measures have been taken at KTPS to control pollution and comply to the norms laid by Environment Protection Act. 1986. Being a Power Station, located in the heart of Kota City, continuous efforts are made to ensure atmospheric emission of suspended particulate matter within the prescribed limits. 180 Meter high stacks have been provided to release flue gases into the atmosphere at an approx. velocity of 25 m/sec. so as to disperse the emitted particulate matter over a wide spread area. The ON-LINE stack SPM monitoring system of CODEL Germany has been installed as per requirement of Central Pollution Control Board.

 Microprocessor based intelligent controllers to optimize the ESP of 99.82% efficiency have been provided. ESPs of 110 MW units # 1 & 2 were augmented under R&M scheme with installation of 7 additional field to enhance efficiency upto 99.82%. Dummy fields provided in ESP of 210 MW units # 3 & 4 were also filled in with installation of 7 th field as such the efficiency has increased upto 99.84%. Adequate water spraying arrangements have been provided at coal unloading, transfer and conveying system to arrest and restrict Fugitive Emission. The system is now further upgraded with latest technology. Development of Green Belt, about 3 lakhs plants of various species have already been planted in KSTPS and ash dyke. The survival rate of plants is watched periodically. * * Existing green cover area within plant Existing green cover area within ash dyke 90 Hect. 100 Hect.

Regular monitoring of Stack emission, Ambient Air Quality and Trade Effluent is carried out. All the drains in the ESP area and Boiler area have been diverted to dedicated tanks and the effluent collected is utilized for transportation of bottom ash disposal of the various units.

ASH UTILIZATION AT KSTPS :

FLY ASH :
In compliance to Govt. of India Gazette Notification issued on 14th Sept. 1999 for making available ash free of cost ,KSTPS has achieved 100% 6

Dry Fly ash utilization. KSTPS signed agreements for dedicated generating units allocations including Construction & Operation of complete dry fly ash evacuation system from each unit in two phases i.e. from ESP to Intermediate Silo and Intermediate Silo to Main Supply Silo near KSTPS boundary with following cement manufacturing companies Unit # 1&2 Unit # 3 Unit # 4 Unit # 5 Unit # 6 Unit # 7 (50% each) - M/s. Associated Cement Co. Ltd. - M/s. Birla Cement Works Ltd. - M/s. Ultratech Cement (Vikram cement & Aditya cement) - M/s. Ultratech Cement (Vikram cement & Aditya cement) - M/s. Mangalam Cement & Shree Cement Ltd. - M/s. Ultratech Cement (Vikram cement & Aditya cement) & M/s. Shree Cement Ltd.

POND ASH :
Concerted efforts have been made towards utilization of disposed fly & bottom ash accumulated in KSTPS ash dykes. The ash is provided free of cost and has been utilized by various small entrepreneurs i.e. Brick-kiln industries, small fly ash product industries, Cement manufacturing Industries and for land filling by National Highway Authority of India in construction of NH-12 and NH-76.

EXTENSION PROJECT NEW UNIT # 7 (195 MW)

SALIENT FEATURES OF UNIT-7 :
Capacity 195 MW 7

Project cost - Rs. 962 Crores Investment 20% Equity by state Govt. & 80% Term loan by PFC & National Capital Region Planning Board Plantation of 75,000 additional plants in Plant dyke & colony premises. Dry Fly Ash Collection system with 100% fly ash utilization. ESP with 99.83% designed efficiency and stack emission within 50 mg /NM3 Totally Hydrogen cooled Generator. Induced Draft Cooling Tower for Condenser Cooling etc. Effluent treatment Plant (ETP) for treatment of recycled ash pond water / waste water for Unit 1 to 7. UNIT WAS FIRST 30th MAY2009. SYNCHRONISED AT 14:30 hrs of

COMMERCIAL GENERATION COMMENCED FROM 00.00 hrs. OF 1st JAN10. UNIT ACHIEVED 96.27% PLF DURING THE FIRST YR. OF COMMISSIONING i.e. 2010-11.

FACILITIES ALREADY AVAILABLE: Land & Township. D.M. Water Plant. 125/25 Ton EOT Crane. Office Buildings & Road etc. 8

Ash Dyke for disposal of Ash. Construction Power and Water. Railway siding and railway network. Fuel Oil handling and Storage Plant. Coal handling plant except conveyor system. Workshop & Canteen. Other service buildings. Communication Service. Transmission Network for power evacuation.

MAIN SUPPLIERS: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Boiler, Turbine, Generator Exciter, M/s Bharat Heavy Electricals Limited. ESP, Generator Transformers Consultant M/s Desein Pvt. Ltd., New Delhi. Balance of Plant Cooling Tower CW & ACW Pumps Coal Handling Plant Clarifier Hydrogen Generation Plant Fire Fighting System Bottom Ash Handling Air Compressors Air Conditioning System Air Washer System Steel Structure of MPHB & Mill bay Electrical Package M/s Tata Projects Ltd., Hyderabad. M/s Paharpur Cooling Towers Ltd., Kolkata M/s WPIL, Kolkata M/s Tecpro Systems Ltd., Chennai M/s Thermax Ltd., Pune M/s Sukan Engg. Ltd., Mumbai M/s Unitech Machines Ltd., Gurgaon. M/s United Conveyors Corp.Pvt. Ltd., Kolkata M/s ELGI, Coimbatore M/s Voltas Ltd., New Delhi M/s C. Doctor & Co., Coimbatore M/s Sunil Hitech, Nagpur M/s ABB Ltd., Faridabad

DETAILS OF IMPORTANT SANCTIONS: 1 2 3 180 M chimney NOC by Airport Authority of India Administrative approval of State Govt. NOC for Installation of Unit # 7 01.12.05 02.12.05

Environmental clearance by Raj. State Pollution 12.12.05 9

Control Board. 4 5 6 7 8 9 Environmental clearance by MOEF, New Delhi Financial sanction of State Govt. Award of contract for Consultancy Award of Main Plant Contract to BHEL Award of contract for BOP works Hyderabad to M/s 07.02.06 12.04.06 24.07.06 15.06.06 TPL, 12.10.06 09.05.07

Award of contract for C&I Works to M/s IL, Kota

MAJOR MILESTONE: 1 2 3 4 5 6 7 8 9 10 Zero Date Boiler Drum Lifting Hydro test of Boiler (Drainable) Hydro test of Boiler (Non-drainable) Boiler Light up LP Turbine Box up Steam Blowing Back Charging of GT First Synchronization on Oil Declaration of Commercial Operation 15.06.06 28.10.07 31.05.08 22.12.08 22.01.09 05.02.09 01.05.09 14.05.09 30.05.09 01.01.10 (00 hrs)

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