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Page 1: GETS 2016 - NTPC GETS e-Compendium.pdf · 1 GETS 2016 MESSAGE Gurdeep Singh Chairman & Managing Director NTPC Limited I am delighted to be a part of GETS 2016, a confluence of technology
Page 2: GETS 2016 - NTPC GETS e-Compendium.pdf · 1 GETS 2016 MESSAGE Gurdeep Singh Chairman & Managing Director NTPC Limited I am delighted to be a part of GETS 2016, a confluence of technology

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GETS 2016

MESSAGE

Gurdeep SinghChairman & Managing DirectorNTPC Limited

I am delighted to be a part of GETS 2016, a confluence of technology experts from across the globe dedicated to addressthe future challenges of the Indian power sector.

GETS 2016 is all about redefining India's Power generation landscape through 5Rs- Reduce, Renewable, Reuse, Retrofit &Rebuild. I am sure, this shall address the challenge of providing power to all at an affordable cost with minimum impact toour environment.

Running one of the largest renewable capacity expansion programs, India targets to add 175 GW of renewable energygeneration by 2022. With the increasing contribution of renewable to the power sector, numerous new challenges such asintegration with grid, energy storage and reliability are emerging. Flexible generation, reducing carbon foot print, reducingemissions, water consumption, land use are other emerging challenges for fossil fuel plants. I hope this Summit will bringout pioneering technological solutions for these challenges.

The student section in GETS-2016 is expected to enhance industry-academia interface. I believe such involvement andparticipation will generate consciousness for sustainable development of power sector in our future technical leaders.

Further, I would like to congratulate my team members for their diligent effort to make the event a grand success.

Wishing the best for the event.

(GURDEEP SINGH)

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MESSAGE

Anil Kumar Jha

Director (Technical)NTPC Limited

It is a matter of great pride for all of us that NTPC is organizing the third edition of the Global Energy Technology Summit(GETS-2016) focusing on emerging new technologies in the power sector and making it a regular event.

As India's largest power producer and one of the biggest in the World, NTPC is always a forerunner in Indian powergeneration technology. The idea behind hosting this summit is to provide a formal knowledge-sharing platform not onlyamong industry but also among academicians. In this context, it was envisaged to gather all technology leaders from thepower and energy industry and academia to share their knowledge and experience, and enlighten the industry with theirvision and ideas for the sustainable growth of power sector in coming years.

With the ratification of Paris deal and massive renewable capacity addition targets, there is a perception that the days of coalbased energy are over. However, coal is still expected to remain mainstay of India's power generation for at least next 15years. With most aggressive renewable targets, around 450 GW to 500 GW capacity is expected to be based on fossil fuels,predominantly coal, by 2030, requiring on an average, about 20 GW capacity addition every year. Along with renewableenergy technologies, efficiency enhancement technologies for coal, emission reduction technologies, and other clean coaltechnologies will therefore play a vital role in the future energy scene. The 5R Way through Reduce, Renewable, Reuse,Retrofit and Rebuild, shall help us in redefining the power generation landscape which is the central theme of the summitthis year.

NTPC organized its first international technology summit GETS 2014, which was a grand success with delegates participatingfrom all over the world. The takeaways were insight into new technologies through 150 technical papers contributed byknowledge leaders. GETS 2015 also saw huge partaking by all national and international power professionals through acontribution of 200 technical papers.

I am thankful to the authors and presenters, as this year GETS 2016 sees spontaneous participation with a record numberof 275 technical papers from world over. I am glad that GETS by NTPC has opened up an international platform for knowledgesharing by the technology leaders in the field of Power Generation for sharing their state of art technologies. Through thisknowledge platform, I am sure, the participants will gain a significant insight into the latest 5R technologies and carry backwith them a great experience of the Summit. My heartiest welcome to all invitees, delegates, authors and exhibitors to theSummit and also the best wishes to the technical team and the organizing team in their endeavour to hold such a megaevent.

(ANIL KUMAR JHA)

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GETS 2016

MESSAGE

S C PandeyDirector (Projects)NTPC Limited

It is a matter of immense pleasure that the third edition of the Global Energy Technology Summit (GETS 2016) is beingorganized on 7th Nov. 2016. Being a socially responsive corporate, it's our responsibility to contribute to the sustainabledevelopment of our nation and GETS is a step in this direction.

The development of the power sector is of paramount importance for achieving over 8% targeted growth rate of oureconomy, since all important industrial sectors be it manufacturing, services, public health, infrastructure, mass transportationand logistics, telecommunication etc. require electricity as its backbone.

New capacity addition with most modern power generation technology and greater emphasis on renewable at affordablecost without affecting the ecological balance, will hold the key to future energy model. A prudent balance between fossil andnon-fossil fuel based electricity to meet energy need and environmental challenges require 5R strategy, which is aptly thetheme of GETS2016.

Surely, sharing of views & experience on emerging technologies by the eminent experts and world technology leadersduring the Summit will go a long way in building up the required knowledge base for finding the most optimum energysolution for the country and will benefit the Power Sector immensely in terms of cost, efficiency & environmental care.

Wishing GETS - 2016 a great success.

(S C PANDEY)

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MESSAGE

K Biswal

Director (Finance)NTPC Limited

I am extremely delighted that NTPC is organizing the third edition of the Global Energy Technology Summit (GETS 2016).Global Energy Technology Summit has been initiated by NTPC as an annual event, to be held every year from the 7th to 9thNovember, with an objective to identify and assess emerging new technologies of power generation for the future and toaccelerate their adoption and assimilation.

The vision & commitment of the Government of India towards clean, sustainable power is quite pronounced. The "Make inIndia" initiative of the Government of India with a quest of "zero defect and zero effect" is a loud invitation to the globaltechnology leaders to partner in India's march to a better developed economy.

Maintaining operational efficiency & sustained plant-loading of the existing power stations and new capacity addition withadvanced-technology based super-critical/ultra-super-critical plants as well as quantum increase in power production fromrenewable resources are the need of the hour to meet the challenge of supply-demand gap.

In view of India ratifying Paris climate deal in COP-21 on 2nd October, 2016 and accordingly committing that by 2030, atleast 40% of its electricity will be generated from non-fossil fuels, the theme of the summit has become very relevant.

I am sure that GETS-2016 will be a true confluence of knowledge and experience of power professionals and technologistsfrom all over the world.

I wish all the success to Global Energy Technology Summit, GETS-2016.

(K BISWAL)

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GETS 2016

MESSAGE

Kaushal Kishore Sharma

Director (Operations)NTPC Limited

I am delighted that NTPC is organizing a major technical conference "Global Energy Technology Summit (GETS-2016)" from7th to 9th November 2016. This conference has emerged as a large platform for sharing technical knowledge in the field ofpower value chain in a very short span of time. It is a tremendous and commendable endeavour on the part of membersof NTPC Team.

NTPC is the largest power generating company in India having installed capacity of 47,228 MW. This includes Thermal,Hydro and solar power plants. Operation of such a large fleet of power stations with variety of fuel mix has its ownchallenges. Being the largest power producer of the country (about 24%), NTPC has greater responsibility of providingreliable, affordable and environment friendly power to the customers. Further, changing Regulatory and Environment Normsmake power market landscape very dynamic. It has become imperative for us to produce power in a most efficient wayconsuming lesser fuel and include more renewable energy sources into our portfolio.

Advancement in technologies and sharing ideas can enable sustainable growth with minimum impact on environment andcreate lasting energy supply solutions. Reduce, Renewable, Reuse, Retrofit & Rebuild, (i.e. 5Rs), this year's theme of GETSwill facilitate driving the industry in a direction to meet India's energy need in increasingly sustainable way.

I am sure that the summit will provide a platform for divergent technological options for the power plants including futuretrends that will fulfil the country's power demand with minimal environmental impact.

Wishing all the best for success for the summit.

(KAUSHAL KISHORE SHARMA)

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MESSAGE

Saptarshi RoyDirector (Human Resources)NTPC Limited

It gives me a sense of great satisfaction and pride that the 3rd edition of the Global Energy Technology Summit (GETS-2016)is being organized. It is also heartening to note that in a very short span of time, GETS has established itself as the mostsought after technology event attracting experts from across the globe.

Electricity is a key and essential infrastructural ingredient for economic growth of the country. Although at present more thantwo-third of the installed power generating capacity in India is thermal in nature, concerted efforts are being made todiversify the energy sources for sustainable power development.

For accelerated and sustainable growth of any sector, new and emerging technologies prove to be a key success factor. Ata time when India has embarked on a journey of rapid renewable energy capacity addition and simultaneously making useof its abundant coal reserves for power generation, technological innovation for maximum efficiency in energy conversionis the need of the hour. The need further gets heightened in view of the programs such as 'Make in India', Digital India etc.

In this backdrop, GETS-2016 summit is an opportune event for the experts from across the globe, for deliberations andsharing of innovations and advancements in energy technologies. The discourse, I believe, will bring a great insight, to oneand all, on the latest and future trends.

My best wishes for the grand success of the summit.

(SAPTARSHI ROY)

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GETS 2016

PREFACE

Arun Kumar Sinha

ED (Engg) & ChairTechnical Committee GETS 2016

On behalf of NTPC, I am excited and gratified to bring this third edition of GETS 2016 to the participants of this Summit. Mywords here, undeniably, are not adequate to express my gratitude to the authors, technology leaders and experts across theworld whose contributions since inception have brought "Global Energy Technology Summit (GETS)" to the stature it isenjoying today.

Today, we are at the crossroads of a different sort where the destination to reach is the same but the paths are diverse. PostCOP21 ratification, with the need for cleaner power with mammoth capacity addition, Indian power sector seemingly hasreached a cusp where contemporary challenges of carbon footprint, plant retrofits, project cost pressure, land and waterscarcity, SOx / NOx mitigation etc. have driven us to look beyond the business-as-usual endeavors. The roadmap for sucha journey has to factor in deep cerebral support of technical leaders and experts to reach our destination of capacity additionof 750 GW by 2030 out of which 40 % needs to be from renewable. The power generation landscape is, thus, going throughan unparalleled change. The energy transitions are forcing utilities to reorganize their power generation strategies. In thisbackdrop, GETS 2016 brings the "5R" concept of Reduce, Renewable, Reuse, Retrofit and Rebuild. We are confident thisyear's thematic sessions will suggest the future path in conformity with India's COP21 resolutions jelling with the needs andaspirations of the people of India.

We started a special section for Students in GETS 2015 and the response motivated us to continue further with the initiative.In addition, a special session "Make in India Success Stories" for power generation equipment manufacturers to narratetheir experiences and also to showcase their products at GETS EXPO 2016 has been introduced this year. NTPC being apioneer in technology adoption in power sector, a need was felt to facilitate a brainstorming session on "Digital

Transformations for the new power generation landscape" by industry leaders through round table discussions. Thissession is expected to help strategize the way forward for digitization leading to valuable takeaways for the power industry.There has been an endeavor to go paperless this year. The entire process of technical paper submission, approvals andregistration will be paperless. We have tried to provide all Summit related information, including the e-Compendium, onlineand through mobile apps.

I am immensely thankful to all the authors of GETS 2016 for their valuable contribution of more than 275 technical papersout of which 65 papers are from international authors. I am also hugely thankful to my GETS 2016 team for their diligent anddedicated efforts which is surely going to make GETS 2016 a great success, more than ever before.

(ARUN KUMAR SINHA)

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GETS 2016

GETS Themes 11

5R Sessions 15

Reduce 17

Renewable 65

Reuse 105

Retrofit 139

Rebuild 181

Special Sessions 215

Make In India 217

Student Section 245

Contents

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GETS 2016

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GETS themes

NTPC organized its first International technology Summit 'Global Energy Technology Summit' in 2014, which was a grand success.

GETS 2015 also saw huge partaking by all national and international power professionals. GETS by NTPC Ltd has opened up an

opportunity for knowledge sharing by the technology leaders in the field of Power Generation around the world to share their state

of art technologies to power professionals worldwide.

Thanks to the authors and presenters, the event every year sees spontaneous participation and high quality contribution from

domain experts of power and energy sector across the globe. Industry experts present emerging technologies under various

sessions over two days at the NTPC 'Power Management Institute'. This year again the third GETS 2016 summit is being planned

from 7th Nov to 9th Nov 2016.

The power generation landscape is going through an unprecedented change. The energy transitions are forcing utilities to rethink

the power generation strategies. In these changing times GETS 2016 brings The 5 R concept of Reduce, Renew, Reuse, Renovate

and Rebuild. This year's theme sessions shall show the path for future power.

Session: Reduce

The first concept of Reduce for resource management is very relevant today in power generation. When we define the concept of

reduce for power generation we are aiming at reduction of fuel consumption by increasing the plant efficiency using ultra-super

critical technologies, heat cycle improvements, co-generation with non-conventional heat cycles, coal blending technologies for

optimization, or any other innovative technological option.

We are also targeting technologies for reducing emissions through various FGD technologies, De NOx and other technologies such

as ZLD technologies to reduce water pollution and bag filter technology to reduce dust. Technologies related to Particulate removal,

Abatement of ground water contamination, Mercury Pollutions, NOX, and SOX emissions control technologies shall be a part of

this session.

This session shall also cover technologies to help reduce land footprint of power generation plants like dry FGD technology,

compact layouts, GIS substations etc. Air cooled condensers technologies for water reduction in power plants, automation

technologies for optimization of manpower are the other concepts of REDUCE the session shall be looked for. Energy efficiency

technologies like innovative solar Led lighting, variable frequency drives, dual speed motor technology can also be presented in

this session.

Authors are welcome to present innovative technologies/Concepts/business models which shall help to optimize cost of power

generation. Authors are advised to select the theme under this session if any of the technologies proposed are targeting the

concept of REDUCE explained above

Session: Renewable

The second R concept is the concept of renewable power generation

Authors are advised to select the theme under this session if any of the technologies proposed are targeting the concept of

Renewable as below:

• Solar PV and Solar Thermal

• Wind generation, Biomass & Fuel Cell

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GETS 2016

• Hydro, Mini-Hydro Power , Geothermal and Tidal Power

• Energy storage

• Integration of Renewables to Grid

Session: Reuse

The concept of Reuse has been there for ages especially in ancient India. Applying the concept to power generation we are aiming

at the following areas for reuse.

Water Reuse: It is often said that an economy runs on oil, but it could also be said it runs on water. Electricity is needed to power

the economy, however in most cases power cannot be generated without water. Conversely, electricity is needed to treat water. It

is therefore critical that we consider the nexus between water and power. In a world where water is an increasingly scarce

resource, policies supporting the conservation and recycling of water for power generation must become an urgent international

priority.

Ash Utilization: Fly ash is used in Cement production, ash bricks and now new technologies are also being developed to produce

aluminum from ash. Use of bottom ash for ash dyke, mine filling and other technologies for ash use shall be a part of this session

on 3rd R.

Waste Heat Utilization: Waste heat utilization had been all time favored by technologist worldwide. Innovative technologies for

using waste heat in process or other applications like air-conditioning shall be a part of this session.

Energy from waste: Every year, about 55 million tons of municipal solid waste (MSW) and 38 billion liters of sewage are generated

in the urban areas of India. In addition, large quantities of solid and liquid wastes are generated by industries. Any organic waste

from urban and rural areas and industries can be a resource, due to its ability to be degraded, resulting in energy generation.

Innovation technologies for energy from waste shall be a part of this session.

Authors are advised to select the theme under this session if any of the technologies proposed are targeting the concepts of REUSE

explained above.

Session: Renovate

The concept of Renovate is dedicated to R & M of conventional power plants and gas based plants. Technological renovation of

thermal power plants can act as a long-term check factor of electricity price growth.

The role of R&M is increasingly becoming important in view of fuel scarcity, and the need to utilize it in the most possible efficient

manner. However, R&M processes are prone to technical surprises, and these must be dealt in a systematic manner. It is expected

that risks and surprises shall be identified by the authors in the session.

Further when new environment norms are in place now, it is all the more important to discuss various suggestions for mitigating/

avoiding various risks and surprises and aid the utility in up scaling R&M activities. GETS 2016 invites authors to contribute in this

new session with innovative suggestions and ideas for R & M in Power Industry.

Session: Rebuild

The fifth R relates to the concept of rebuilding with more innovative construction technologies which save on construction effort

and time without sacrificing quality. Authors are requested to contribute to this session with unique construction technologies, new

construction materials, special study cases of design of difficult structures, under sea or water applications and projects. The

session shall be about technologies to build pipe networks, bridges, roads and retaining walls that will stand up well, modern

materials, and higher construction standards, best practice design principles with the latest technologies. New technology to

repair of underground pipes with "trenchless technologies"

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Further the session aims at technologies aiming at Sustainable landscapes responsive to the environment, re-generative, can

actively contribute to the development of healthy communities. Sustainable landscapes sequester carbon, clean the air and water,

increase energy efficiency, restore habitats, and create value through significant economic, social and, environmental benefits.

Smart Township concepts can be presented in this session. Rebuilding of Old Power Plants into High efficiency new Power Plants,

Decommissioning of Power Plants, Geotechnical & environmental assessment, New techniques, technologies and materials like

Drone surveying, Pre cast & Pre fab technology, Bolted structures, Trenchless technogy, Box culvert technology etc. and Sustainable,

smart townships shall form the part of the session.

Special Session: Make in India

A special session dedicated to the efforts of Indian manufacturers who have established factories and production facilities in India

by technology transfer from abroad. Case study of the technology transfer and the journey undertaken by the company shall be

presented by the authors. It shall be preferable that the manufacturer display in the GETS 2016 EXPO Exhibition stalls.

Special Session: Student Section

In an endeavor to encourage and make students pursing B Tech/M Tech or PHD in Engineering Institutes a part of the summit, it has

decided to hold an App (multiplatform) Competition based on the 5 R concepts explained above. The App can be presented by a

team (not more than 3 members).

The App shall inbuilt one of the 5R concept for use. For example App indicating the energy saved or waste recovered through a

particular recycle technology etc.

Students can also participate for a technical paper contest. The technical papers can be based on the any of the themes listed

above. Selected technical paper authors shall be the opportunity to present their paper. Best judged paper based on the merit and

potential for successful deployment shall be awarded.

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GETS 2016

Reduce

Renewable

Reuse

Retrofit

Rebuild

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GETS 2016

REDUCE

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GETS 2016

REDUCE

RELIABILITY IMPROVEMENT AND ENERGY SAVINGS IN VIBROFEEDERS –

A CASE STUDY OF NTPC DADRI

Abstract:

In CHP area, Wagon Tipplers are installed for coal unloading from BOXN wagons by lifting and rotating it sideways. Vibrofeedersare installed below the tippler system for transferring coal from hopper onto the conveyor belts at a controlled rate. Vibrofeederconsists of a tray that moves rapidly back and forth and as it vibrates, coal is transferred from one point and drops down at afarther point along the tray. The existing vibrofeeder is driven by eddy current based dyno drive system clutched with an inductionmotor and speed is controlled by varying DC excitation coil voltage. The maintenance of these vibrofeeders are an importantaspect & breakdowns involved must be minimised since any delay in coal unloading directly affects the demurrage charges andhence utmost care must be taken while designing the retrofit solutions for existing system. Since the vibrofeeders are located in adusty environment in the underground level, frequent problems of shaft keyway damages and bearing failures ,due to excessmechanical stress & dust accumulation inside the dyno drives were faced affecting the availability of the system. Moreover, bulkydynodrive assembling / reinstallation is a time consuming process leading to non-availability of vibrofeeders. A directly coupledVFD motor has been installed in place of existing motor and eddy current coupling, without external speed control mechanism(eddy current clutch). Moreover, with VFD system, energy costs are reduced and maintenance is easy due to diagnostic featuresand the maintenance is restricted to induction motor & VFD only.This paper highlights the successful case study of installing VFDbased directly coupled system in vibrofeeder applications and the technology can be deployed in NTPC across all the stationswherever eddy current based couplings are installed. It not only eliminates the aforementioned demerits associated with thecurrent system but also is more reliable and energy efficient with ease in operation & maintenance.

Authors(s)

Sanjay SenAGM/NTPC Dadri

Gaurav ChakravartyDy. Manager/NTPC Dadri

#481

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FEASIBILITY STUDY OF CO2 MITIGATION FROM COAL POWER

PLANTS VIA CCS WITH AUXILIARY SOLAR THERMAL AND BIOGAS

Abstract:

Recent research indicates that more effective technologies are now needed to keep global warming below 2°C to avoid irreversibleclimate change. This is echoed by warnings from both the United Nations Framework Convention on Climate Change (UNFCCC)and the International Energy Agency (IEA) [1, 2]. These organizations have sufficiently stressed that carbon capture and storage(CCS) will remain a critical greenhouse gas reduction solution. A typical CCS system is expected to capture most (~ 80-90%) ofthe CO2 emitted from a coal-fired power plant, so that it can be transported and then stored in such formations so that it will notenter the atmosphere [3]. However, capturing and compressing CO2 increases the energy needs of a coal-fired CCS plant by about10-40% [3]. Thus, we seek to investigate the feasibility of retrofitting renewable energy technologies to coal-fired CCS powerplants so as to meet their high energy needs and thereby keeping the net power generation of the plant unaffected. The IntegratedEnvironmental Control Model (IECM-cs) has been used to evaluate the energy requirements of a typical CCS power plant [4]. Next,the feasibility of how the energy requirements of the CCS unit can be fulfilled using auxiliary solar thermal and biogas has beenassessed, considering the capital costs, costs of power generation, emissions and overall plant efficiency.

Authors(s)

Pranav C. PhadkeIIT Bombay.

Munish K ChandelIIT Bombay.

Anand B RaoIIT Bombay.

#484

REDUCE

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GETS 2016

UNIT RESPONSE OPTIMIZATION FOR POWER PLANTS

Abstract:

Due to the ever changing electricity demand, variability has become an inherent characteristic of power systems. In India, theincrease in installed generation capacity has not been met by a corresponding increase in load especially during the off-peakhours. Traditionally, only load demand was subject to peak and change, but, with the growing addition of renewable energy boththe generation output from the renewables and the demand will vary. With distributed generation and electric vehicles on the rise,the load demand is also becoming increasingly difficult to forecast. The solution is in having flexible generation sources which canbe ramped up and down quickly. India being thermal power dominant, there is a need for thermal power stations to be flexible tocounter the rapid changes and keep the grid stable. In this paper, we discuss a unit response optimization solution that usesadvanced unit analysis and modelling techniques including fuzzy logic to determine optimal load trajectory for improved unitramping, start-up, turndown, stability and overall performance.

Authors(s)

Dinesh ChandraDirector,Projects & ServicesEmerson Process Management -Power & Water Solutions India

Anupam ChakravartiDeputy Manager,Projects & ServicesEmerson Process Management -Power & Water Solutions India

#487

REDUCE

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ROLE OF THERMAL POWER PLANTS IN PARTICULATE MATTER EMISSION # A CASE

STUDY OF NTPC DADRI PLANT – USING DMAIC APPROACH

Abstract:

India is going to ratify Paris agreement this year which will give a target to reduce its emission by 55%. Thermal power plantscontribute a major role in polluting environment. Around 58% of CO2 emission is carried by thermal units only. Since the genesisof NTPC It has led in environment concern from the front. NTPC Dadri is a unique power plant of NTPC group which has coal basedthermal plant and gas based thermal plant of 1820 MW and 817 MW respectively and 5 MW solar plant . At NTPC Dadri plantambient air quality is measured at three distinct point and various parameters like Sox, NOx, CO2 , PM10, PM2.5, wind speed,Relative humidity, Solar radiation, O3 , rain are measured on real time basis. In present paper DMAIC study has been done to findout the emission trends in Dadri plant. Using Minitab 17.0 software.The purpose of DMAIC study helps in analysis and alsoprovides us how much minimum emission figure can we achieve statistically? Process capability curve of PM2.5 and PM10 aremeasured. Six month data has been taken for analysis and it is found NTPC Dadri is maintaining emission norms defined by MoEFbut in PM10 emission it has scope for improvements. PM2.5 emissions has high 3.45 sigma level of conformance while PM10 isrunning under 1 sigma level of conformance. Various approaches adopted by Dadri management has also been discussed and astudy of retro fitment in ESP is also discussed briefly. NTPC stands on renewable sources of energy especially solar energy ishelping in cutting carbon emissions. NTPC has to go for power bundling in old plants (where PPAs are complete or about tocomplete) and promising in increasing RGO (renewable generation obligation) target as specified recently by ministry of power.

Authors(s)

Himanshu KumarPrimary authorManager ( OPN) NTPC Dadri)

Aditya AgrawalSec AuthorSenior system engineer,Siemens Energy Gurugram

#492

REDUCE

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GETS 2016

SCALE-BAN - A NOVEL TECHNOLOGY TO REDUCE AND REUSE WATER

Abstract:

Water is nature's most wonderful, abundant and useful substance. It also occupies a unique position in industries as a coolant. Itcontains lot of impurities in dissolved and suspended form. These dissolved impurities, combined with rise in temperature duringheat exchange process, forms hard scale inside the heat exchangers, a common phenomenon in all industries. Hard water scalehas higher thermal insulating properties resulting in poor heat transfer coefficients, thus affecting the economics of the operatingsystems. The cleaning process is recurring & tedious combined with life reduction & availability of heat exchangers. To combatthis, the regular chemical treatments with their inherent limitations, leads to high quantity of cooling water blow-down from thesystem. To Reduce this blow-down and to prevent the root cause of scaling, SCALE-BAN technology offers tremendous flexibilityin plant operations. It drastically Reduces the high blow-down water and stops water pollution, simultaneously ensures the system'shealthy and near design condition operation.

SCALE-BAN technology is a non-chemical water conditioning equipment, prevents hard water scaling in the heat transfer area. Itis a 'Fit and Forget' mechanical equipment, working on the Galvanic Principle by transforming the dissolved solids into colloids andholding it till another phase change of temperature takes place in the cooling tower. While handling very high magnitudes of TDS,TH, TSS & Chlorides, it Reduces consumptive water.Sustainability of SCALE-BAN operating with disruptive levels of water impuritiesand without any adverse effect, has given the impetus to Reuse all the available water resources in a plant, i.e., to use any type ofvirgin water OR any character of water, be it ETP treated / RO reject or spent wash / distillery rejects, as a cooling medium in heatexchangers.

Authors(s)

Purnendu DuttScale-Ban equipments Pvt. LtdIndia

#496

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24

REDUCED WATER USAGE IN POWER GENERATION: STEAM TURBINES FOR AIR-COOLED

CONDENSER APPLICATIONS

Abstract:

The rapid growth in industrial infrastructure in India places increasingly higher demands on the available natural resources. Amajor focus is the efficient management of the precious commodity of water. The availability of such a critical resource plays animportant role in the planning of new power generation facilities, especially in locations where water scarcity severely restricts itsusage.

This paper reviews the particular challenges imposed on the steam turbine design when an air-cooled condenser solution isadopted and presents the latest product developments in this field which are driving to higher levels of thermal efficiency andoperational flexibility.

Authors(s)

Philip PeelGE Power, [email protected]

Rainer LudorfGE Power, [email protected]

Benjamin MegerleGE Power, [email protected]

#499

REDUCE

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25

GETS 2016

EFFLUENT WATER BALANCE FOR THERMAL POWER PLANT

Abstract:

This paper discusses the methodology for balancing various process and effluent waters at the inception stage of the project toachieve optimum water balance, which conserves water and reduces the capacity and costs of ETP and ZLD projects. This paperalso covers the aspects of implementation and learnings from the ZLD plant based on RO technology, implemented at one of thesites.

Authors(s)

Mr. Vaibhav Korgaonkar(Lead Engineer- Project Engg)Tata Power

Ms. Nilima Sao(Group Head- Water systemProject Engg)Tata Power

Mr. Srinivasa Murthy Goteti(Head-Mech, P E)Tata Power

#599

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26

SCR DESIGN OPTAMIZATION

Abstract:

Selective Catalytic Reduction (SCR) is a proven technology for deNOx of flue gas streams. SCR is used for coal, oil, and naturalgas fired combustion systems. The performance of the SCR system, however, requires careful design consideration related toprocess conditions such as the flue gas velocity patterns, temperatures, ammonia injection technique, and the proper mixing ofammonia and NOx. For coal fired boilers, the presence of fly ash in the flue gas stream can cause erosion and/or pluggage of thecatalyst. If these parameters are not properly optimized, deNOx performance can be degraded and the plant can experienceincreased O&M costs for ammonia usage, pressure drop, and catalyst life. This paper will discuss best practices in SCR systemdesign and operation related to the key factors of:

• Ammonia injection methods

• Static mixer design

• Achieving optimal deNOx performance

• Minimizing pressure drop

• Avoiding ash pluggage and erosion of catalyst

• Flow modelling goals, methodology, and accuracy of results

Examples from various past SCR designs will be presented, comparing the performance of each. The applicability of the variousdesigns to SCR systems in India will be discussed and summarized.

Authors(s)

Robert G. Mudry, P.E.Airflow Sciences CorporationLivonia, Michigan, USA

#507

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GETS 2016

CONDENSATE POLISHING UNITS FOR THERMAL POWER STATIONS

Abstract:

Condensate polishing has been adopted in thermal power stations to reduce the level of impurities in the feed water during variousoperating conditions of the turbo-generator unit, thereby preventing corrosion/scaling of internal surfaces of heat exchangers andboiler tubes. In addition, the need for condensate polishing has also been justified for producing high purity steam, reducing thechance of boiler tube failures and consequentially reducing demineralized and raw water consumption. The consequences of poorfeed water quality from polishing plants, or cross contamination of resins due to improper separation and regeneration processescould cause serious damages to the heat cycle and at times even result in shut down of the unit resulting in considerable revenuelosses. A proven design of polisher units and selection of the regeneration technologies are therefore absolutely essential for thesafe and successful operation of the heat cycle. This paper will provide the technology status of condensate polishing plants forsub critical and super critical power stations along with associated feed water chemistries, types of resins used, need for pre-filtration, technologies of resin transfer/separation/regeneration and O&M considerations. A strategy to implement cost effectivecondensate polishing plants for upcoming power projects and Renovating & Rebuilding existing power plants in India will also bediscussed.

Authors(s)

Venkatesh KrishnaswamyGE POWER

#514

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28

STEAM TURBINE TECHNOLOGIES ENABLING ADVANCED CYCLES

Abstract:

COP21 targets and their implementation in India accelerate environmentally friendly coal power generation technologies by settinga regulatory framework for greenhouse gas emissions. Reducing coal consumption is the strongest contributor to reducing emissions.Advanced USC cycles inevitably come under consideration to improve cycle efficiency as recognized by the Indian 700°C programmelaunched under the 'National Action Plan for Climate Change'. This paper presents the technology maturity and product readinessfor both single and double reheat cycles for AUSC steam conditions. It reflects on the relevant steam turbine design features thatenable cost effective and flexible designs for such high temperature cycles.

Authors(s)

Rainer LudorfGE Power, Brown Boveri Str. 7,Baden CH-5401, Switzerland

Eur Ing Philip PeelGE Power,Brown Boveri Str. 7, BadenCH-5401, Switzerland

Rod VanstoneGE Power, Newbold Road,Rugby, Warwickshire, UK

#515

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GETS 2016

ROTARY AIR PREHEATER DESIGN REVIEW & PERFORMANCE EVALUATION

(A SOFTWARE BASED EXPERIMENTAL AND NUMERICAL ANALYSIS)

Abstract:

Many times, it has been observed that during performance guarantee test, air heater doesn't give the guaranteed performance andit becomes a difficult task to reach on any conclusion that either it is due to unsuitable design selection or because of deteriorationin its performance due to change in operating conditions. Very often this creates a cord of contention between buyer and vendororganisation as buyer organisation doesn't have any tool to validate the design of APH and on other hand thorough design calculationis not shared by vendors due to proprietary reasons. Hence, need for a tool to validate the design of an APH is being felt. Therefore,a software based on experimental and numerical analysis has been developed to review the rotary APH design and to evaluate itsperformance at different operating conditions. The scope of experiment lies in the fact that heat transfer coefficient, friction factorfor different type of heat transfer surfaces cannot be determined numerically, so experimental data i.e. PG test data like flue gas andair flow rate, inlet /outlet temperatures, seal leakage quantity, pressure drop etc. have been used in establishing solution fordetermination of heat transfer coefficient and friction factor for a particular type of basket element.

This software can be used as a tool to analyse effect of rotor RPM, flue gas characteristics, seal leakages, geometrical variablesof APH and different type of basket characteristics etc. on the performance of an APH which are considerable aspects duringdesign and R&M phase of a rotary APH. It can also predict the performance of a rotary APH at different operating conditions. Innutshell, this software has been developed as a solution for design and performance related problems of an APH and can beutilized to reduce the overall heat rate of a power plant.

Authors(s)

Ashwini Kumar VermaManager (PE-Mech),NTPC Ltd., EOC, Noida.

Amit KulshreshthaAGM (PE-Mech),NTPC Ltd., EOC, Noida.

#521

REDUCE

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REDUCE SPACE AND EMISSION BY CHOOSING ENCLOSED SILO SOLUTION

Abstract:

In India, it is expected that the coal-based power generation will continue to play a critical role in the next 30-40 years, despite thefact that most of the existing Indian coal-based power plants are occupying huge area of land, produce more CO2, consume morewater and much of the coal produced in India is of relatively inferior grade. As India is now aiming for its next 100GW thermalpower generation capacity, the challenge is to achieve rapid scaling up of generation capacity and to meet the stringent environmentnorms set under COP 21, Paris.

Adoption of enclosed coal storage systems with coal blending facility in place of traditional open stockyard would help in cuttingdown the foot print area required by the Coal Handling Plant, reducing the air pollution caused by the dust emission. In addition, itwould help reduce losses caused due to oxidation, wind, high moisture etc. Since, enclosed storage requires very low auxiliarypower and downtime for maintenance; it would help improve the cost-effectiveness of the old and new plants. Now, since all thenew and existing thermal power plants shall have Flue Gas Desulphurization (FGD) unit, enclosed storage could help in thehandling and storage of very sticky FGD gypsum, which is not an easy material to deal with and to store for more than a few days.

Authors(s)

Jaap P.J. RuijgrokM.Sc. (Mech.Eng)Managing Director, ESI Eurosilo B.V.,[email protected]

Richard SpaargarenM.Sc.(Mech.Eng)Sales Manager, ESI Eurosilo B.V.,[email protected]

Mini P.S. Puri,Advisor India, ESI Eurosilo [email protected]

#535

REDUCE

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31

GETS 2016

MEASUREMENT & CONTROL OF SO2 EMMISSIONS FROM POWER PLANTS

Abstract:

All industries are now facing new environmental laws and regulations. Meeting tighter environment compliance requirement createsserious challenges for power and industrial plants. The problem is magnified by the increasing use of lower quality coals generatinghigh concentration of dust & harmful emissions. With the passage of notification by Ministry of Environment, Forests and ClimateChange (MoEFCC) on Dec, 2015 many Power utilities are forced to clean their flue gas emissions before release into the environment.By far the most common way to meet these new regulations will be by scrubbing the flue gas emissions using a sorbent commonlyknown as scrubber. The entire process is called as Flue Gas Desulphurization (FGD). All power plants built after 2003 are requiredto maintain SO2 level which may calls for implementation of flue gas desulphurization (FGD or scrubber) units to reduce thesulphur from the coal's combustion gases before the gases go up the stack and are emitted into the environment. A reagent, suchas the commonly used limestone, captures the sulphur and extracts it out of the gases. The reagent and sulphur combine to formeither a wet paste (wet scrubber), or a dry powder (dry scrubber) to trap the sulphur. This paper covers experience and solutionsrelated to Measurement & Control of complex flue gas desulphurization processes for optimal system performance. It will also talkabout the advantage of implementing the FGD Controls & how it can help in optimizing the scrubber technology by reducingexcessive emissions, regulating reagent usage, and increasing air flow.

Authors(s)

Manoj Kumar DubeyAssociate DirectorPower & Water Solutions IndiaEmerson Process Management

Shubhi GoelDeputy ManagerPower & Water Solutions IndiaEmerson Process Management.

#537

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32

MEETING NEW MOEFCC NORMS -CAN CFB BE A B SOLUTION?- A TECHNICAL ANALYSIS

Abstract:

The recent MoeFCC, norms imposed on gaseous emissions had initiated discussions on Boiler Supplier and plant owners front onthe hitting the right cord for an effective and economical solution. The recent emission norm for SO essential for an plant user toscrutinize not only on pollution control equipment ,but need to analyse the coal source itself .However Plant owners often has aless control on the compositions on the coal quality except for calorific value various technologies available ,CFB combustionoffers a fuel flexibility and an option for reducing the majority of Pollutants within furnace envelope and less investment. CFB enjoysa feature of Low temperature combustion, ineffective Ca/S utilisation which makes the tail end Pollution equipment investment andoperating expenditure moderate ,compared to Pulverised Fuel firing Technologies. With multi fuel capability ranging from Coal,emission control on these front needs a detailed analysis for arriving at optimum configuration of Pollution control system andperipheral system design for reliable operation. This paper shall analyze economically viable solutions of MoeF norms while firingfossil fuel and Process Wastes in CFB Boiler.

Authors(s)

C R SubramaniamThermax Ltd.

Abhay R PatilThermax Ltd.

#538

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GETS 2016

DIGITAL SUBSTATIONS

Abstract:

In most engineering fields, digital technologies such as communication have replaced point-to-point wiring since more than adecade. In substations however still thousands of point-to-point signaling copper wires have to be laid out in the ground ofsubstations in order to interconnect the primary equipment such as switchgear and transformers with protection, control andmonitoring devices. Digital Substations overcome these using standardized fiber optic communication buses and sensors integratedinto the primary high voltage apparatus. High precision analogue voltage and current sensors replace heavy and bulky current andvoltage measurement transformers. The output signals of these sensors are sampled and digitized by means of high precisionelectronics directly at the sensor. From there these digital signals are broadcasted to substation control and protection equipmentby means of communication buses based on standard Ethernet technologies. Given the existing IEC 61850 standard and itsapplication on the process bus, the trend for digital substation is starting to accelerate, it follows the global trend for digitalization.Digital substations will be one of the strategic core elements for flexible smart grids, needed for a safe and stable integration ofintermittent renewable energy sources.

Authors(s)

Ujjal DasAsst Vice PresidentEngineering, Grid Integration,ABB India Limited

#558

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34

DESOX TECHNOLOGIES TO MEET NEW INDIAN ENVIRONMENTAL NORMS

Abstract:

The fast economical and industrial growth in India causes an increased demand for electricity. Sustainability and environmentalprotection is one of the key factors in the framework of future power generation. To meet the challenge to reduce the environmentalimpact of power generation, the Indian government established new emission limits for air pollutants such as SO2 and waterconsumption limitations in its "Environment (Protection) Amendment Rules 2015". These new rules and limitations have to beachieved by the end of 2017. Since these new regulations not only effect new build power plants, but also existing facilities, theretrofit of existing units is crucial. The paper will show various desulphurization technologies and explain the differences betweenthese technologies to find an optimal solution for the respective boundary conditions of the various power plant projects in India.

Authors(s)

Dr. Annette Ziemann-NötheProduct Management,Doosan Lentjes GmbH

Frank OberheidProduct Director APC,Doosan Lentjes GmbH

Andreas KarpinskiDirector Center of Competence,Doosan Lentjes GmbH

#560

REDUCE

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35

GETS 2016

THE OPTIMAL HEATING SURFACE ALLOCATION OF SUPERHEATERS AND REHEATERS

IN A BOILER

Abstract:

In this paper we explore the opportunity to maximize the production of power in a stream- turbine power plant by properlyconfiguring the hardware at the interface between the stream of hot gas produced by the furnace and the steam that circulatesthrough the power producing cycle. The interface consists of four heat exchangers, superheaters and reheaters, in parallel flowand counter flow. The search for better configurations is based on constructal design, and consists of searching for the distributionof heat exchanger surface (number of heat exchangers, types, sizes) such that the total power output of the turbines is maximum,subject to fixed total size for the heat transfer surface, and fixed maximum allowable steam heat exchanger wall temperature. Theemergence of the more effective configurations is documented along with the migration of the spot of maximum temperature alongthe flow path.

Authors(s)

S. LorenteDoosan Heavy industries& Construction,South Korea

J. Lee, Y. KimDoosan Heavy industries& Construction,South Korea

A. BejanDoosan Heavy industries& Construction,South Korea

#564

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36

WATER RESOURCE MANAGEMENT FOR 2 X 660 MW COAL BASED POWER

PLANT AND COMPARATIVES FOR WET AND DRY COOLING SYSTEM

Abstract:

The utility electricity sector in India had an installed capacity of 304.76 GW as of 31st July 2016. Water is important consumablesin the power plant for condenser cooling, cycle makeup, ash slurry preparation, coal dust suppression, HVAC makeup, drinkingand cleaning and so on. On continuous development of industries, ever growing demand of water for power projects and otherindustries is making this precious resource scarce. India's Ministry of Environment, Forests, and Climate Change has publishednew rules for the emission standards for coal-fired power plants that includes significant reductions in raw water makeup and zeroliquid discharge from the plant. The first step in water usage optimization and reuse is to identify various users of water and thewaste generated in the process. This paper presents water resource management techniques that highlight options how newenvironment norms of specific water consumption along with zero liquid discharge could be achieved for existing as well asupcoming power plants. This paper also provides a comparison to water usage in wet cooling system with respect to dry coolingsystem and discusses newly invented thermo syphon cooling technology which is under development stage because the makeupfor cooling tower evaporation loss and blow down is one of the major components to maintain the cycles of concentration.

Authors(s)

Mr. Yogendra MishraGroup HeadMechanical EngineeringL&T-Sargent & Lundy Ltd

Mr. Karthick BelligunduDeputy General ManagerL&T-Sargent & Lundy Ltd

Mr. Nirav ParekhAsst. ManagerMechanical EngineeringL&T-Sargent & Lundy Ltd

#569

REDUCE

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GETS 2016

REDUCING POWER CONSUMPTION OF ID FAN BY CFD APPLICATION

Abstract:

The paper deals with reducing the specific energy consumption of ID fans in power plants and improving energy efficiency. Thepertinent problems faced by Power Plant Industries are related to flue gas flow such as Pressure Drop, Erosion, High auxiliarypower consumption, ash accumulation, Formation of turbulence & Recirculation zones etc. Various technical advancements arebeing carried out in the field of power generation. Using CFD a state of art engineering tool which is used as an economic & timeeffective solution to address above all issues. The flue gas distribution along the duct cross sectional area is usually non-uniformresulting in high turbulence & higher loads on fan. Hence proper study of the flue gas path is required as it influences the powerconsumption of ID Fan. CFD technique is one of the most optimized & proven method to analyze flow variations & pressure dropin flue gas ductings. A detailed case study of Jindal Power Limited Unit#3 Raigarh, its analysis of existing conditions & turnkeysolutions adopted for reducing specific energy consumption and improving the performance (energy savings) is evaluated in thispaper.

Authors(s)

Mr. Mehul ShahGeneral ManagerMechwell R&D Center, India

Mr. Akshay ShahSr. EngineerMechwell R&D Center, India

#571

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38

EFFECTIVE MAINTENANCE TECHNIQUES FOR BEVEL PLANETARY GEARBOXES OF COAL

MILLS CONTRIBUTING TO REDUCED COSTS OF SPARES, ELECTRIC POWER, MANPOWER,

FUEL & MILL BREAKDOWN

Abstract:

Vertical Roller Mills used for grinding of various materials across the industry, for Power Sector the specialized coal pulverizesdeveloped & supplied by many companies across the Globe to various thermal power plants. One of the most important componentfor these mills is the Gearbox which is responsible for providing the required torque for coal grinding, absorbing the grinding forcesand supporting the mill table.

Gearbox being one of the most critical component of coal mill & ultimately to operations of boilers, it needs to be maintained withutmost care so as to get best performance & savings in terms of cost reductions for spares, electric power, manpower, fuel & millbreakdown.

This paper aims at describing the development & design changes for the Vertical Coal Mill Gearboxes. Maintenance schedules &procedures to be followed for current Bevel Planetary Gearboxes to get the best performance for the years of operation.

A practical example for above case will be discussed from the FLSmidth MAAG Gear vast experience with bevel planetary gearboxes.It will mention the benefits of shifting to latest design leading to improving efficiency, reliability and simplification of maintenance.

Authors(s)

Gaurav TiwariManager - Business Development(India - Power Sector)FLSmidth MAAG Gear- India

Sujith V GeorgeHead Sales -Indian SubcontinentFLSmidth MAAG Gear- India

Mauro ZacconeBusiness Development ManagerFLSmidth MAAG Gear- Switzerland

#588

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39

GETS 2016

SCR DENOX TECHNOLOGY - BAT FOR NEW INDIAN EMISSION STANDARDS

Abstract:

After several debates, starting from December 2017 Indian government is planning to apply the new air pollution limits for powergeneration that will concern for the first time also NOx emission. According to those new emission limits, SCR Technology will bethe most suitable option for new installation (after January 2017) that will reach NOx < 100 mg/Nm3 starting for an estimatedemission baseline of about 600-700 mg/Nm3 and might represent a consistent solution for existing power plant (installed between2003-2016), that will respect the limit of 300 mg/Nm3, with a long residual life.

According to the Indian coal higher ash content, the removal of NOx from the flue gas in high ash application is challenging innature. The type of Selective Catalytic Reduction (SCR) catalyst plays a major role in high dust concentration in the flue gas.

NANO Co., Ltd. is a leader SCR catalyst manufacturing company established in 1999 and developing his own patented technologyfrom Titanium powder manufacturing technology, to Catalyst manufacturing, both extrusion and coating, to manufacture highlycontrolled Honeycomb and Plate catalyst, having the capability of process engineering and design in order to achieve the performancetarget.

In this paper we will introduce our own varieties of SCR catalyst and related technologies for the consideration of future applicationto Indian Market with the reference experiences, including the main opportunity to tailored our Catalyst Management System withour patented technology for Regeneration and Recycling of exhaust catalyst

Authors(s)

Mr. Alessandro PaceTechnical Sales EngineerNANO Co. Ltd,

#592

REDUCE

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40

THE REDUCTION OF FLUE GAS TEMPERATURES TO ENHANCE COAL PLANT OPERATIONS

Abstract:

The Ljungström® air preheater (APH) is the preferred technology for combustion air preheat in the global coal fired power generationindustry. The sulphur content of the coal is one of the key parameters that define the thermal performance of the boiler, in that theair preheater gas outlet temperature is established to avoid excessive fouling, plugging, and corrosion in the equipment downstreamof the boiler, thus optimizing efficiency, availability and equipment life.

On-going global discussions regarding emission reductions, plus an industry focus on SO3 plume mitigation and improved thermalefficiency have defined a need to further reduce the gas outlet temperature of the APH below the historical operating ranges. Insupport of these market drivers, LJUNGSTRÖM initiated this research as a means to provide better solutions for efficiency,availability and equipment life as the market moves forward with improving the performance of coal fired power plants.

This paper presents the results of research performed on the mechanisms affecting the deposition of particulate and sulphuricacid on the heat transfer surfaces within a Ljungström® air preheater at reduced gas outlet temperature operation. In addition, thesuccessful results of both pilot scale and full scale demonstrations are presented. Finally, proposed methods for utilizing this newtechnology are presented for consideration.

Authors(s)

Kevin O'BoyleDirector of R&D,LJUNGSTRÖM, 3020 Truax Road,Wellsville, NY 14895, USA

#593

REDUCE

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41

GETS 2016

BIOMASS COMBUSTION ON LARGE PULVERISED COAL – FIRED BOILERS

Abstract:

In continued efforts to safeguard the environment and reduce emissions from the power sector, India made commitments inCOP21 to reduce the emissions intensity of its GBP by 33% to 35% of the 2005 levels by 2030 and achieve 40% cumulativeelectric power installed capacity from non-fossil fuel based energy. In addition, the Ministry of Environment, Forest and ClimateChange have issued new environmental targets regarding NOx, SOx, Mercury and Particulate Matter. Co-firing of biomass in coal-fired power stations is a key stepping stone technology towards lower CO2 electricity generation while also offering the possibilityof significant reductions in NOx, SOx, Mercury and Particulate Matter. Biomass co-firing also represents an attractive option forbiomass utilisation and for the delivery of renewable energy in terms of capital investment and generation cost which are typicallylower than for dedicated biomass power production. Further, biomass co-firing is an attractive option in terms of security of supplyas when biomass feed stocks are unavailable, the generation output can be maintained using 100% coal. The Ministry of New andRenewable Energy estimates the potential for 18.7GWe of power production from agro-residues and 14.6GWe from forest andwasteland residues in India.

This paper will provide an overview of the different technology options for the combustion of biomass in large pulverised coal firedboilers, identifying the key advantages and disadvantages, and the potential impact of biomass co-firing on boiler performanceand integrity.

Authors(s)

Stuart DuncansonDoosan Boiler Europe R&D centerUK.

#598

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42

INNOVATIVE GENERATOR PRODUCTS FOR HIGH OPERATIONAL FLEXIBILITY AND LOWER

OPERATIONAL COSTS

Abstract:

Global increase in utilization of renewable energy has a significant impact on the operating regimes in conventional power plants.Power supply from renewable sources is not constant, which creates the need for cost effective solution with operational flexibilityin modern gas and steam turbine power plants. Today, turbine-generator shaft train components are exposed to extremely volatileoperating modes with high number of start/stop cycles, numerous steep load ramps, frequency and voltage fluctuations. As aconsequence, thermo-mechanical stresses and accelerated ageing of the shaft train components including generators must beconsidered in the design to avoid unexpected cost and extensive outage periods. Siemens has implemented the above designfeatures in the new generator portfolio Pressurized Air cooled generator (300-450MW) and Water cooled generator (450-660MW).The new air pressurized technology offers additional benefits in regards to plant safety (no hydrogen), reduced maintenance cost,duration and the capability of unstaffed operation for synchronous condenser applications. The paper will further describe thedesign features and product benefits as new or retrofit solutions for thermal power plants.

Authors(s)

James JaborovskySiemens Energy Inc.

Matthias BacaSiemens Energy Inc.

Mayuresh JoshiSiemens Energy Inc.

#611

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GETS 2016

MODERNIZATION OF STEAM TURBINES FOR HIGH EFFICIENCY UNDER FLEXIBLE

LOAD CONDITIONS

Abstract:

In the power generation market in India a steadily growing percentage of fluctuating renewables are noticeably changing the loadrelated requirements of modern steam power plants. Whereas the past has seen mainly coal- fired units being operated in baseload now highly efficient part load behavior becomes more and more important as well as quickly responding frequency supportat minimized investment costs.

In the presentation various approaches will be identified, discussed and evaluated under economic criteria focused on the abovedescribed challenges for future power generating technologies. One central idea is to shift the pure sliding pressure mode down toan intermediate load range where the upper limit is reached at around 70% and optimize the blade path efficiency according to thispoint. Along with this strategy concepts are presented which allow frequency support from primary to hour- reserve of maximizedload steps. Moreover it shall be explained how it is principally possible to use the same cycle conditions for load steps andincreasing part load efficiency at the same time. Another idea is to improve the plant performance at lower load ranges by raisingthe main and reheat steam temperature accompanied by special maintenance concepts. The ideas presented in this article aremainly derived from a steam turbine point of view. Nevertheless some requirements and effects on the overall plant are taken intoaccount additionally.

Authors(s)

Thorsten StrunkSales and Marketing Manager -Steam Plant ModernizationSiemens AGPower Generation Services -Power and Gas

Amrish MaheshwariManager - Customer SupportSiemens Ltd IndiaPower Generation Services -Power & Gas

#614

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44

RECENT NON-LEAK GGH APPLICATIONS IN CHINA

Abstract:

Non-Leak GGH, also known as leak-proof GGH, containing cooling part and reheating part and using water as heat exchangemedium, is an important element for energy saving and environment protection. It has some positive characteristics, such as leakproof, easy to operate and maintain, heat recovery which can be used to reheat boiler supply water or flue gas after FGD, SPMresistance reduction and dust removal efficiency increase if cooling part located before ESP. Typical cases in China with designingand running data in 100MW, 600MW, 1000MW unit undertaken by SEC-PGEPE in past several years have been concluded in thispaper.

Authors(s)

Yang ZaitaoEngineer, now works at SEC-PGEPEon environmentalprotection projects of coal firedpower plant, mainly working onSCR & FGD & WESP.E-mail is [email protected]

Hang YifeiEngineer, now works at SEC-PGEPEon environmental protectionprojects of coal fired power plant, mainlyworking on SCR & NL-GGH.

Liu MinEngineer, now works at SEC-PGEPE onenvironmental protectionprojects of coal fired power plant,mainly working on NL-GGH.

Guo ShiyiSenior Engineer, now works at SEC-PGEPEas Director of Technology Group

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GETS 2016

SCR AND REGENERATION OF CATALYST – APPLICATION OF RETROFITTING EXPERIENCE

FOR SCR FOR INDIAN HIGH ASH COAL

Abstract:

With the notification of new emission norms by MOEF for thermal power plants, the selection and application of suitable DeNOxtechnology for Indian high ash coal is a real challenge.

Mitsubishi Hitachi Power Systems, Ltd. (MHPS) is a pioneer SCR technology and has both plate and honey comb type catalysts.MHPS have successfully installed in green fields as well as in retrofits for thermal power stations.

The fuel coal usually includes catalyst poisons like Alkaline metals, Arsenic, Calcium, Silicates compound, etc. and thus catalystactivity will be decreased by the addition or masking by such catalyst poisons. In order to keep the catalyst healthy, it has either tobe replaced with new or regenerated catalyst when the catalyst activity was decreased. The removed spent catalyst was usuallyscrapped or regenerated at site or regeneration facility.

In this paper, we will discuss and share our experience in retrofitting of SCR for high ash applications and issues like spaceavailability and plant auxiliaries like Air-Preheater and ID Fan etc.

Authors(s)

Tetsuo HikinoMitsubishi Hitachi PowerSystems Ltd.

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46

COMPARISION OF VARIOUS FAN ARRANGEMENT IN TERMS OF POWER SAVING AND

OTHER BENEFITS

Abstract:

The paper reviews alternate arrangement of Induced Draft (ID) Fans and Flue Gas Desulphurization (FGD) booster fan in coal basedthermal power plants. To compensate for the pressure losses in a steam power plant, it is necessary to install either additional fanor upgrade the existing ID Fans. Comparison of various fan arrangements in terms of power savings as represented below willcovered.

A) Booster fans arranged on hot vs. cold side of FGD scrubber.

B) Booster fan (BUF) + Induced draft fan vs. combined ID fan (CID).

Following topics would be discussed at length in this Technical Paper Presentation

a) General arrangement of axial flow fans in thermal power

b) Installation arrangements of induced draft (id) and booster fans in power stations after electro static precipitators (ESP)

c) Optimized environmental performance of new power station with FGD & SCR system

d) Power comparison between combined id fan and id + booster fan for 660 mw power plant. Combined id fan advantages

e) Booster fans for new FGD / SCR system in existing power stations. merits and demerits of dry and wet FGD fans

f) Power comparison between dry and wet booster fan with an example of 660 mw power plant.

g) Summary

Authors(s)

Ujjaval PrajapatiTLT Turbo India Pvt Ltd.

Manish PatelTLT Turbo India Pvt Ltd.

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47

GETS 2016

RENEWABLE ENERGY AND FOSSIL PLANTS: UTILIZING THE CONVENTIONAL POWER

PLANTS TO BALANCE THE FLUCTUATING POWER SOURCES AND TO STABILIZE THE NA-

TIONAL GRIDS

Abstract:

Renewable energies with their, cleanliness and low operating costs, are wanted everywhere. Germany has accumulated a greatexperience in renewables like wind power, PV and along with that in balancing the fluctuating load. In Germany the "Energiewende"resulted in massive investments into the renewables, which lead to a lower consumption of fossil resources and lower CO production.But also we are witnessing the new renewable energy sources causing troubles on the European energy market and to the gridstability. Sometimes the energy trading market has to deal with negative energy prices in Germany, which means, that energysuppliers are not rewarded but on the contrary they are even punished for producing energy. Yet, the very same day, as at dusk theshadows grow and the wind calms down, the renewable energies fade out and the energy prices start to shoot up. Therefore weobserve that the renewable energy revolution has a missing link.The following solutions can be envisaged to handle these issues:

• Solutions for the Grid Stabilization by existing fossil power plants

• New solutions to increase the flexibility of operational power plants

• Efficiency and Emission improvements

• Maintenance costs and parasitic loads

• Operational Safety and plant reliability

All the above mentioned solutions are no fantasies. They are realized and proven in several different power plants all around theworld, and they summed up to great improvements regarding the load range, load flexibility and plant efficiency. These packagesalso can be modified and adjusted for other use cases. There are more than 100 SPPA-P3000 installations worldwide which provethat these optimization solutions really make the difference.

Authors(s)

Jan WeustinkSiemens Ltd.

Ketan MehraSiemens Ltd.

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48

NTPC POWER HUB - SMART PHONE APP

(Effective monitoring of Variable Cost)

Abstract:

In Power generation, being a nonstop production process unlike other commodities, unhindered flow of critical information is vitalto the employees engaged in it. With the revolution in information technology the smart phones turns out to be a cutting edge toolin this regard. In the current scenario we monitor variable cost on monthly basis. We have to wait for one full month before takingany decision pertaining to variable cost, and changing conditions demand day to day monitoring of variable cost. We have takena step forward towards modernization of IT based services of NTPC by creating the Android/IOS based application "NTPC POWERHUB". The purpose of NTPC Power Hub is to provide a platform to share information related to power generation to the employees,who are directly or indirectly engaged in power generation activity. This application is an attempt to harness the untapped potentialthat lies within this powerful I.T. tool, of which almost every member of the organization has access to. This application highlightsthe variable cost of different NTPC stations by effectively processing the real time data collected from different sections of theindividual plant such as Heat rate, APC, Gross calorific value and Landed price of fuel. The application will assist in formulating thestrategies for keeping the generation cost in check thereby ensuring availability of schedule for plants. This application will help inspreading cost consciousness amidst the employees, thereby attracting participation and inputs from different levels, stimulatingresponse and efficiency by instigating sense of engagement.

Authors(s)

Rakesh KumarSenior ManagerOS.WR-2, HQ, Raipur

Prasanjit RoyManagerOperation NTPC Ltd. Korba

Mohit GuptaAsst ManagerOperation NTPC Ltd. Korba

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49

GETS 2016

RELIABLE WORM GEARS FOR COAL GRINDING MILLS

Abstract:

In coal fired Power Stations an important part of energy consumption is caused by grinding of the coal. Over the past decades thepower stations used grinding mills from 300 to 340, 500, 630 kW and to 800 and 900 KW per unit. Whereas the bevel planetaryunits are expected to run without special maintenance; for the smaller unit astonishingly the market accepts in the last 15 years animmense use of spare parts: the grinding mills are driven by use of worm gear units. Even if a lot of care is given to the goodmaterial and for establishing of a good contact pattern some gearboxes are failing after 10 000 to 20 000 h of operation and theworm gears have to be changed. The waste by this expensive operation mode is even more severe as during the short operationsuch failing gear sets are causing higher losses than properly designed worm gear sets. The authors are showing that by using thesuperior CAVEX® profile for the worm gear sets, the efficiency of the gearboxes can be increased from the commissioningonwards in a progressive manner over a much longer lifetime. The waste is therefore reduced drastically as a product of higherefficiency and longer lifetime.

Authors(s)

Dr. Peter LeoniCEO

Dr. Jens HeilemannHead of R&D

Mr. M HariharakumarSales Manager

Company:Cavex GmbH & Co KG, Germany

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50

DURABLE SCR CATALYST DESIGNED FOR THE SUPER-HIGH DUST COALS

Abstract:

Nitrogen Oxide (NOx), one of the main cause of acid rain, is now also well-known as the source to foam the harmful PM2.5. Toachieve the environmental limitation, the SCR technology was originally established in Japan in the mid of 1970's and thencommonly applied all over the world to tackle the NOx reduction. Although this SCR technology had been designed for thestationary applications like power plants at early stage, additional mobile applications like automobile, locomotives and oceanvessels are currently adopting this SCR technology.

Dust Load [g/Nm3] is one of the most important issues to design both SCR Catalyst and SCR Systems for any kind of coalapplications to avoid the troubles like plugging and/or erosion. According to the continuous increase trend about Dust Load from10g/Nm3 in 1980's to 60g/Nm3 after 2010's, the required strength and proper pitch of Catalyst has always been improved.Currently, the Indian coal requires the record-braking Dust Load for SCR suppliers up to 100g/Nm3. This is the exciting challengenot only for Catalyst but also the SCR System suppliers to achieve the stable performances. More and more technical discussionmust be needed to overcome this Dust Load issue in the Indian market.

We, Hitachi Zosen Corporation, has also been started the development of SCR technology in the late of 1960's as a pioneer. In thetechnical sessions, we would like to introduce our own unique SCR Catalyst and our design capability to apply the Indian CoalApplications with strong confidence based on our 45+ years experiences.

Authors(s)

Tetsuo KODAMASenior Manager of SCR SystemsBusiness UnitHitachi Zosen CorporationMachinery Business HeadquartersMarine Machinery & SCRSystems Business Unit

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GETS 2016

ENERGY ENVIRONMENT IMPLICATION BY ELECTRICAL ENERGY AUDIT IN THERMAL

POWER PLANT - INDIAN SCENARIO

Abstract:

In this paper electrical energy conservation measures in thermal power plant is discussed. The implementation of energy conservationmeasures drawn from energy audit study will reduce the energy consumption about 15 to 20% and saved energy can be madeavailable to feed in the grid which increases net electrical energy generation. In house Auxiliary consumption reduction can provideattractive method to increase the net generation capacity, which reduces CO2 emission factor. In this paper CO2reduction /annumis calculated as 13980.24 Tons of CO2. It also shows that energy environment implication can be reduced by means of electricalenergy Audit in thermal Power Plant.

Authors(s)

Anil B. OnkarB.E.(Electrical Engg.),Additional Executive Engineer atM.S.P.G.C.L., Koradi, Nagpur,Maharashtra (India).

Dr. Gunwant A. DhomaneProfessor in Electrical EngineeringGovt. College of Engineering,Chandrapur, Maharashta(India).

Dr. Ravindra M. MoharilElectrical EngineeringYeshwantrao Chavan Collegeof Engineering, NagpurMaharashtra

Prashant P. MawleAsstt. DirectorNational Power Training Institute(WR), Maharashtra,Nagpur.

#733

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FLUE GAS DESULPHURIZATION TECHNOLOGIES FOR MEETING REVISED EMISSION NORMS

FOR THERMAL POWER PLANTS IN INDIA

Abstract:

Continued reliance on coal and other fossil fuels in India coupled with the new Environment (Protection) Amendment, to limit SO2and Particulate Matter emissions from thermal power plants will require Flue Gas Desulphurization (FGD) systems. The revisedemission norms vary based on size of the Thermal Power Plant units and year of Installation. Selection of appropriate FGD systemdepends on:

• Outlet emission requirements

• Location of the Thermal Power Plant

• Size and numbers of the Power Plant Units at a single location

• Utility requirements (Reagent, Power, Water)

• Space availability

This paper will review various Flue Gas Desulphurization (FGD) technologies available to cater to the requirement of reducedparticulate and SO2 emission limits as per revised norms, for upcoming as well as existing Thermal Power Plants.

Authors(s)

G. SrikanthSr. Manager - Proposal andEngineeringThermax Limited (Enviro Division)Environment House, Plot No. 90-92BG BlockMIDC Bhosari, Pune 411026

Nitin DharapSr. Manager - ProposalThermax Limited (Enviro Division)Environment House, Plot No. 90-92BG BlockMIDC Bhosari, Pune 411026

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GETS 2016

DIGITIZATION OF COAL POWER PLANTS TO ACHIEVE CLEANER EMISSIONS, HIGHER

EFFICIENCY AND FLEXIBILITY

Abstract:

Coal-fired power plants in India are required to operate with higher efficiency, cleaner emissions and improved flexibility. Increasingcontribution from renewable energy sources will place coal plants in a tough spot to comply with stiffer fluctuation requirementfrom load dispatch centers. It becomes imperative to implement a deck of applications that optimizes the component's life,performance, and reliability that eventually achieves the aforementioned requirements. We are presenting a boiler optimizationapplication which consists of integrated soot and combustion optimization modules. These applications pull real-time data fromsensors to generate optimal operating conditions and relays feedback to the digital control system. The soot optimization moduledynamically directs boiler cleaning actions to achieve unit reliability, efficiency and emission goals while the combustion optimizationmodule optimizes fuel and air mixing to reduce emissions and improve efficiency. In this paper, the authors are going to discuss thebenefits of similar applications which digitizes the operation of coal-fired power plants.

Authors(s)

Navin BhateraGeneral Electric

Thillairajan SGeneral Electric

Amitava BhattacharyaGeneral Electric

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54

OPTIMIZATION OF FLUE GAS DESULPHURISATION SYSTEM DESIGN BY

USING ALRD® TECHNOLOGY

Abstract:

One of the primary design criteria for achieving a desired level of SO2 reduction is the liquid-to-gas (L/G) ratio or the quantity ofliquid sprayed relative to the volume of flue gas. Increasing the L/G ratio improves SO2 removal by exposing the gas to moreabsorbing liquor, but comes at the expense of higher power consumption. The ALRD® Technology (Proprietary & Patented byMarsulex Environmental Technologies of US , licensor of Thermax Limited ) is a device designed to modify the annular portion ofthe absorber total cross-sectional area near the absorber wall, and redirect the falling liquid film from the absorber wall back intothe gas stream. This slight decrease in the cross-sectional area of the tower has a minimal effect on the flue gas pressure loss inthe tower, but has a major effect on gas-liquid contact. The major benefits includes:-

• Increased SO2 removal

• Allows meeting new & more stringent emission levels

• Reduce power consumption

• Enhances fuel flexibility

This paper also talks about how the application of ALRD® technology in FGD design helps in optimization of L/G ( Liquid to Gasratio), sizing of pumps , motors . and piping thereby reducing power consumption.

Authors(s)

G. SrikanthSr. Manager - Proposal andEngineeringThermax Limited (Enviro Division)Environment House, Plot No. 90-92BG BlockMIDC Bhosari, Pune 411026

Nitin DharapSr. Manager - ProposalThermax Limited (Enviro Division)Environment House, Plot No. 90-92BG BlockMIDC Bhosari, Pune 411026

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55

GETS 2016

ADVANCEMENT ON ESP TECHNOLOGY IN POWER UTILITY SEGMENT

Abstract:

ESP is key Air Pollution Control device for SPM control in Indian Utility sector for long term. ESP Technology passed throughseveral challenges of Indian Coal Fired Fly ash, high ash content (>50%) coupled with very high resistivity (10^¹³ to 10^¹?ohm-cm). The lower migration velocities out of Indian high resistive Fly Ash needs field additions &

electrical upgrades of existing ESPs, but space constraints is the key challenge. Use of 3- phase T/R set and Pulse energizationthru' Switch Mode Pulsing System (SMPS) are the developments of the next phase, which essentially cuts the "ripple effect" anddecreases gap between KV(p) and KV(avg) values significantly and as a result pumps up effective power to ESP fields. Primarily,Indian Power sector ESPs have Spiral electrodes in the DE system, which has unique characteristics of "Low & Uniform CoronaGeneration" mainly influenced by European ESP designs, whereas, American ESP manufactures more relied on rigid electrodeswith spikes resulting in " High & non-Uniform Corona Generation. The integration of ESP and bag filter (Combo Filter) is the latesttechnology, where both negative attributes of ESP and Fabric Filters are eliminated by each other's' positive attributes and theCombo Filter becomes the right solution. In combo filter, dust load on bags will effectively come down and differential pressureacross combo filter is also 50% lesser than normal Fabric filter & emission will be effectively reduced < 20 mg/Nm3.

Authors(s)

Arijit DuttaThermax Ltd.

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56

INNOVATIVE PULSING SYSTEM IN LARGE PROCESS BAG FILTERS

Abstract:

Bag Filters is a globally proven technology for lower emission control of Suspended Particulate Matters (SPM) in all core IndustrialSegments like Power (Utility & Captive), Cement & Steel. However, being a higher energy consuming device & more maintenanceprone nature the OPEX (operating Expenses) are higher than ESP systems as a Air Pollution Control (APC) device.

A new innovative technology of on line cleaning for pulse -jet bag filters with considerable energy efficiency have been developed. The patented nozzle (Patent no. APP NO. 875/MUM/2012, dt.28th March 2012 ) cross section is optimized with CFD simulationin a manner that the higher pulse impulses are created for a given tank pressure as compared to conventional nozzles therebyaiding operation at a significantly lower tank pressure. The nozzle not only operates with low over pressure on the filter bag, butalso with low required volume of the compressed air. The differential pressure across the dual jets are optimized in a mannerwherein simultaneous subsonic and supersonic regimes are established which which ensures uniform cleaning of the bagsthrough ripple effect and uniform bag aging as a result. These measures contribute to lower differential pressure across the filter,reduced wear and tear of the bags and reduced energy demand and operating costs.

Authors(s)

Arijit DuttaThermax Ltd.

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57

GETS 2016

Dr. K. KumarScientist B, CWPRS, Pune

Sudhir ShindeM.Tech Final Year,Department of Technology, Pune

A NOVEL APPROACH TO EVALUATE THE PRESSURE DROP OF FILTER UNDER REAL

TIME APPLICATIONS

Abstract:

The analysis of fluid flow in a closed conduit is important for many engineering applications like fluid transport piping and filteringsystem, process control of an industrial applications etc. A recent research study shows that 70% - 90% of hydraulic systemfailures are due to the contamination and the poor liquid conditions. Therefore, filters are necessary in modern hydraulic systemsto provide a specified level of cleanliness, reliability. The hydraulic efficiency and performance of the filters need to be addressedfor real life applications. The theoretical performance of head loss against the flow rate across the any filter is often calculated byusing empirical formulae given in Perry's chemical hand book. Whereas the performance of the water filters are generally simulatedat laboratory conditions like ambient temperature, density, available system pressure etc. For an example, the operating temperatureand the pressure of the feed water inlet to the BFP of a super critical boiler is about 205 ? C and 18 bar. In such a real time issuescannot be simulated in the laboratories. Therefore, scientists and engineers are mainly relying upon the CFD tools for the approximationof solutions in place of real time site

conditions. The relationship of flow rate, specific gravity and the pressure drop at any hydraulic filter can be expressed in the formof flow coefficient (Kv). The flow coefficient is the function of flow rate in m3/hr passing through the element at a head loss acrossthe element of 1 bar. An extensive experimental investigation has been carried out at flow

calibration laboratory at CWPRS in order to analyse the flow characteristics pattern on heavy duty water filters and the performancesat high temperature and pressure on real world conditions established using flow coefficient methodology. Further researchinvestigations were simulated using solid works CFD flow simulation approximation

tool to analyse the expected head loss for the given operating range of flow for the validation. These results show that the approachbased on the flow coefficient is more preferable to analyse the pressure drop against the flow rate through the filters under real timeapplications.

Authors(s)

A P SamalAGM (PE-M-TG) NTPC Limited,New Delhi

Somnath NandiAssociate Professor,Department of Technology, Pune

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58

REDUCED FUEL CONSUMPTION AND IMPROVED AVAILABILITY BY ANOMALY

DETECTION IN POWER PLANT DATA

Abstract:

Today utilizing resources in an efficient way is a key aspect of the power plant operation. That includes natural resources such asfossil fuels as well as human resources in the power plant. Reducing fuel consumption means improving the heat rate of the unitand limiting the degradation of the unit in a cost effective way. Efficient employment of staff means focusing the manpower onassets, which do show indications of damages or degradation and it means using planned outages to fix the faults.

Both aspects require an early detection of changes in the plant behaviour in order to identify the critical assets or process parameters.Advanced pattern recognition has been applied as a tool for that purpose. Recently the development of Big Data and MachineLearning technologies and their introduction into the industry within the Internet of Things has extended that toolbox by newtechnologies for anomaly detection. Especially Deep-Learning has proven to be a flexible, powerful tool to build large scale autoencoders for anomaly detection in power plant data.

This paper describes an implementation of this approach for a 350MW coal fired supercritical unit and demonstrates the benefits.Results from anomaly detection are compared with recorded failures and maintenance measures to demonstrate the potential ofthe method.

Authors(s)

Dr. Peter DeeskowSteag Energy Service, GmbHGermany

Dr. Tomasz KaminskiSteag Energy Service, GmbHGermany

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59

GETS 2016

UMBRELLA SNCR TM : ADVANCED POST COMBUSTION NOX

REDUCTION TECHNOLOGY

Abstract:

GE's Umbrella SNCR™ is an implementation of the Selective Non-Catalytic Reduction(SNCR) process, a common NOx removalprocess applied in various industries. This paper will provide a brief overview of the SNCR process, of the main features of theUmbrella SNCR™, and of its advantages over other SNCR process implementations. The SNCR process consists in the non-catalysed reduction of NOx molecules by a reagent, commonly aqueous urea, which is injected in a stream of flue gas generatedby a combustion process. In coal boiler applications, there are two challenges to maximizing the performance and efficiency of theprocess. The first challenge consists in ensuring that the reagent and the flue gas are appropriately mixed. The second challengeconsists in ensuring that the reagent and the flue gas remain in contact long enough in the

appropriate temperature range. Standard SNCR applications typically attempt to address these challenges by introducing urea intothe boiler using large numbers of wall injectors, requiring a sophisticated control system. The Umbrella SNCR™ employs a smallnumber of retractable injection lances which introduce urea directly into the centre of the boiler. GE's patented spray shapingmethod ensures near-complete mixing of the flue gas and of the reagent, while simple adjustments to the injection height ensurethat residence time and temperature challenges are met at all times. Thanks to these features, the Umbrella SNCR™ ensuresexcellent NOx removal rates at a wide range of boilers.

Authors(s)

Sunil ChauhanGeneral Electric (GE)

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60

REDUCING DRY FLUE GAS LOSSES

Abstract:

Efficiency is a ratio of output to input. By increasing the numerator or by decreasing the denominator we can achieve higherefficiency. In practice, there is little scope to increase output but by rigorous efforts we can decrease the input for same output.

As a practising process Engineer, it has been worked out to feed 2% less coal for same power generation by extracting waste heatfrom exit flue gases from Chimney. This effort is helpful to fight against global warming and enhance Boiler efficiency by 2% andthermal cycle efficiency by 0.8%. The recovered heat will be utilized to heat a part (say, 25%) of condensate from 550C to 95CCin a heat exchanger in flue gas duct after discharge of ID Fan. In this innovative process flue gas will be cooled from 1400C 1000C.

Authors(s)

R.S. MuduliEx. AGM / NTPC Limited

#784

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GETS 2016

COAL FLOW MEASUREMENT

Abstract:

The benefits of proper combustion and well-tuned burners can be significant for a coal fired boiler. These can include improvedcombustion efficiency by reducing unburned carbon losses, reduced NOx emissions due to imbalanced fuel and air mixturesentering the furnace, or reduced slagging and water wall corrosion. Extractive coal flow measurements in the burner pipes areperformed used to tune and optimize combustion in coal-fired boilers and to ensure the pulverisers are operating properly. Butthere are several techniques, various test instruments, and many possible sources of error in these coal flow measurements. Thispaper will discuss best practices and test equipment for accurate, efficient, and safe coal flow measurement, focusing on the keyfactors of:

• Air flow measurement in the coal pipes and mills

• Extractive coal flow sampling methods and equipment

• Automated versus manual testing methods, including sources of errors and data quality

• Data and results from advanced experiments at an EPRI coal flow research facility

• Example results and comparisons from actual plant testing

Authors(s)

Robert G. Mudry, P.E.Airflow Sciences CorporationLivonia, Michigan, USA

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62

STUDY ON THE REMOVING FINE PARTICLES OF WET ELECTROSTATIC PRECIPITATOR AT

HIGH GAS VELOCITY

Abstract:

Wet electrostatic precipitator has a significant removal for fine particulate matter like PM2.5. By improving its structure andcombined with experiments to explore a new type wet electrostatic precipitator which could handle a lot of smoke is the purposeof the article. Experimental results show that the new type wet electrostatic precipitator with 9m long tube at 60kV voltage and 4m/s wind velocity for PM2.5 removal efficiency reached 85%, it's a new way for coal-fired power plants to reduce emissions of fineparticulate matter.

Authors(s)

#638

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Shi Chaolin, Engineer, now worksat SEC-PGEPE on environmentalprotection projects of coal firedpower plant, mainly working onFGD & WESP.

Yang Zaitao, Engineer, now worksat SEC-PGEPE on environmentalprotection projects of coal firedpower plant, mainly working onSCR & FGD & WESP.

Guo Shiyi, Senior Engineer, nowworks at SEC-PGEPE as Directorof Technology Group.

Ding Chenggang, SeniorEngineer, now works at SEC-PGEPE as Vice MD.

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63

GETS 2016

HIGH VOLTAGE MIXED TECHNOLOGY (HYBRID) SWITCHGEAR - STEPS UP TO 400KV

Abstract:

For many, the world of high-voltage equipment has always been divided between air-insulated switchgear (AIS) and gas-insulatedswitchgear (GIS). Previously, space requirements usually predicated which option was chosen - with GIS allowing a far morecompact, though more expensive, substation footprint. Stated simplistically: AIS was the preferred choice in rural areas while GISwas usually chosen in urban settings. This picture changed dramatically some years ago with introduction of High Voltage HybridSwitchgear's.Hybrid Switchgear, or, as it is termed by CIGRE, Mixed technology switchgear (MTS) combines the best of the AISand GIS worlds into one switchgear. Even if basic equipment costs are higher than AIS, MTS delivers a lower cost of Ownership -usually related to lower land costs and shorter construction times CIGRE states, "... the comparison of technologies indicates thatMTS combines a lot of advantages of AIS and GIS and leads to a good compromise". In a case study, CIGRE concluded that"...substantial savings in total ownership costs, even when basic equipment costs are higher, could be achieved by adopting MTSequipment. The savings produced are directly linked to land cost. Overall construction times are also reduced. Unanticipatedbenefits included easier permitting due to the reduced visual impact of the substation and less complicated negotiations with landowners due to the lower land intake required". MTS adopts GIS technology for the main interrupting components of the circuitbreaker and the disconnect/ earthing switch, thus guaranteeing highest reliability and compactness. At the same time, MTS usesAIS to connect to the grid, thus positioning itself between AIS technology and GIS technology. Till date the MTS was confined tovoltage level of 66kV to 220kV, the paper discusses the basic innovative design of 420kV Hybrid Switchgear which is factory fitted,factory tested and arrives at site with HV Bushings installed, thus minimizing installation time and carry forward MTS legacy ofcompact and reliable switchgear which can be installed on site very quickly and provides cost effective GIS technology for reliableoperations.

Authors(s)

Anurag PanditABB India

Amit SharmaABB India

#548

REDUCE

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REDUCE

#740

AN EXPERIMENTAL INVESTIGATION ON A HEAVY DUTY CONICAL STRAINER

Abstract:

The dynamic analysis of the fluid flow in a closed conduit is important for many engineering applications like fluid transport pipingsystems, filtering system, process control and industrial applications involving transfer of fluid. A properly sized, installed andmaintained hydraulic filtration in a flow conduit plays key role in break down prevention and maintenance planning. An experimentalinvestigation has been carried out on a heavy duty conical type inline water filter at 100% clean and 50 % clogged condition at thelarge flow calibration laboratory in CWPRS, Pune. The head loss across the strainer assessed at forward and the reverse directionof the in-line conical strainer flow rates ranging from 30 m3 /hr to 150 m3 /hr is reported in the paper. The results show that a dropin head loss of about 12-15% is observed at forward direction as compared to reverse direction of the conical strainer at designflow rate. These results paved way for a energy saving potential in this specific application of inline conical strainer in closedconduits. The method employed and the results are validated with Solid works CFD software tool for the range of applicability anduncertainty band.

Authors(s)

Dr. K. KumarScientist 'B', CWPRS

K. U. FarandeAssistant Research OfficerCWPRS

T K SahuResearch AssistantCWPRS

P. M. Abdul RahimanScientist 'D'CWPRS

S. AjaiScientist 'B'CWPRS

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GETS 2016

RENEWABLE

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67

GETS 2016

REVIEW STUDY ON CST SYSTEMS: APPROACH AND METHODOLOGY TO EVALUATE &

INTEGRATE WITH SPV & RWH SYSTEMS

Abstract:

Solar thermal energy harvesting needs development of solar absorber receivers, components, products and systems. This paperis reviewing and proposing the approach, methodology and applications of commercially viable Solar Thermal absorber surfacese.g. Alumina (AAO/Al2O3) with an aim to explore more research and development in solar thermal energy harvesting with integratedor hybrid applications. It is proposed that surface characteristics & architecture of the product design should be evaluated at sitespecific application since the lab test results need to be validated for site before application, when mass production is the requirementof site.

Also, some cost reduction strategies for solar thermal power systems and hybridization of Solar Photo Voltaic (SPV) with ConcentratedSolar Thermal (CST) & rain water harvesting (RWH) for agriculture, domestic, industrial, commercial or transport applications arealso being discussed in view of the learning had at India-One 1 MWe Solar Thermal Power Project, Abu Road, Rajasthan; with anaim to maximise the use of renewable energy potential as well as to reduce the overall cost of living in urban & rural environmentsleading to rebuilt more eco-friendly infrastructures and overall energy economy.

Authors(s)

Ashutosh Arora

Prof. (Dr.) Chandra Mohan Arora

Prof. (Dr.) Pulak Mohan Pandey

Prof. Achintya Choudhury

Dr. Suparna Mukhopadhyay

Dr. Tapan Kumar Ray

RENEWABLE

#480

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68

ENHANCING FACTORS TOWARDS RELIABILITY OF SOLAR PHOTOVOLTAIC POWER PLANTS

Abstract:

Renewable Energy is a fast growing power generation resource for electricity grids. It has greater significance due to three mainfactors: Reduction in carbon foot print, long term energy security and meeting global demand. Out of the renewable energysources available, solar is expected to make significant contribution in the renewable energy mix because of its abundance.However, due to its intermittency, integration of large scale solar plants from MWs to GWs to the existing grid adversely impactutility system operation. Hence, the design of PV systems in high penetration scenario must be compatible to dispatch the energyyield effectively to meet the demand irrespective of source and sink variations. It is essential to choose the right factors whiledesigning the PV area i.e DC field. This paper focuses the technical challenges faced during the integration of solar PV plant to griddue to natural variability and grid fluctuations due to transient disturbances. Methods to enhance the power reliability from solarplants during such conditions are also addressed. Case study of one of the MW scale grid connected solar PV plant in India isanalyzed and the recommendations including higher DC loading to address the challenges faced for maintaining power reliabilityare presented.

Authors(s)

Janani.KSolar Business Unit,L&T Construction

Ramesh. PSolar Business Unit,L&T Construction

RENEWABLE

#486

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GETS 2016

CONTOUR FOLLOWING MODULE MOUNTING STRUCTURES IN UTILITY SCALE PV SOLAR

POWER PLANT

Abstract:

This paper describes about the structural design of contour following structure and challenges faced during the installation of theCFS in the undulated terrain in Maharashtra. The use of CFS has helped in maintaining the land in its natural state and to maintainsustainability.

Authors(s)

Rams ThalluriPE(CA, USA), M.ASCE, (MICE)Head - Solar EDRCL & T Construction, Chennai

Santhanalakshmi. SAsst. Engineering Manager,Solar EDRCL & T Construction, Chennai

Santhosh B.R.Asst. Engineering Manager,Solar EDRCL & T Construction, Chennai

RENEWABLE

#488

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ENHANCING GENERATION OF CONVENTIONAL SOLAR PV SEASONAL TILT SYSTEM USING

NORTH FACING TILT IN SUMMER MONTHS

Abstract:

Energy output of a Solar photovoltaic (PV) system depends on the amount of incident solar insolation on the photo-active surfaceand to maximize generation from a PV panel it has to be oriented towards the sun as closely as possible. A typical seasonal tiltsystem comprises of three south facing tilt adjustments and gives between 3 to 4% higher energy output than a fixed tilt systems.

This paper assesses the potential of a north-facing summer tilt, i.e. orienting the tilted PV panel with 180° azimuth in summermonths, to enhance the benefits from a seasonal tilt system at latitudes less than 23.45° in northern hemisphere.

The paper attempts to quantify the gain in energy generation with the employment of north facing summer tilt over typical seasonaltilt system. Results of the comparison also suggest the optimal tilts for the chosen locations.

Authors(s)

Aparna Sankar

Faisal Kamran

RENEWABLE

#489

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GETS 2016

SOLAR POWER TREE 'AN INNOVATIVE SOLUTION TO TAP SOLAR POWER'

Abstract:

SOLAR POWER TREE is the perfect solution to the question of availability of the land in the future. This relatively new concept wasconceived in an attempt to merge new technology relating to the absorption and use of solar power.

A solar tree harnesses solar energy for producing electricity with an innovative vertical arrangement of solar cells. The constructionof solar tree is quite simple, the solar panels arranged on a pole, in a manner that they harness maximum solar energy.

"Solar Power Tree' takes only 4 sqft of land to get 5 KW Power, compare to 400 sqft in conventional layout." Solar tree is mostadvantageous for countries like India having high population and less space. The efficiency of the plant can be improved by usingthe technique known as "SPIRALLING PHYLLATAXY". It provides the way to help the lower panels from th shadow of upper ones,so that it can track maximum power from sun.

TREE Stands For:

T - Tree generating

R - Renewable

E - Energy and

E - Electricity

Authors(s)

H.S.Bagga

Vikas Khare

RENEWABLE

#491

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72

HYDROGEN: THE PERENNIAL SOURCE OF ENERGY

Abstract:

Hydrogen can be produced from a variety of feedstocks. These include fossil resources, such as natural gas and coal, as well asrenewable resources, such as biomass and water with input from renewable energy sources. A variety of process technologiescan be used, including chemical, biological, electrolytic, photolytic and thermo-chemical. Each technology is in a different stage ofdevelopment, and each offers unique opportunities, benefits and challenges.

Hydrogen can be produced from the splitting of water through various processes. This paper briefly discusses water electrolysis,photo-electrolysis, photo-biological production and high-temperature water decomposition.

One thermochemical water-splitting cycle, i.e the sulfur-iodine cycle has been investigated as a way to supply hydrogen for ahydrogen-based economy. The whole process takes place in water and high-temperature heat, particularly, in the decompositionsteps, and releases hydrogen and oxygen.

This technology pathway with potentially low or no greenhouse gas emissions has the potential to produce a perennial source ofenergy. The paper aims to discuss the various technologies with thermochemical process in particular for generation of hydrogenand its application for power generation.

Authors(s)

Ashish Jain

RENEWABLE

#501

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GETS 2016

BARRIER ASSESSMENT OF CONCENTRATING SOLAR POWER (CSP) IN INDIA

Abstract:

It is well established that Concentrating Solar Power (CSP) can offer 24 hours power to grid using solar energy if used with thermalenergy storage (TES) system. With the global installed capacity of around 5 GW; CSP has still not taken significant space in Indiaand is limited to only around 250 MW capacity operational projects. At the inception stage of National Solar Mission (NSM), it hasbeen envisaged that the share of the solar power technologies of solar Photovoltaic and CSP will be 50:50. The capacity allocationof 500 MW CSP projects has also been made as per the ratio under the Phase-I of NSM but only few developers have successfullyimplemented the projects. The performance of operational projects has been reported satisfactory (especially of 50 MW CSPproject of Godavari in Rajasthan). No further capacity allocation has been made under any batch of Phase-II of NSM; howeverConcentrator Solar Thermal (CST) for process heat generation has received significant attention of market. The techno-commercialpotential of CSP in India has been estimated more than 2800 GW in India.

This study highlights the key techno-commercial barriers towards accelerated deployment of Concentrating Solar Power (SolarThermal) technologies in India. The communication addresses the technical barriers specially availability of required direct normalirradiance (DNI), manufacturing and supply of key equipments, technical skills of designing and implementation along with bankabilityissues related to CSP projects in India. Based on the review of global practices towards techno-economic viability of CSP projects,few recommendations have been made in the paper towards sustainable deployment of CSP in Indian market.

Authors(s)

Dr. Ishan Purohit

Saurabh Motiwala

RENEWABLE

#503

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74

LOW TEMPERATURE SOLAR THERMAL POWER GENERATION BASED ON KALINA CYCLE

Abstract:

Recently, with decreasing oil resources and environmental issues associated to use of fossil fuels, solar thermal power plants haveattracted much attention mainly due to zero emission and huge fuel savings they bring about. Efficient utilization of the lowtemperature heat is a challenge. Kalina cycle was proposed to exploit the opportunity of extracting this low grade energy as theconventional Rankine is very inefficient for low temperature applications. The Kalina cycle has recently seen increased interest asa replacement for the more traditional steam Rankine cycle for geothermal, solar, ocean thermal energy conversion and waste heatrecovery applications. The Kalina cycle uses a mixture of ammonia and water as the working fluid. The ammonia-water mixtureevaporates and condenses with a temperature glide, thus providing a better match with the heat source/sink temperature profile.This better match results in reduced thermal irreversibility, but at the cost of relatively larger heat exchanger areas. The parabolictrough collector is the most mature technology for the conversion of solar thermal energy into electricity. In this paper preliminarythermal design calculations are performed for a low temperature Kalina cycle based solar parabolic trough power plant withstorage along with basic economic analysis.

Authors(s)

Shri Mishree RamAGM (Oprn & Chem I/C)NTPC Unchahar

Shri Ravi Prakash SinghAGM(Oprn & Comm.)NTPC Unchahar.

Shri Ritesh AgarwalManager (Operations)NTPC Unchahar.

RENEWABLE

#504

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GETS 2016

LARGE SCALE GRID CONNECTED SOLAR PV POWER PROJECTS IN INDIA –

AN ANALYSIS OF OPERATION AND MAINTENANCE ASPECTS

Abstract:

In the current scenario, several number of large grid connected solar PV power projects installed in various parts of the countryand supporting the conventional grid for meeting day-to-day energy demand. Practically, solar PV power projects are consideredto be the simplest among other electrical generator technologies to implement by Solar Project Developers (SPD) and Engineering-Procurement-Construction (EPC) companies, which result in giving less attention to the optimum project design, quality workmanshipand quality O&M practices.

In this communication the real time energy generation data of around 9 large grid connected solar PV power projects have beenconsidered which are implemented under different policies across the country. The project size varies from 10 MW to 40 MWcapacity. The energy generation data (at power plant and at grid substation) along with associated meteorological parameters hasbeen analyzed and a significant gap found in between predicted energy and actual energy delivered. Route-cause analysis hasbeen carried out via addressing each technical losses associated with energy generation. Based on the identified key causes, keyrecommendations have been made towards energy yield estimation at project design stage and effective O&M practices of solarPV power projects.

Authors(s)

Dr. Ishan Purohit

Sudhakar Sundaray

RENEWABLE

#505

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76

PERFORMANCE ASSESSMENT OF LARGE SCALE SOLAR PV POWER PROJECTS IN INDIA

IMPLEMENTED UNDER NATIONAL SOLAR MISSION

Abstract:

In this communication we have analyzed 15 large scale operational solar PV power projects located in different parts of thecountry towards analyzing their performance. Taking in to account the actual design considerations (solar PV modules, inverters,DC/AC capacities, tilt and orientation etc.) the energy yield of the all selected projects has been estimated through PVSYSTcomputer software using various static (IMD, SEC-NASA, NREL, SWERA) and dynamic (Meteonorm 7.0, 7.1 and SolarGIS) solarradiation and meteorological databases in context of India. The inter-comparability of the annual energy generation has been madewith actual generation versus estimated generation through selected databases. The impact assessment has been carried out viatechno-economic evaluation. The mutual variance in annual energy generation operational projects has been estimated from 3 to20 percent which cause a mutual deviation of 4 to 22% on the levalized cost of electricity.

Authors(s)

Dr. Ishan Purohit

Gaurav Rawat

RENEWABLE

#511

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77

GETS 2016

TECHNO-ECONOMIC EVALUATION OF LARGE HYBRID WIND SOLAR POWER PROJECT IN

JAISALMER (RAJASTHAN), INDIA

Abstract:

In this communication an approach has been explored towards developing large scale hybrid wind and solar PV power projects(HWSPP) at a common place. Under the approach of HWSPPs the optimization has been made from the point of view of three keydimensions namely i) Land, ii) Power evacuation infrastructure and iii) Project Cost.

Authors(s)

Dr. Ishan Purohit

Alok Kumar Jindal

Rahul Tyagi

RENEWABLE

#512

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78

APPROACH NEEDED TO CONVERT MSW INTO VALUE CHAIN FOR THE SOCIETY

Abstract:

Management of MSW is a totally ignored area in India so far. There are many perceptions attached to this subject too. Unfortunately,even Big Corporations have no allocated budgets to process waste in a safe and eco-friendly manner. No big corporates havetaken serious interest in the subject so far, nor is there an adequate policy frame work prevailing around this subject. In many citiesaround the country, a big mountain formed by waste is a very common sight - an occurrence that is the outcome of lack ofscientific and timely processing of waste.MSW also comes with a lot of social issues and human index implications. One needs toassign a cost for not treating MSW in time. Untreated MSW occupies land, causes a bad odour in surrounding areas, and pollutesall ground water and air, while causing spread of diseases. It is the need of the hour to convert this liability into an asset as well asaligning methods and approaches towards this subject.

Although this subject needs a different outlook, it is not difficult to address especially when other countries have establishedsuccessful operations of such waste disposal and energy generation projects. We would like to share our views around thissubject for the larger benefit of society.

Authors(s)

Pankaj PatelPresident & Member on BoardAbellon Clean energy Ltd

RENEWABLE

#522

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GETS 2016

SOLAR RESOURCE ASSESSMENT AND ENERGY PREDICTION IN INDIA:

CHALLENGES AND WAY AHEAD

Abstract:

Renewable energy sources have a prospective towards providing solutions to the upcoming energy problems in India. India hasbeen consistently ranked among the top five countries globally in terms of its market potential for renewable energy. India receivesabundant solar irradiation round the year; with over 300 sunshine days in a year it receives a daily average irradiation varying from4.5 to 7kWh/m2 in most of the geographical areas. Selection of best resource while developing solar energy portfolio is currentchallenge which is ultimately linked with actual energy generation. The accuracy of any solar energy yield prediction is profoundlydependent on the accuracy of the solar resource dataset used. Typically, solar irradiation data are currently not being measured atthe location of the proposed power plant and it is necessary to use alternative data sources to obtain estimates of the irradiationfigures for the site. This paper will explore different resource dataset available for solar energy yield prediction along with pragmaticapproach in selection.

Authors(s)

Omkar Dixit

Gaurav Gandhi

RENEWABLE

#531

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80

CIRCULAR ECONOMY A 5-R STRATEGY FOR SUSTAINABLE ECONOMIC DEVELOPMENT IN

INDIA

Abstract:

In this paper we explore potential and prospects of circular economy in energy sector in Indian context. Using system dynamicsapproach we demonstrate how sustainability improves by implementation of CE in this sector. A multi pronged strategies and toolswould be needed to implement and further integrate it in the 'Make in India' program initiated by the new government by PrimeMinister Modi.

In energy sector circular economy strategy can be implemented by maximum utilization of renewable sources like solar, wind etcand upgrading age old thermal power plants by advance technology inputs, Coal fly ash utilization, reducing transmission wastages,increasing energy efficiency usage by upgrading appliances, gadgets etc.

Authors(s)

Rashmi Varma

R. P. Dahiya

Sushil

RENEWABLE

#533

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GETS 2016

POWER QUALITY ENHANCEMENT AND REACTIVE POWER MANAGEMENT FOR

RENEWABLE POWER GENERATION

Abstract:

The renewable penetration in INDIA is growing at rapid rate due to feasibility for having bulk power generation using solar and windpower plants. However, the intermittent nature of the renewable generation and interconnection of the same with very strong gridat 400kV and 765kV levels is going to be a challenging task. In this context, power quality enhancement and reactive power lossminimization during down time of renewable generation shall be given a key attention. In this paper, the means to achieve reactivepower management for renewable power generation using FACT devices viz. STATCOM, SVC, TCR have been presented. Furthermore,based on down time; the application of Point on Wave (POW) switching to turn off renewable generation to save reactive losses intransformers and long HV cables have been discussed in detail. The necessary modifications in existing structure for ElectricalBalance of plant to achieve the same has also been elaborated. The additional advantages of employing reactive power managementand POW switching in context to asset management and equipment life cycle enhancement have also been presented.

Authors(s)

Dr. Urmil Parikh

Jignesh Patel

Ravi Goyal

RENEWABLE

#539

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82

SODIUM SULPHUR (NAS®) BATTERY FRO RENEWABLE APPLICATIONS

Abstract:

NGK has developed a sodium sulfur battery (NAS® battery) originally for load leveling applications, allowing the grid to deal withincreasing peak. Recent growth in environmentally friendly renewable energies causes network instability. A secondary batterybased energy storage system is seen as one of the optimum solutions to stabilize the network while improving the efficiency andusability of these renewable energy technologies.

NAS battery features long duration discharge, compactness, and a long lifespan of 15 years with DOD 100 %. Capability for longduration discharge is one of the most notable features of this technology, a feature which becomes more important as renewableenergy generation increases. In this paper, it is described how NAS battery system can solve various problems caused by increaseof renewable energies.

Authors(s)

Hiroyuki Abe

RENEWABLE

#545

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GETS 2016

MONITORING & DIAGNOSTICS OF MICRO GRID - AN ESSENTIAL TOOL TO MONITOR ITS

HEALTH AND SAFETY

Abstract:

A good M&D solution should be able to monitor real time generation from plants of heterogeneous vendors in distributed locationsand encompass three essential features.The first is to ensure that asset performance and health risks are identified and resolvedeffectively. The second is to provide detailed visibility into the performance and reliability of the assets in the system. The third isto provide insight into the technology, operation, and benefits of the assets highlighted.

Remote M&D solution enables one to remote monitor all the equipment that is present on the site, without having to be physicallypresent. Functionality like Integration with SCADA / controllers, alarms escalation using email / SMS, web access on mobilephone, integration with existing SAP / ERP systems make the solution more user-friendly. The solution helps in taking informedbusiness decisions and save on operational costs.

Black & Veatch headquarters implemented an in-house microgrid consisting of roof top solar, battery storage system, gas poweredmicro turbines, geo thermal, electric vehicle charging station along with remote M&D. This produces circa1,300 MWh per year.

This paper discusses about issues, features and benefits of remote M&D solution for micro-grids and some case studies ofimplementation.

Authors(s)

Pothala Koteswara Rao

Jacob Ohlhausen

RENEWABLE

#547

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84

DYNAMIC REACTIVE POWER COMPENSATION IN SOLAR POWER PLANTS

Abstract:

Inherently, a typical Utility Scale Solar PV plant draws/absorbs 10 to 20% reactive power from the grid irrespective of Grid Voltageand Grid system reactive power requirement. Typically Solar Plants are located at the fag end of the Grid and connected near therural Load centres. As a consumer of reactive power, with 100GW of ambitious capacity addition of Solar power by 2022, the gridneed to pump 10 to 20GW of reactive power to these plants. This will be fatal for Grid voltage regulation and may lead to collapseof the grid or huge capital investment.

This paper discusses in detail the challenge, various options to mitigate risk and through Plant modeling/simulation brings outsolution such as Dynamic Reactive Power Compensation through Solar Inverters. The paper also discusses several reactivepower capabilities of Solar Inverters and the implementation procedure of Dynamic reactive Power compensation in the solar plantbacked-up by actual results.

Authors(s)

Sudhir Pathak

RENEWABLE

#554

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GETS 2016

ICT BASED WIND TURBINE MONITORING SYSTEM DEVELOPMENT FOR WINDS3000

Abstract:

This paper aims at developing an Wind ICT (information communication technology) based WinDS3000 WTs (wind turbines)monitoring system which can support various wind farms' O&M (operation and maintenance). Wind ICT system consist of foursubsystems which are Supervision, DM (data management), Wind O&M and Helpdesk. We proposed a Wind ICT system frameworkfor differentiated other WTs monitoring system and showed weather, equipment and space status for maintenance plan. And wedescribed system configuration, architecture, data flowchart and user interface.

Authors(s)

Jong-Duk Son

Seung-Man Eom

Sung-Tae Kim

Jeong-Hoon Lee

RENEWABLE

#556

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86

RENEWABLE ENERGY TECHNOLOGY AND GRID RELIABILITY

Abstract:

This paper briefly describes current technology trends, including various aspects of wind generators and inverters and their impacton grid performance. It also indicates the latest generator technology trends and their pros and cons with respect to grid reliability.It explores the supporting mechanism technologies such as battery energy storage and energy forecasting in mitigating the risk ofrenewable energy's generation instability. This paper will help the grid operators and renewable power project developers identifyvarious techniques to increase grid reliability to support the addition of more renewable energy into the grid.

Authors(s)

Chintan Shah

Ashish Khant

RENEWABLE

#589

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GETS 2016

HYBRID RENEWABLE SYSTEM

Abstract:

At GE Global Research GE, researchers are keeping track of emerging trends and challenges in power sector both from local andglobal perspective. GE engineers are constantly evaluating technology solution serving market challenges with optimal utilizationof resources and meeting regulatory requirements. With smart analytics, controls and energy storage/PV integrated Wind Turbinescan overcome challenges with power variability and efficient utilization of deployed infrastructure.

The presentation proposes to introduce these new power architecture and controls enabling turbine integrated hybrid systems.Presentation will cover innovative solutions and key projects deployment experience in the domain.

Authors(s)

Arvind TiwariGE Global ResearchIndia

RENEWABLE

#591

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USING LIDAR SYSTEM FOR WIND TURBINE PERFORMANCE IMPROVEMENT

Abstract:

LIDAR (Light Detection and Ranging) technology allows remote sensing and measurement of the wind field at ranges from 10 mup to 400 m upstream of a turbine. These LIDAR measurements can facilitate determination of turbine performance, optimisationof energy capture, protection against extreme gust events and minimization of structural fatigue loading.

Authors(s)

Rohit Gupta

Vaibhav Korgaonka

Shivprasad Lakhapati

Shrinivas Murthy Goteti

RENEWABLE

#600

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GETS 2016

CHALLENGES AND TECHNOLOGICAL ADVANCEMENTS IN SOLAR ENERGY – THE GREEN

SOLUTION TO POWER SCARCITY

Abstract:

Solar power generation technologies can be broadly classified into two categories (a) Solar photovoltaic technologies (b) Solarthermal power plants. Klemchuk et al (1997),M.G.Figueiredo et al (2008) and Upadhyay et al(2014) not only shared their thoughtsabout solar energy in different forum, but also depicted few important observations about sun tracking system . But total literaturesurvey comprising of challenges and technological advancements of solar energy and solar thermal power plants with a comparisonis really scanty. The annual global solar radiation in average varies from 1600 to 2200 kWh/Sq.m. As, India is sun-kissed countrywith a huge source of renewable energy, practical real time data analysis regarding Solar Energy and different procedures toenlighten the performance of solar energy may broaden the answer to the problem related with thermal energy for a growing steptowards green solution.

Authors(s)

Dr. Suparna MukhopadhyayDGM(TS),TSTPS

RENEWABLE

#609

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90

INCREASING THE FLEXIBILITY OF COAL POWER PLANTS WITH DIGITAL

Abstract:

The massive introduction of solar power creates new challenges for grid operators. Thermal power synchronous productionsources are replaced by non-synchronous sources, thus reducing the grid inertia, grid short circuit power, and available active andreactive power reserves required for grid stability. This becomes critical in solar as demand and generation fluctuate with times ofday. By offering the largest possible range of operation between low load (<< 40% nominal) and maximum load, advanced coalfired power plants have the capacity to balance the active power. The consequence is an increase in the variety of modes ofoperation and the participation requested per unit, in amount and in dynamic. Digital Applications, combining the power of dataanalytics, intelligent models and the real-time status of the plant, are the solution to assist and optimize this new mode of operation.In particular, Digital will bring the following advantages: " Power consumption, stability of combustion, fuel savings, reliability andnet efficiency at low load " Management of thermal transients, steam temperatures and thermal stress levels " Automatic generationcontrol adaptations " Compliance with regulations in all range " Dynamic support availability By increasing flexibility and allowinghigh fidelity control response in a large range of operation, Digital for the coal power plant allows increasing the rate of penetrationof renewable power, still maintaining reliable power delivery and grid safety. In present energy transition period, by being thepermissive for renewables acceptance, Flexible Coal contributes widely to decrease the CO2 emissions.

Authors(s)

Olivier DrenikGE Steam Power Systems

Sam O'LearyGE Steam Power Systems

Christoph GundertGE Steam Power Systems

John L. MarionGE Steam Power Systems

RENEWABLE

#616

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91

GETS 2016

FORECASTING AND SCHEDULING OF WIND AND SOLAR POWER GENERATION IN INDIA

Abstract:

Wind and solar energy are the major components of renewable energy in India but the variability and unpredictability inherent towind and solar power raise a number of issues associated with grid integration. The integration of significant wind and solar energyinto existing supply system is a challenge for large scale renewable energy penetration; hence the day-ahead and short-termrenewable energy forecasting is needed to effectively integrate renewable power to the grid. As per CERC regulation, FOR regulationand different state regulations, day-ahead forecasting and scheduling of wind and solar energy is required to be submitted by IPPsand hence the forecasting and scheduling of renewable energy has become a widely pursued areas of research at Indian context.Though there are different methods in forecasting renewable power generation, in this paper, we are showing how the mixedapproach technique using artificial intelligence, the algorithm of which are developed by del2infinity, is useful in forecasting of windand solar power generation. Since the regulation deals with the deviation settlement mechanism due to erroneous forecast results,this paper also shows the theoretical structure and simple penalty calculation methodology using probabilistic model for differentscenarios of forecast accuracy. The approximate statistical model correlating forecast accuracy and penalty due to erroneousforecast can act as an essential tool in maximizing the energy accuracy to minimize the penalty due to deviation.

Authors(s)

Abhik Kumar Das

RENEWABLE

#619

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92

POTENTIAL AND SUITABILITY OF WASTE BIOMASS FOR HARNESSING RENEWABLE

POWER AT NTPC STATIONS

Abstract:

Owing to its virtues, biomass gasification in India could play a key role in the electrification of rural and remote communities if wegave a solution of continuous supply chain, suitable technology to utilize abundantly available Biomass. Keeping above in mind, asystematic study has been carried out for availability and suitability of waste biomass to produce renewable power at one of theNTPC station. This paper covers the study of waste biomass (wood/stem, leaves and grass) w.r.t its ability to use as fuel for powergeneration. Quantity of biomass (wood/stem, grass and leaves) was found to be around 1033 MT/yr. Out of which, woods/stem(332MT), leaves (146MT) and grass (555MT) are in the range. Woody part shows high flow ability, positive ignition test and ashfusion temperature more than12000 C. Woody part can easily be gasified. On the basis of available quantity & suitability of woodybiomass, 2X50 kW biomass power is being developed at NTPC Singrauli. Rest of the biomass i.e. grasses and leaves havepotential but not been utilized so far due to low ash fusion temperature, poor flow ability, poor bulk density etc. To utilize this,NETRA has installed a 250 kg/hr briquetting plants for carrying out experiment on briquettes of un-utilized grass and leaves.Analysis of two sets of briquettes of grass and leaves (1-pure form & 2- mixture) have been carried out . In the 2nd set ofexperiments, several types of briquettes were made of grass and leaves having wheat straw ( 5%) and mill rejects (1-2%).Proximate analysis of briquettes were carried out and their results are given here, moisture%(4.35-5.11),ash% (35-40.1),VM%(51-53),fixed carbon% (18-22)

Authors(s)

Dr. H N Pandey

N C Jain

RENEWABLE

#647

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93

GETS 2016

GREEN ENERGY CLEAN ENERGY: A POTENTIAL USAGE OF CW CHANNEL FOR GREEN

POWER GENERATION

Abstract:

In the era of growing power sector, land or space utilization is a basic challenge for any power generating company. At the sametime production of green and clean energy has become a necessity for the power companies with the strict environmental norms.Solar photovoltaic cell and hydrokinetic turbine are the two best feasible options in view of the best utilization of space andproduction of environment friendly power, among the existing technologies for green off- or on-grid power generation in a runningthermal power plant. Nowadays solar PV cells are widely used for commercial and domestic applications and the cost of PV cellshave been drastically reduced. However, requirement of huge space is a challenge for Solar panel installation. To overcome this, anunused space like circulating water (CW) channel has been proposed in this paper. Talcher Super Thermal Power Station (TSTPS,6 x 500 MW) CW channel for Unit-1, 2, 3 & 4 has approximately 1.5 km stretch and 5-8.5 m width. Solar PV cells can be installedover the CW channel with help of suitable support frame structure. However solar PV has certain limitations, such as, only daytime operation, limited power production during cloudy weather, regular cleaning of receiver surface, etc. For further utilization ofCW channel and to compensate the limitation of PV cell, hydrokinetic turbine can be introduced to generate green power fromunder water current of CW channel. It has a minimum potential of 600 kW of combined power generation. The estimated projectcost for green technology based solar- water power generation in TSTPS CW intake channel of U#1-4 CW pump house isapproximately Rs. 5.0 - 7.0 Cr for minimum of 600 KW power generation. Solar - water green power generation system in the CWchannel area at TSTPS site can be a great initiative of off-grid or on-grid green power production.

Authors(s)

Dr. Krishnendu Saha

Anshu Kumar

RENEWABLE

#653

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94

PRECIPITABLE WATER EFFECT ON SPECTRAL SHIFT AND SOLAR PV MODULE ENERGY

Abstract:

Photovoltaic (PV) module technologies are characterized according to Standard Test Conditions (STC) as per IEC 60904-3. Thisstandard defines reference conditions at an irradiance level of 1000 W/m2 and an ambient temperature of 25 °C; less commonlyknown is that the standard also defines a spectral irradiance distribution characterized by ASTM G173. The G173 spectrumrepresents terrestrial solar irradiance at each wavelength under specified atmospheric conditions, as different atmosphericconstituents absorb and/or reflect irradiance at particular wavelengths. Just as module performance will vary from its characterizationat STC due to field temperature and irradiance levels, module performance is also affected by the actual spectral irradiancedistribution. The effect of spectrum on module performance is known as spectral shift, and this article will discuss the impact ofthis effect on various PV technologies, details of spectral shift observed in the field and recognized by Independent third partylaboratories and how spectral gain can be modelled into energy prediction. The inclusion of spectral variation into energy modelshas the potential to improve prediction accuracy which will lower the risk of projects failing performance commitments, and makeprojects more bankable and easier to finance.

Authors(s)

Amit Kumar MittalTechnical DirectorFirst Solar Power India

Kendra PassowPerformance andPrediction EngineerFirst Solar

Mitchell LeePerformance andPrediction EngineerFirst Solar

RENEWABLE

#688

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GETS 2016

INNOVATIVE GAS MIXING TECHNOLOGY AS CORE ELEMENT FOR UTILIZATION OF BIOGAS

IN COMBUSTION PROCESSES

Abstract:

These days the increase of renewable fuel share in power generation represents a global endeavor. In this course it is a strong trendto utilize Biogas as well as other process related Off-Gases within various industrial applications. The major prerequisite for thispurpose is to ensure an excellent conditioning of the combustible fuels. Gaining highest efficiency in view to the blending withcommon Fuel Gases and the ability to feed most modern as well as economical combustion systems are the key factors for theconditioning process.

Due to the low calorific values of the utilized Biogas or Off-Gas the blending with a regular fuel gas - like e.g. natural gas - isrequired for which the wide quality fluctuation range of the renewable combustibles represents a hurdle in regards to efficiency. Torealize a stable quality the respective technology for Gas Mixing has to be rapidly adaptive ensuring quality fluctuations will beimmediately balanced.

Innovative Gas Mixing Valves are providing the answer for this challenging task. By means of downstream calorific value meteringthese Units are able to spontaneously control the mixing ratio fully automatically with parallel precise flow regulation for anoptimum furnace feed. Case studies from European sites in which the devices have been deployed are proving the extremelysatisfactory performance of this particular state of the art technological approach.

Authors(s)

Stephan SIMONManaging Director,KUEHME Armaturen GmbH,Bochum - Germany

Patrick KOHLSSenior Sales Manager,KUEHME Armaturen GmbH,Bochum - Germany

RENEWABLE

#697

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96

OPERATIONAL EXPERIENCE WITH GASIFICATION OF BIOMASS PELLETS

Abstract:

BHEL is having vast experience with Fluidised Bed Gasification technology using coal to generate synthesis gas (syngas). One ofthe advantages of the Fluidised bed gasification is fuel flexibility. Experiments were carried out in Advanced Pressurised FluidisedBed Gasification (APFBG) test facility available at BHEL, Corporate R&D using Biomass in the form of pellets. Two types ofbiomass materials were gasified, one is made of Rice husk and the other is of saw dust powder. The gasification performance wasevaluated at atmospheric pressure and temperature in the range of 850-950 °C. The range of syngas calorific values obtainedthrough this experimentation was closely meeting the required end applications. The operational issues were discussed in detail.

Authors(s)

A.Gunasekaran

C.Thirugnanam

N.Siva Rama Krishna

D.Satya Mohan Rao

RENEWABLE

#700

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97

GETS 2016

MODULAR SOLAR SYSTEMS FOR 24X7 ELECTRICITY AND PROCESS HEAT

Abstract:

Successful electrification of India requires dependable power all the time, 24x7. But few clean emissions power technologies canoperate as baseload plants 24x7. Concentrated solar power (CSP) can because it stores energy at 10-15% of the cost of batteriesand can then burn fuel when its solar resource is exhausted. However, many see first generation CSP as too costly, complex, risky,and economical only at utility scale. Alternatively, by mimicking the all-factory, standardized, modular approach of wind and PV,next generation CSP with low-cost dry thermal storage (i.e., not molten salts), and using no water/steam (just hot air) may giveCSP the potential to fulfill on its baseload promise. A major Engineering and Cost Feasibility Study funded by the US Department ofEnergy shows that through mass production, modular CSP systems with dry thermal storage may be able to compete against allpast and current forms of baseload power generation.

Such modular CSP systems also offer continuous industrial steam-grade heat for a wide variety of applications, such as forabsorption chilling; water purification; crop drying; etc. Systems can be stand-alone off-grid or be connected to a grid. Most of thesystem components can be made in India are are proven and off-the-shelf. Such modular CSP systems can be installed as singleunits of 400kWe at village or industry scale, or can be assembled into large power plants. Such systems stabilize grids byresponding nearly instantaneously to changing power demands and voltage fluctuations, similar to batteries, while offeringdispatchable, reliable electricity. The redundancy of multiple modules increases overall grid and system flexibility and reliability.

Authors(s)

Bruce N. Anderson247, Solar Inc.

R. K. Sikri

RENEWABLE

#707

Pranav Mehta

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98

CONTROL SYSTEM FOR MICROGRID

Abstract:

The heart of a microgrid is the microgrid controller that manages all parameters of load and generation assets for the most reliableand cost-effective operation. In this white paper, the technical characteristics of microgrid and the controller that manages themicrogrid will be covered in further details.

Authors(s)

Anik Agrawal

RENEWABLE

#714

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GETS 2016

HARMONICS AND RESONANCE ISSUES IN SOLAR PLANTS INTEGRATED TO THE GRID

Abstract:

The paper elucidates the key harmonic issues that need to be investigated while interconnecting large solar power plants to the gridwherein there is a need to comprehensively assess the harmonic impacts of the solar projects on the power grid and vice versa.Harmonic resonance issues in renewable energy systems have been studied extensively in recent times since the large-scaleemergence of renewable energy sources and interconnection to large grid and distributed networks for a detailed overview ofresonances. Such systems contain both capacitive and inductive elements and therefore always have one or more natural resonancepoints, of either parallel or series resonance type, or both.

Modern renewable energy systems containing power electronic converters can produce a spectrum of harmonics over a widefrequency range. Further, other sources of harmonics may be present, such as harmonics generated during grid side disturbances.If a harmonic generated by the renewable energy generators is close to a naturally occurring resonance point of the system, thereis a potential for sustained resonance. Such conditions must be identified at the design stage of a generation interconnectionproject to avoid undesirable situations such as equipment damage and power curtailment.

Integration issues and challenges for DER with a case study of 5MW Dadri Solar Plant integrated to 220KV grid are also discussedwherein field studies were done for inverters tripping on load increase, simulation studies based on modelling and implementationof solution done thus mitigating overvoltages and THD (Total Harmonic Distortion).

Authors(s)

Sunil Chandra DasAddl Gen Manager(EM)NTPC Ltd- Farakka

RENEWABLE

#731

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100

CASE STUDIES IN THE USE OF ENERGY STORAGE TO ACHIEVE HIGH PENETRATION OF

RENEWABLES IN WEAK GRIDS

Abstract:

When penetration of renewable generation in weak grids exceeds about 50%, energy storage is considered mandatory. Casestudies are presented for the use of lithium-ion energy storage in a variety of weak grids and microgrids with high renewableenergy penetration, including the ability to run with diesels off.

Authors(s)

Jim McDowallSaft America Inc.

RENEWABLE

#760

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GETS 2016

SEA WATER PUMPED STORAGE POWER PLANT-CONCEPT PAPER

Abstract:

Today there are plenty of energy storage technologies available including battery Storage which looks promising but only whenused in electric vehicles, emergency situations or grid stability. But for large Grid size energy storage the pumped storage plantsstill proves to be the best bet in terms of economy, reliability & technical maturity. Sea Water Pumped Storage is a type of artificialpumped storage scheme which harness coastal mountainous topography and abundant seawater. A sea water pumped storageprovides a simple solution for storing electrical energy minus the problems associated with the conventional hydro plants ofobstructing natural freshwater flow, high cost of building dams, water availability etc. India which has almost 3500 km coastlineand islands dotted with mountainous topography such plants of the scale of MW to Few MWs can be readily built.

In this paper, the merits and demerits of various types of energy storage technologies have been discussed. We have also done astudy which demonstrate the importance of energy storage in an Island (isolated grid condition) where they become an absolutenecessity if substantial renewable energy addition is done. Further, a preliminary techno economic study is presented for constructionof a typical sea water pumped storage plant at any suitable site (inland or in an Island) in India.

Authors(s)

Prashant Pandey

Dr. Anubhav

Pawan Kulmi

Amar Kumar Prasad

RENEWABLE

#765

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102

INTEGRATION AND FULL ABSORPTION OF RENEWABLE ENERGY IN THE INDIAN GRID

Abstract:

India has demonstrated its intention by announcing an ambitious target of adding 175 GW of renewable energy generating plantsby the year 2022. The problems of variability and intermittency of solar PV and wind turbine plants are well known, and integratingsuch large-scale addition into the grid would be particularly challenging and could threaten the reliability of the system. Recognizingthis, Power System Operation Company (POSOCO) came up with a set of recommendations suggesting, among other things, thata certain mix of 'flexible generation" is required to counter the variability. A wider transmission network alone cannot balance thesystem demand and variable generation in real time.

A report released in April 2016, by The Technical Committee for "Large Scale Integration of Renewable Energy, need for balancing,Deviation Settlement Mechanism (DSM) and associated issues" after several rounds of discussions has recommended a set ofactions to be implemented to ensure such large -scale absorption of renewable energy, without affecting the reliability of the grid.

This paper will present a practical solution that will help fulfil many of the recommendations put forth by the Technical Committeereport cited above.

Authors(s)

M.Rajagopalan

Zakir Khan

RENEWABLE

#771

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GETS 2016

OPTIMAL SYSTEM FOR WIND-SOLAR HYBRID

Abstract:

MNRE in its policy is promoting Wind-Solar Hybrid for optimal and efficient utilization of transmission infrastructure and land,reducing the variability in renewable power generation and thus achieving better grid stability.

There are multiple ways of integrating solar with wind farm viz., Standalone systems, Co-located / Farm level integration (ACintegration), Turbine Integration (DC integration) to utilize infrastructure more optimally.

The paper focuses on:

a) Comparison of various integration schemes along with its benefits and eludes to the optimal integration scheme to efficientlyutilize transmission infrastructure

b) Aspects of "Hybrid controls" which is paramount for managing two forms of energy.

c) Key aspects of developing a "Hybrid Farm": Requisite evaluations and analysis.

Authors(s)

Anand RevankarGE Renewable Energy

Nagesh PGE Renewable Energy

RENEWABLE

#781

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104

GRID INTEGRATION OF VARIABLE GENERATION: KEY LESSONS LEARNED

Abstract:

Global solar installation is expected to grow rapidly from the current global installed base of ~250GW to over ~700GW by 2020driven to a great extent by the rapidly decreasing solar generation costs. The characteristics of this variable generation (which alsoincludes wind) - variability, uncertainty, and non-synchronous generation-present reliability and stability concerns for the bulkpower system, especially at higher penetration. Several grid integration best practices that have emerged to address these concernswill be discussed in this presentation. Some of the key lessons learned based on our experience in developing and operating over3 GW of utility-scale PV plants ranging in size from 10MW to 550MW will be discussed. By leveraging experience in wind industry,we have developed grid friendly PV plants that actively stabilize the power grid and address grid reliability concerns. The operationalcharacteristics of utility-scale PV plants with advanced features and capabilities such as voltage regulation, active power controls,ramp rate controls, fault ride through, frequency droop control and others will be discussed. In addition, the role of forecasting andenergy scheduling to manage the variable generation and address the load balancing concerns faced by grid operators will bediscussed. The increasing interest in electric storage technology as well the use of PV plants to provide ancillary services will bediscussed as well.

Authors(s)

Mahesh Morjaria, Ph.D.

RENEWABLE

#785

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GETS 2016

REUSE

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106

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GETS 2016

ELECTRODEIONIZATION – AN INNOVATIVE & SUSTAINABLE WATER TREATMENT TECH-NIQUE FOR POWER INDUSTRY

Abstract:

Water being an essential resource for life, sustainable growth and healthy ecosystems, has been high on the industrial requirement.The water requirement for industries especially power sector is substantial high. De-mineralized water is one of the key inputresource required in boilers and its quality directly impacts the process efficiency. Offlate, DM plant has been the most populartechnology to meet the DM water requirements in power plants, however it is associated with limitations to control certain parameterslike Colloidal silica, TOC, BOD , COD etc. Electro Deionization has emerged as one of innovative and sustainable water treatmenttechnique that can substitute the existing DM water treatment plants in power plants. The EDI technology has been industriallyacknowledged in many power plants across the globe and has given an effective treatment and sustainable water solution toprocess industries.

EDI is a process which combines semi-impermeable membrane technology with ion-exchange media to provide a high efficiencydemineralization process. Electro dialysis employ electrical current and specially-prepared membranes which are semi permeableto ions based on their charge, electrical current, and ability to reduce the ions based to their charge. The electrical current is usedto continuously regenerate the resin, eliminating the need for periodical regeneration. The EDI process produces industrial processwater of very high purity, using less than 95% of the chemical products used in the conventional ion exchange processes.

Authors(s)

Prag SoodTel. No.: +91 9404951546Email: [email protected]

Priya SL

#502

REUSE

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108

CONDENSATE POLISHING UNITS FOR THERMAL POWER STATIONS

Abstract:

Condensate polishing has been adopted in thermal power stations to reduce the level of impurities in the feed water during variousoperating conditions of the turbo-generator unit, thereby preventing corrosion/scaling of internal surfaces of heat exchangers andboiler tubes. In addition, the need for condensate polishing has also been justified for producing high purity steam, reducing thechance of boiler tube failures and consequentially reducing demineralized and raw water consumption.

The consequences of poor feed water quality from polishing plants, or cross contamination of resins due to improper separationand regeneration processes could cause serious damages to the heat cycle and at times even result in shut down of the unitresulting in considerable revenue losses. A proven design of polisher units and selection of the regeneration technologies aretherefore absolutely essential for the safe and successful operation of the heat cycle.

This paper will provide the technology status of condensate polishing plants for sub critical and super critical power stations alongwith associated feed water chemistries, types of resins used, need for pre-filtration, technologies of resin transfer/separation/regeneration and O&M considerations. A strategy to implement cost effective condensate polishing plants for upcoming powerprojects and Renovating & Rebuilding existing power plants in India will also be discussed.

Authors(s)

Venkatesh KrishnaswamyCommercial EngineerGE Power & WaterTel. No.: + 91 9886028867Email: [email protected]

#514

REUSE

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GETS 2016

A SCALEABLE FORWARD OSMOSIS BASED ZLD PROCESS FOR WASTEWATER STREAMS INCOAL-FIRED POWER GENERATION

Abstract:

This paper will discuss the opportunities for incorporation of forward osmosis into power wastewater management in coal powermarkets worldwide. In particular, it will highlight the design, start-up, and operation of a zero liquid discharge plant treating flue gasdesulfurization wastewater at a coal-fired power facility in China, as well as new projects currently being executed. These projectsinclude at their cores a similar forward osmosis based Membrane Brine Concentrator System design to provide flexibility andreliability as wastewater feed conditions change seasonally and with plant operation.

Authors(s)

John TracyDirector,Marketing and Commercial OperationsOasys Water, Inc.E-mail: [email protected]

#517

REUSE

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110

ON SITE CATALYST REGENERATION TO REDUCE THE OPERATION COST AND MINIMIZEENVIRONMENTAL IMPACT

Abstract:

Catalyst regeneration is a state of the art technology to:

• reduce total operation costs of an SCR system dramatically in combination with a strategic catalyst management program

• avoids unnecessary raw material consumption and therefore contribute to the positive environmental impact

• avoids excessive generation of waste materials and reduce the risk of waste handling

The paper looks into the different catalyst deactivation mechanisms and show strategies how to remove this impacts to recoveroriginal plant performance. The investigation not only covers chemical deactivations, but also impacts on the physical properties.

The key focus is sharing experience on several case studies of executed projects in Europe, Asia and US. Special attention is givenon coal fired High Dust applications using Honeycomb or Plate Type Catalyst. The presentation will give insights on required siteactivities with the related space requirements and schedule for each of the working steps.

To highlight the cost benefit of a catalyst management - including reaeration and reuse of catalyst - a financial comparison ofdifferent approaches and strategies is given.

Further the topic of catalyst testing will be covered as it is key to ensure the required regeneration quality and achieve the necessaryDeNOx performance of the SCR system. It is also a mandatory input to optimize the catalyst management process and thereforeminimize the operation cost of the power plant.

Authors(s)

Richard BudinE mail: [email protected]

Christian LechnerE mail: [email protected]

#527

REUSE

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GETS 2016

A NEW APPROACH TO SEA WATER BASED FLUE GAS DESULPHURISATION

Abstract:

1200 MW Ratnagiri power plant of JSW Energy is a coastal plant and was ready for commissioning when MOEF enforced a newcondition making Flue Gas Desulphurization (FGD) installation a must for plant operation. First choice was to install sea waterbased FGD but that would mean drawing of additional sea water leading to substantial additional expenditure and time delay. Thealternative was to install lime stone based FGD. However, installing lime stone based FGD in coastal plant means losing economicadvantage of sea water based FGD and hazard in disposing waste. This innovative method conceived and implemented by TataConsulting Engineers(TCE), made it possible to install sea water based FGD by eliminating the need for additional sea waterdrawal, saving time and about Rs 60 crores and Rs 6 crores in Capex and Opex to our customer. This innovative scheme is alsoideal for both new and retrofit FGD installations for coastal plants. TCE have filed application for Patent in Feb 2014 and has beenpublished in India Patent Website and pending for examination before final grant of Patent. This innovation and also won TataInnovista award- 2014, a Tata in house Annual Innovation content amongst Tata group companies across globe under PromisingInnovation Core process category. This innovation was also presented in finals of Confederation of Indian Industry (CII) for Top 26most innovating companies held in year 2014.

Authors(s)

A K ChaudharyDy. General Manager (Mech)Tata Consulting Engineers Ltd (TCE),BangaloreTel. No:+91 80 6622 6160E Mail: [email protected]

#534

REUSE

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112

MOVING TOWARDS ZERO LIQUID DISCHARGE

Abstract:

Water scarcity, high cost of raw water, growing demand and stricter discharge norms have created an opportunity for the powerindustry to move towards efficient zero liquid discharge. Power industries require large volumes of water particularly for condensercooling. Due to this requirement they are usually located close to surface water sources such as lakes, rivers or the sea. Withincreasing water scarcity, the power sector faces dwindling supplies of fresh water. This has compelled power stations to look forcost-effective, integrated solutions that provide continuous quality water supply along with conserving, recovering and reusingwater.

This paper very specifically highlights a case study where a large thermal power plant has adopted state-of-the-art process toconvert treated sewage as its only source of water for process and utility applications.

The paper also attempts to present how industries that have installed our zero liquid discharge (ZLD) systems in India and globallyhave gained an excellent payback on their investment apart from helping them overcome water scarcity problems by effectivelyand economically recycling vast volumes of waste water and protecting the environment while generating substantial savings.

Authors(s)

Ajay PopatTel. No.: +91 9324002404Email.: [email protected]

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DEMONSTRATION OF A THERMAL ZERO LIQUID DISCHARGE (ZLD) SYSTEM FOR FGDWASTEWATER TREATMENT

Abstract:

In a coal fired power plant particularly, installation of a thermal zero liquid discharge system which consists of evaporators israpidly increasing to treat wastewater from flue gas desulfurization process. To demonstrate the performance of Doosan ZLDsystem for FGD wastewater, a new demonstration plant of 100 m3/d capacity was built in Yeongheung power plant of Korea South-East Power Company in 2016 and the commissioning test was finished in April 2016. It consists of one effect of vertical tubefalling film evaporator equipped with a mechanical vapor re-compressor (MVR), one effect of forced circulation evaporator equippedwith a thermal vapor re-compressor (TVR), and sludge treating system which consists of a centrifuge and a vacuum dryer. Duringa long term continuous operation, the TDS value range of feed stream which is an effluent from primary treatment process was13,000 ~ 20,000 mg/l, an averaged feed flow rate of the demonstration plan was 4 m3/h and the recovery ratio of treated distillatewas 98 %. The overall heat transfer coefficient affected by scale formation was monitored and the dosing rate of antiscalant /antifoam chemical was verified. Sludge characteristics and the composition of mixed salt was also analyzed. Furthermore, entiretreated water with high quality has been supplied to the filtrate tank of FGD process to reuse it as make-up water of FGD process.

Authors(s)

Sangmoon Kim

Weekwan Kang

Gunmyung Lee

Hyungkeun Roh

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DEVELOPMENT OF DOOSAN HIGH RATE CLARIFIER USING SLUDGE RECIRCULATION FORWASTEWATER REUSE

Abstract:

Coagulation-sedimentation is one of the basic processes used in water and wastewater treatment fields. High rate clarifier isdeveloped to resolve the issue of large footprint requirement of conventional coagulation-sedimentation. To improve the sedimentationtank performance, the sedimentation tank performance and chemical dosing were set to key performance index. Various conceivedstructure shapes of the inner sedimentation tank were analyzed by CFD and the jar test for chemical dosing was verified by pilottest for 12 months. The test results showed that the average turbidity removal rate was 67.2% and average total phosphorusremoval rate was 84.3%. These results implied that the developed high rate clarifier could be applied in various water and wastewatertreatment fields including the tertiary treatment and the water containing high suspended solids such as CSO (Combined SewerOverflow).

Authors(s)

Sang eun NohJunior Research EngineerDoosan Heavy IndustriesE mail: [email protected]

Hyun Keun RohPrincipal Research EngineerDoosan Heavy IndustriesE mail:[email protected]

Jin hee MinLead Research EngineerDoosan Heavy Industries.E mail: [email protected]

Youngjun RoJunior Research EngineerDoosan Heavy IndustriesE mail: [email protected]

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UTILIZATION OF COAL WASHERY REJECTS FOR POWER GENERATION

Abstract:

Beneficiation of non-coking coal in India was not given due importance till 2000 or so, due to its low calorific value and lower costcompetitiveness. However realizing the low useful heat value of non-coking coal coupled with stringent environmental requirementswith respect to ash generation, many coal industries in India are forced to set up non-coking coal washeries. The coal washeryrejects is a by-product of coal washery extracted after washing of coal. Depending upon the quality of coal being washed, rejectsare generated from the washery containing ash percentage more than 50 to 60%. The calorific value varies in between 1200 to2000 kcal/kg. The disposal of coal washery rejects is a big problem mainly due to stringent environmental norms. The paperoutlines potential uses for coal washery rejects as an alternative option for thermal power plants either in raw state or after suitablebeneficiation

Authors(s)

T.Gouri CharanTel. No.: +91 9431954315Email: [email protected]

P.S.Prasad

U.S.Chattopadhyay

S.K.Kabiraj

K.M.K.Sinha

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WASTEWATER TREATMENT AND REUSE - AN OVERVIEW OF THE REFINERY EFFLUENTRECYCLE PLANT AT PARADIP

Abstract:

The primary function of the Effluent Treatment Plant (presently under execution) at the 15 MMTPA refinery and petrochemicalcomplex located at Paradip, Orissa, India is to render the refinery effluent for reuse, and to ensure that any effluents discharged tothe environment are compliant with regulatory requirements. Different trains of effluents comprising contaminated streams fromprocess units, spent caustics, landfill leachate, contaminated rain water, regenerate wastewater and blowdowns are treated in theEffluent Treatment Plant. The plant treats around 1356 cu.m/hr. of oily waste streams employing biological treatment (Extendedmode activated sludge process) followed by a water recovery plant comprising rapid gravity sand filters, ultra filtration and reverseosmosis with a design flow of 1941 cu.m/h catering for future requirement. The design recovery of the plant is 78.0%. In parallelspent caustic stream of up to 10 cu.m/h are collected and treated separately by wet air oxidation process, as along with separatetreatments for Landfill leachate and Hard COD reduction in RO Reject before its discharge to sea. The plant is an example of howconstraints on water resources often dictate additional wastewater treatments and compel the petrochemical industries to examinewater recycling strategies more closely which can make water recycle an attractive option.

Authors(s)

Dr. Yagna PrasadChief Technology OfficerTechnology DivisionVA Tech Wabag Limited, ChennaiTel. No.: +91 9380569910Email: [email protected]

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RE-USE OF TREATED SEWAGE & MUNICIPAL SOLID WASTE INTHERMAL POWER STATIONS

Abstract:

Besides producing power, Thermal power stations can become scavengers of waste produced from domestic operations. Reuseof liquid and solid waste generated from near by urban/ rural areas can create a win win situation for the industry and populationaround it. Thermal power stations can be user for both liquid and solid waste.

The treated water from sewage treatment plants can be reused for huge cooling requirements in Thermal power plants. This willspare large quantity of drinking water for domestic use. Reusing treated sewage water can give water security to Thermal powerplants in present water scarce situations in large part of our country.

Refuse derived fuel (RDF) generated from solid waste treatment plants of urban areas can be used as fuel in Thermal power plants.By purchasing and reusing RDF, Thermal power plants can make the solid waste treatment plants a more viable option there bypromoting its treatment.

Present paper discusses various technologies available and successfully implemented in Indian conditions to achieve above goal.

Authors(s)

Satya Narayana Y V VTel.No.: +91 961898808Email: [email protected]

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THE IMPACT OF SYSTEM PARAMETERS ON LJUNGSTRÖM® GAS-GAS HEATER SELECTIONFOR WET FGD APPLICATIONS

Abstract:

Stack Gas Reheat (SGR) can protect equipment downstream of a wet scrubber from corrosion, reduce the potential for acidrainout near the plant stack, preclude visible stack plumes, and reduce ground level pollutant concentrations by increasing plumebuoyancy. A number of SGR systems have been utilized since the introduction of wet scrubbers with gas-gas heaters (GGH)becoming the industry standard. The global use of GGH has provided the industry with valuable knowledge and experience todemonstrate its suitability for the application, and proper sizing of the GGH can help to optimize both the capital cost and operating& maintenance costs of the wet flue gas desulphurization (FGD) system. There are many factors that can impact the sizing andconfiguration of the Ljungström® gas-gas heater, and selecting the correct amount of reheat downstream of the FGD is essential.Too little reheat may increase the risk of corrosion problems in the ductwork and stack. Too much reheat can result in extremelyhigh system costs, of both equipment and operations.

This paper will introduce the Ljungström GGH technology for wet FGD applications, and present the effects of stack reheattemperature specifications on the sizing, configuration and costs of the Ljungström GGH for power plants in India. Typicalapplication data will be used to highlight the complexities of the application and the importance of stack reheat temperature, andimpacts on many key areas such as GGH operation and maintenance costs, sizing and cost of booster fans, FGD water consumption,etc.

Authors(s)

Gary MerglerDirector, SalesLJUNGSTRÖM, 3020 Truax Road,Wellsville, NY 14895, USA

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COMBUSTION SYSTEM OPTIMISATION FOR APPLICATION TO THE INDIAN MARKET

Abstract:

The Environment Ministry of India recently issued new emission standards for both new and existing coal based thermal powerplants. The new standard mandates that units installed before December 2016 comply with a Nox target of 300 mg/Nm3 and unitsinstalled after January 2017 achieve a Nox target of 100 mg/Nm3. To meet this demand Doosan Heavy Industries (DHI) havedeveloped a high perforance, low Nox, high wear resistant wall-fired combustion system suitable for both retrofit and new buildapplicaitons and offers a powerful solultion to meet India's Nox emission targets.

This paper provides details on the 3 year development of Doosan's state-of-the-art combustion system that focused on low Noxperformance, wear resistant component developemnt and optimised performance at maximum turndown. Using a combination ofnumerical simulation via Computational Fluid Dynamics (CFD), physical modelling and large-scale combusiton testing, an optimumdesign suitable for both new build and retrofit applications, was developed. This unique features and key components of thecombustion system will be discussed along with performance results from pilot and full-scale testing.

Authors(s)

Moresh Wankhede

Euan Cameron

Allan Love

Sandy Black

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4-E ANALYSIS OF A SOLAR ASSISTED AND KCS11 INTEGRATED COAL – FIRED THERMALPOWER PLANT FOR FLUE GAS WASTE HEAT RECOVERY

Abstract:

This paper proposes a thermodynamic performance analysis based on 4-E (Energy, Exergy, Environment, and Economic) of asolar assisted air-preheater and Kalina Cycle System 11(KCS11) integrated 500MWe Subcritical (SubC) coal-fired thermal powerplant for additional electric power generation through flue gas waste heat recovery. Ammonia-water (NH

3-H

2O) binary mixture is

used as a working fluid for the KCS11.

A typical high-ash Indian coal is considered for the analysis. The flow-sheet computer programme 'Cycle-Tempo' is used tosimulate the plants at different operating conditions of the plant. Results show that the net energy and exergy efficiencies of thesolar assisted combined plant are increased by 0.10 % point and 0.09 % point, respectively over the standalone 500MWe SubCthermal power plant. Reduction of flue gas exit temperature from 145°C to 120°C resulting in an additional net electric powergeneration of about 1 MW and the annual CO

2 emission is reduced by 1,970 t.

The cost of fuel saved for integrating the technology is about Rs.9.226 /- per kg of fuel which is about 6.15 times higher than thefuel cost. The LCoE of standalone solar thermal power plant is about 84.23% higher than the solar assisted air-preheater andKCS11 integrated thermal power plant. Therefore, the novel concept of combined plant based on solar assisted air-preheating andKCSS11 will be a good choice for energy efficient, environment friendly, and economically viable power generation in future.

Authors(s)

Goutam KhankariExecutive Engineer (Mechanical)Mejia Thermal Power Station,DVC, Bankura, India.E mail: [email protected]

Dr. Sujit KarmakarAssistant Professor,Department of MechanicalEngineering, National Institute ofTechnology Durgapur, West Bengal,IndiaTel. No.: 91 9434788144E-mail: [email protected]

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TECHNO- EFFECTIVENESS IN ENERGY CONSERVATION/ GENERATION - "REUSE"

Abstract:

Resource that go into power stations (of any type) like land, water, spares, equipment etc or its outcomes like heat, flue gas, wastewater, wastes, ash, gypsum, catalysts, chemicals, municipal solid waste (MSW), coal mill rejects, coal washery rejects etc.

Conserving energy has become the biggest issue in present scenario. This paper proposes a cheap and effective method fordesign and manufacturing of Reusable power generation. Due to the development and modernization the electricity demand isincreasing at high extent. To fulfill this demand globally which is without any harmful effect on environment is possible by usingReusable of resources for power generation.

Authors(s)

Abinash PandaKirloskar Pneumatic Company LimitedTel. No.: + 91 9717716686Email: [email protected]

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122

INDUSTRIAL WATER REUSE

Abstract:

The term wastewater reuse is often used synonymously with the terms wastewater recycling and wastewater reclamation. Waterreuse is defined as "using wastewater or reclaimed water from one application to another application".

Fresh water scarcity & stringent environmental norms against wasting water has increased the importance on recycling & reuse ofwater by waste water treatment systems in modern day world. In addition to conserving natural resources of water from depletion,reuse of waste water also helps in minimizing the environmental impact caused by discharge of waste water / effluents.

The major types of Water Reuse are as follows:

1. Urban reuse

2. Agricultural reuse

3. Recreational impoundments

4. Environmental reuse

5. Industrial reuse

This paper plans to highlight the importance & merits of the industrial water reuse concepts with case studies wherein, it wassuccessfully implemented by BHEL at Raw Water Treatment Plant of capacity 4000 m3/hr (96 MLD), at OPAL, Dahej, Gujarat.

Authors(s)

M.Natarajan I.M.Ramalingeswara Rao

S.VivekE mail: [email protected]

M.Salaimanalan

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REUSE OF WASTES TO GENERATE ENERGY

Abstract:

Wastes and residuals are undeniably part of human society. The accumulation of these materials and the "throw-away philosophy"result in many environmental and health issues and safety hazard problems, and prevent sustainable development in terms ofresource recovery and recycling of waste materials. The carbon sources in the wastes can be converted to energy (electricity,heat, chill, fuels) and even materials using different technologies including collecting and converting current landfill gases, wet ordry anaerobic digestion to biogas, incineration, gasification and pyrolysis.

Authors(s)

Ajay JohariTel. No.: +91 8805022723Email: [email protected]

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USE OF VESPEL CR 6100 AS WEAR PARTS FOR THE CENTRIFUGAL PUMPS TO INCREASEEFFICIENCY AND RELIABILITY

Abstract:

Conversion of metal pump wear parts to advanced composite materials can lead to substantial annual cost savings throughincreased seal and bearing life, less risk of pump seizures, increased MTBR (Mean Time Between Repair), and reduced energyuse. This is demonstrated by major industrial companies that transitioned from metals to DuPont's Vespel CR-6100 wear parts forsome of their toughest pump applications.

This paper is intended to provide a standard method for the appropriate design, installation and application of Vespel® CR-6100composite wear components in pump repairs, new pump design and pump upgrades. Vespel® CR-6100 wear components arebased on an advanced composite material consisting of a high performance Teflon® PFA fluorocarbon resin and oriented carbonfibers. Vespel® CR-6100 wear components have been successfully used in thousands of centrifugal pumps in major refineries,chemical plants, power plants, pipeline terminals, and municipal water utilities since 1996.

Authors(s)

Pradeep Narayan DholeDirector - TechnicalMascot Dynamics Pvt Ltd.,Factory: Plot No. W-89 & 90,MIDC Indl Area,Ambernath (E ),Maharashtra-421506, IndiaTel.: +91( 0251)2620602,Mobile: +91-7666385004E-mail: [email protected]

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MODELLING PRESSURE DROP AND PIPELINE BLOCKAGE CONDITION FOR DENSE-PHASEPNEUMATIC CONVEYING OF FLY ASH

Abstract:

Fluidized dense-phase pneumatic conveying of fly ash is becoming increasingly popular in powerstations. An accurate estimationof total pipeline pressure drop and blockage boundary are of paramount importance for the reliable design of a pneumaticconveyingsystem. Under the present study, a validated two-layer based model has been developed by separately considering the solidsfriction contributions of the non-suspension bed of powders flowing along the bottom of pipe and the suspension of particlesoccurring on top of the non-suspension layer.

Based onthe test results of 21 different powders conveyed through 37 pipelines, a unified model for the minimum transportboundary has been developed that represents gas Froude number as a function of solids loading ratio and particle Froude number.Both the models have provided reliable predictions under scale-up conditions of pipeline lengths and diameter.

Authors(s)

Dr. S.S.MallickAssociate Professor,Thapar University, PatialaTel.: +91 9592697176E-mail: [email protected]

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126

PLANT MANAGEMENT TODAY: PUTTING PEOPLE IN FOCUSTHE IMPACT OF THE CONTROL SYSTEM ON THE PERFORMANCE OF A POWER STATION

Abstract:

A power plant's performance is largely determined by the people operating it, and the control system can have a major impact onthis.

At a power station in US, they're doing just that: recognizing the importance of effectiveness and efficiency in overall plantoperation, allowing personnel to interact more easily and smoothly with the process by optimizing the interface between theoperator and the plant; the control system.

In the daily business of the power-plant operators, their responsibilities include monitoring the thousands of pieces of sensorinformation coming from the processes and controlling the equipment that determines plant output. In addition, reporting, recording,and coordinating all the work is necessary to manage the plant as effectively and efficiently as possible. With the massive amountof information operators have to decipher nowadays, it has become more and more critical to support them with the right tools,with targeted information and guided procedures for sound operation - which, in turn, provides the platform for optimum powerplant performance.

This paper will discuss the upgrade to the latest SPPA-T3000 technology, and how its emphasis on operator effectiveness andefficiency increased the plant performance - while proving itself as a reliable investment.

Authors(s)

H.-Christian OstertagProduct management SPPA-T3000Siemens AG,Process Industries andDrives Division

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METHANOL ECONOMY : SCENARIO FOR FUTURISTIC FUEL IN INDIA

Abstract:

The methanol economy is a suggested future economy in which methanol replaces fossil fuels as a means of energy storage,ground transportation fuel, and raw material for synthetic hydrocarbons and their products. It offers an alternative to the proposedhydrogen economy or ethanol economy.

Methanol is a fuel for heat engines and fuel cells. Due to its high octane rating it can be used directly as a fuel in flex-fuel cars(including hybrid and plug-in hybrid vehicles) using existing internal combustion engines (ICE). Methanol can also be used as afuel in fuel cells, either directly in Direct Methanol Fuel Cells (DMFC) or indirectly (after conversion into hydrogen by reforming).Because of an increase in the methanol demand the past decades, energy efficient and innovative solutions for methanol productionare highly valuable. Methanol Economy has the potential to replace petroleum-based fuels and chemicals with methanol andmethanol-derivatives - as a path to sustainable development.

Present paper deals with the methods to synthesise methanol, its properties & applications particularly in dimethyl ether(DME) andfuel cell beside a transport fuel. Papers also covers possibilities of its production using CO

2 from thermal plants and electrolysis

using renewable sources. Some of the technologies & research work being initiated in India like CTL is also discussed with costeconomy & SWOT analysis.

Authors(s)

Dr. R K SharmaAGM (Chemistry), IGSTPS, NTPC Ltd.Tel. : +91 9650992886E-mail: [email protected]

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MAC® SYSTEM - MAGALDI ASH COOLER

Abstract:

Indian coals typically have a high ash content (up to 45% and even more), which results in low calorific value. So, the burden ofcoal combustion residues, both fly ash and bottom ash, is really an issue and requires acres of land in case they are disposed toponds. In fact, in India only a minor fraction of ash is presently recycled and reused in various applications. The major utilisationis in cement and concrete production, bricks manufacturing, soil stabilisation and road construction. Therefore, additional effortshave to be paid to the development and deployment of clean coal technologies to improve conversion efficiency and minimize theenvironmental burden associated with coal conversion, especially that associated with climate change, achieving: Lower emissionsat the stack, Higher combustion efficiency & Recovery of the combustion by-products. The MAC® is a unique system for "dry"extraction, air cooling and mechanical handling of bottom ash from pulverized coal-fired boilers. With hundreds of installationsworldwide since 1980’s, the MAC® is the world's leading dry bottom ash handling system for utility and industrial boilers, of anysize and burning any kind of solid fuel.

Authors(s)

Fulvio BassettiTechnical Director, Process DeptE mail: [email protected]

Daniele RicciSenior Process Engineer.E mail: [email protected]

Michele CorradoE mail: [email protected]

Lorenzo LeporeProcess EngineerE mail: [email protected]

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ZERO LIQUID DISCHARGE CASE STUDIES AT POWER PLANTS AROUND THE WORLD

Abstract:

Zero liquid discharge (ZLD) systems have been in operation at gas based and coal-fired power plants since the 1970's. As waterscarcity is increasing and wastewater discharge regulations become more stringent, power plants and other industrial facilitiesaround the world are increasingly looking for more ways to minimize raw water requirements and to recycle and reuse as muchwastewater as possible. In many cases, environmental regulations now require ZLD, resulting in all wastewaters retained on siterequiring large holding ponds or reduced to solids suitable for disposal off site. ZLD or "closed-loop" wastewater treatmentsystems typically use membranes, evaporators (brine concentrators), crystallizers and other advanced process equipment tomeet ZLD environmental regulations. This paper will provide case studies of four different gas based and coal-fired power plantsin North America, Europe, and Australia with detailed examples of the wastewater streams treated along with design considerationsand the ZLD system operations. A strategy for implementing ZLD for existing and future thermal power plants in India will also bediscussed. ZLD has a great play in managing FGD waste water as well. Waste Water from FGD contains all challenges from Coal-High Sulphates, Heavy Metals

Authors(s)

CiszewskiDavid Global Sales Director at GEPower & Water

Himanshu GuptaSales Director at GE Power & WaterTel. No: +91 9999907981E mail: [email protected]

Michael ReesSenior Sales & Proposal Managerat GE Power & Water

Venkatesh KrishnaswamyCommercial Engineer at GE Power& Water

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130

SEWAGE WATER REUSE FOR THERMAL POWER PLANTS - A PRACTICAL APPROACH

Abstract:

Globally Water availability is getting stressed and Industries have been asked to reduce dependency on fresh water. On other siderivers are getting polluted from sewage water getting generated from Municipalities. Societies are finding methodologies to recycleand reuse Sewage Water for Industries. MBR - Membrane Bio Reactor as technology was developed to reuse water from Sewageand Industrial Waste Water and over a period of time has been implemented to various applications including using municipalsewage for power generation. This paper will talk about technology and references and how Power Utilities have benefitted fromthis technology. MBR technology is a combination of Activated Sludge Process followed by Membrane Filtration and ensuring BOD< 5 ppm, COD < 50 ppm, Turbidity and TSS as Nil, TN / TP in desired requirement. MBR systems offer several operational andeconomic advantages compared to conventional wastewater treatment plants. By incorporating membrane technology, MBRsystems eliminate the need for secondary clarifiers and tertiary treatment. This allows for increased performance with a smallerfootprint. Over 1000 units are operating globally and including > 100 in India and customers are utilizing recycled water back inthe process. India has two references of application of Sewage Treated Water In Power Industry: Pragati Power - Treated Sewageused for Boiler Feed using MBR technology" Badarpur Thermal Power Station - Utilizing MBR technology to reuse Sewagecontaminated" river water for Power Generation.

Authors(s)

Monica SharmaTel. No.: +91 9945730508E mail: [email protected]

P. Vijaysai

Himanshu GuptaVenkatesh Krishnaswamy

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GETS 2016

FLUE GAS DESULPHURISATION BY E-BEAM METHOD & FLY ASH UTILISATION

Abstract:

Fly ash utilization is the biggest challenge for any coal based thermal power plants. In addition to that at present the thermal powerplants are also facing severe problems due to stringent environmental norms regarding SOx/NOx emission in flue gas. Presentlywet FGD is most common method in India to minimise only SOx emission in flue gas. In this method Lime stone is used as inputand Gypsum is produced in large quantity as end product. Handling of both lime stone and Gypsum are another headache forpower plants that are still struggling with fly ash utilization. Here we suggest an innovative method for removal of SOx as well asNOx in flue gas by using electron beam oxidation method and subsequent treatment with fly ash slurry. The end product in thisprocess is a liquid coagulant which is very much useful for water treatment in power plant itself. By using electron beam SOx/NOxin flue gas gets oxidised and reacts with Al

2O3 and Fe

2O3 present in fly ash to form liquid coagulant. So the removal of SOx and NOx

from flue gas by using fly ash is very promising and environment friendly method that needs more attention for exploration. In Indiait is still to be explored and keeping in view of the future demand of power in India this technique has right potential to solve theenvironment related problems in the form of fly ash and SOx/NOx emission that arises due to power generation form fossil fuel likecoal.

Authors(s)

Anjana BhardwajDy.Mgr. (EMG-HRHQ NTPC -Vindhyachal)

Ram Manohar TiwariAsst. Mgr, NTPC-VindhyachalTel. No: +91 9406711123E mail:[email protected]

#754

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Ritwick GoswamiAsst. Mgr, NTPC-Vindhyachal

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132

THE CANSOLV SO2 SCRUBBING SYSTEM:

A SOLUTION FOR SUSTAINABLE EMISSIONS REDUCTION FOR POWER INDUSTRY

Abstract:

Many Coal-fired power plants worldwide are now faced with the challenges in meeting the stringent SO2 emissions and eliminating

liquid and solid waste emissions at the same time. The CANSOLV SO2 Scrubbing System has been proven to be a simple, effective,

and reliable regenerable solution with almost 15 years commercialization worldwide. It represents a new alternative to solve thecoal power challenge: sustainably meeting more and more stringent SO

2 emission targets, while converting the captured SO

2 to

produce valuable by-product instead of landfill waste generated from non-regenerable flue gas desulfurization technologies.Regardless of the gas conditions, the CANSOLV Process can reach the stringent emission regulations and do so in a regenerable,economical, and technologically innovative manner.

This paper will focus on the application of CANSOLV SO2 Scrubbing system in a 1.2 GW coal-fired power plant in China. The paper

will explore the economic value chain of using-coal to generate power, the capture of SO2 from the power plant flue gas to meet the

very stringent SO2 emission standards of 200 mg/Nm3, and the subsequent conversion of SO

2 to produce valuable sulfuric acid for

sale in the fertilizer market. The CANSOLV Process achieves this by virtually eliminating liquid and solid waste emissions comparedto limestone FGD technology.

Authors(s)

Vijay BhambhaniPrincipal Service ManagerShell Chemicals Americas Inc.Tel. No.: +91 9108049669E-mail: [email protected]

#762

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133

GETS 2016

INTEGRATED APPROACH FOR POLLUTION CONTROL & WASTE UTILIZATIONIN POWER STATIONS

Abstract:

In Power stations, the Utility Boilers give generation of Fly ash and as well as SO2 as particulate pollutants & gaseous pollutants.

In Power stations ESPs/Bag Filters are widely used for Suspended Particulate Emission contol with stipulated emission norms. TheESPs or Bag Filters generates solid waste in terms of Fly ash, which are required to be diposed as waste or its utilization in termsof Fly Ash Bricks/road fillers etc.

Also the FGD (Flue Gas Desulphurisation) system are widely used for reduction in SO2 level with stipulated emission norms. The

FGD process gives rise to solid waste generation, i.e., Gypsum, which also needs to be disposed/reutilised.

The Waste Management systems in Power Stations do the Safe disposal and effective utilization of Fly Ash & Gypsum. Anintegrated systems along with APC systems like ESP's/ Bag Filters and FGD's can help Power industry totally neutralize all pollutants.

The paper describes about the integrated approach towards Pollution control and effective use of waste utilization.

Authors(s)

Vivek TanejaTel. No.: +91 9823099955Email: [email protected]

#773

REUSE

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134

WASTE HEAT RECOVERY IN POWER STATION BOILERS

Abstract:

Since coal is still the main fuel for generating power around the world older stock also needs to be upgraded and since theoperating pressures are set the obvious route is to improve combustion efficiency and maximise the conversion of the heat toelectricity capturing as much of the exhaust waste heat as possible. Some options available are

1. Replacement of Economiser.

2. Additional heat exchangers to reduce heat exhaust temperatures.

In the recent years, the concept of Low Temperature (LT) Economisers generally known as GAS HEAT EXCHANGER (GHE) forThermal Power Stations, are used to enhance the system efficiency. The objectives to develop the GHE are,

1. To reduce the exhaust gas temperature from 160 ~ 170 C to about 110-120 Deg C.

2. While a Desulphurisation / Denitrification equipment are considered, the GHE shall assist to reduce the inlet gas temperaturethereby reducing the water consumption.

3. Similarly to reduce the inlet gas temperature for the next generation ESP's.

OPTION 1: GHE installed after the ID Fan.

OPTION 2: GHE installed before ESP

OPTION 3: GHE used to control the flue gas temperature entering stack.

The GHE used for recovering waste heat and the useful recovered heat can be used for following

1. To produce chilled water in vapour absorption machine to be used in air conditioning

2. To produce flash steam for Desalination

3. Increase feed water temperature at economiser inlet

4. In parallel to LP heater

Authors(s)

Baskar NamasivayamGreens Power Equipments India Pvt. Ltd.S - 178, MIDC, Bhosari, Pune-411026,Maharashtra.Tel. No.: + 91 8380060101E-mail : [email protected]

#780

REUSE

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GETS 2016

AN APPROACH TO OPTIMIZE FGD – RETROFIT INCOAL FIRED THERMAL POWER STATIONS

Abstract:

This paper presents an approach to optimize the cost of FGD retrofitting projects of coal fired thermal power plants. FGD Retrofitwill start from a site visit for feasibility study. The focus areas considered for this optimization approach is compact layout,minimize reagent consumption, minimize aux power and minimize process water requirement. Lime stone source and gypsummarket location are to be planned to minimize the logistics expenditure. To meet the recent MoEF notification issued by Governmentof India, BHEL approach for making cost effective solution to meet De-Sox requirement in existing power plants is covered in thispaper.

Authors(s)

R. LakshmananAdditional General ManagerEDC-FGDFGD EngineeringBHEL - RanipetTel. No : +91 9443343650Email:[email protected]

Sashi KumarDy.Manager/FGDFGD Proposal andContract engineering.Email: [email protected]

Manoj Kumar ThakurFGD Proposal andContract EngineeringEmail: [email protected].

#663

REUSE

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136

ASPECTS OF REUSE - EXPERIENCES OF AN POWER PLANT OPERATOR

Abstract:

Reuse is a key topic in today's power plant operation from different points of view. At least efficiency items as well as aspects ofsaving of reserves and resources are touched. For STEAG as owner and operator of power stations as well as a worldwide activeengineer these items have to be discussed considering local boundary conditions and techno-economical possibilities. The followingreuse opportunities will be touched:

1. Reuse of waste heat and thus heat recovery especially when dealing with flue gas treatment systems.

2. Ash utilization

For our German power station high value reuse of byproducts like ash and gypsum is essential. But certain technical propertieshave to be fulfilled.

3. Reuse of components

In Europe more and more coal and gas fired power stations are shut down due to increased share of renewables. Reuse ofpower plant components as well as of entire power plants has to be considered.

4. Water

Water resources are quite limited, so reuse of water especially when discussing further flue gas treatment is of importance.

5. Catalysts

For NOx reduction with high efficiency catalyst technology is used. Instead of buying new ones after some years of operationSTEAG has experience with regeneration of used catalysts.

6. Reuse of waste in general in municipal waste incinerators generating electricity is important for the more and more upcomingmega cities.

7. At least know how should be reused. Why make same mistakes twice?

Authors(s)

Prof. Dr.-Ing. W.A. BeneschDirector Energy TechnologiesSTEAG Energy Services [email protected]

#673

REUSE

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137

GETS 2016

CARBON CAPTURE

Abstract:

With CO2 concentration in the Earth's atmosphere above 400 parts per million (ppm), and increasing 2-3 ppm/year, there is an

increased sense of urgency to reduce anthropogenic CO2 emissions. Carbon capture and storage (CCS) provides a cost-effective

means to reduce such emissions at large scales. According to the Intergovernmental Panel on Climate Change (IPCC), the cost oflimiting the increase in global average temperature below 2°C doubles if CCS is unavailable to help decarbonize the world economy.The International Energy Agency (IEA) estimates that a 2oC scenario requires a total investment of $3.6 trillion in CCS, of whichapproximately $2.5 trillion is in the electricity generating sector. The IEA further estimates if CCS is removed as an option for 2oC,then the total investment in the electricity sector increases by 40% or about $1 trillion more. For the electricity generating sector,CCS will be necessary for both coal- and natural gas-fired generation under lowcarbon scenarios. The current suite of CCStechnology, if deployed, would lead to increases in the cost of electricity of 100% and 55% for coal and natural gas, respectively.This increase is due to the substantial reduction in plant efficiency and the high capital requirements for the processes.

Authors(s)

Abhoyjit S. BhownElectric Power Research Institute3420 Hillview Avenue Palo Alto,California, 94304USA.Tel. No : +1 -650-855-2383Email [email protected]

#732

REUSE

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138

REDEFINING POWER GENERATION –ADVANCED CFB TECHNOLOGY FOR WASTE RE-USE

Abstract:

MoEF has setup very challenging Environmental Norms for the industry mainly Power & Cement Sector. These changes has comewhen industry is going through very tough times due to global economic slowdown. To overcome these challenges industry is inlookout of some solution which can help them in Capacity / Resource Utilization, Efficiency Improvements at the same timecompliance with new enviromental norms. ISGEC together with Amec Foster Wheeler is offering advanced CFB technology forpower plants to meet these changes viz a viz firing wastes like Coal Fines, Washery Rejects, Etc.

Authors(s)

#783

REUSE

Naresh KumarISGEC Heavy Engineering LimitedTel.No :+919810837339E mail: [email protected]

Niranjan Shastry

Anil Saini

S Raghunath

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GETS 2016

RETROFIT

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140

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141

GETS 2016

COMPARISON OF SEMI-DRY FGD AND WET FGD FOR THERMAL POWER PLANTS TO

ACHIEVE THE NEW ENVIRONMENT NORMS

Abstract:

The new environmental norms issued by the Ministry of Environment, Forest, and Climate Change (MoEFCC) require sulfur dioxide(SO2) abatement technologies for most power plants, which brings uncertainties and challenges. As power producers considermoving forward with SO2 emissions control projects, it will be important to build upon the experience and technologies that havebeen proven globally - the most cost-effective applications that minimize the cost of compliance. The Wet Flue Gas DesulphurisationSystem (WFGD) and Semi-Dry Flue Gas Desulphurisation System (SDFGD) are the two well proven SO2 control technologies.WFGD is currently more popular globally because it has lower operational costs. However, SDFGD may be the better SO2 controltechnology for Indian power plants that burn low sulfur coal. This paper provides a detailed techno-commercial comparison ofWFGD and SDFGD by considering a case study for Indian power plant. Factors like consideration of wet stack, new water consumptionlimits, and achieving stringent particulate matter limits are also evaluated in this paper to compare the feasibility of implementationof the SDFGD or WFGD system.

Authors(s)

Deepthi ValsanBlack & Veatch

Pratik MehtaBlack & Veatch

RETROFIT

#495

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SNCR-SCR HYBRID DENOX SYSTEM

Abstract:

YiXing Union Thermo Electron Group is a subsidiary of JiangSu Guoxin Union Energy Co., Ltd., a company that has major businessin the thermoelectricity and biochemical industries. The Thermo Electron Group has five coalfired units that were mandated toreduce NOx emission to be below 100mg/Nm3 under the "Emission standard of air pollutants for thermal power plants" issued in2011 by the Ministry of Environmental Protection. After the first phase low-NOx burner retrofit by LP Amina, the units achievedsignificant reduction to be below 300 mg/Nm3, and Union contracted LP Amina to further reduce NOx to be under 100mg/Nm3.The typical solution is to apply Selective Catalytic Reduction (SCR) technology to achieve reliable high reduction rate by building astandalone SCR reactor to accommodate catalysts between the economizer and the APH, and injecting reagent into the flue gas toreact with NOx inside the reactor to convert it into N2 and H2O. However, due to limited plant space, standalone SCR reactors wereinfeasible at the plant. Therefore, LP Amina came up with an innovative solution of SNCR+SCR hybrid system to achieve therequired reduction rate with less catalysts inside the boiler backpass in lieu of a standalone reactor.

Authors(s)

Kincheiu WeiL P Amina

RETROFIT

#497

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GETS 2016

THE "PATH FOR FUTURE POWER" – RETROFITTING HIGH EFFICIENCY DYNAMIC

CLASSIFIERS

Abstract:

As the Coal fired Power Generation Industry goes through many areas of change owing to the global turnaround on EnvironmentConservation, this presentation reviews the NOx reductions achieved and fuel flexibility considerations attained post replacementof Static Design Classifiers with that of High Efficiency Rotating Dynamic Classifiers at 2 (two) X 800MWe plants.

Combined these plants units have had retrofitted 6 (six) units totalling installation, commissioning and optimization of 42 CoalPulverizers over the last 3 years.

Concepts for discussion shall include:

• High Efficiency Rotating Classifier operation and design parameters and adaptability to typical High Ash Indian Coal.

• NOx emissions control technologies in conjunction with Dynamic Classifiers leading to a 10-12% overall NOx reduction andimproved Boiler Performance.

• Fuel flexibility improvements along with coal blending leading to a reduction of fuel consumption and Loss Of Ignition (LOI)thus increasing the plant efficiency through reduced pulverizer recirculation.

• Combustion and heat rate benefits associated with the delivery of the correct and consistent PF particle size distribution to theburner, for sustained results.

This interactive presentation aims at delivering a learning and discussion platform with the objective of associating coal pulverizerupgrades and boiler optimization with NOx reductions and raw coal improved throughput by improving PF sizing and distribution.

Overall "The key to good combustion in the furnace starts with pulverizers that produce coal pf with the right & consistentfineness".

Authors(s)

Paul GarnhamLoesche Energy Systems- UK

Srivastava BrishankLoesche Energy Systems- India

RETROFIT

#479

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144

DIRECT INJECTION SCR

Abstract:

LP Amina (LPA) has demonstrated its direct liquid ammonia injection selective catalytic reduction (SCR) technology on a 1x1combined-cycle plant built by Mitsubishi in Beijing, China. The plant, which was built without space for the SCR in the heatrecovery steam generator, was retrofitted in 2013 using LPA's patented direct injection technology with Haldor Topsoe corrugatedcatalyst. Emissions were reduced 82% (from 34 ppmvd at 15% O2 to 5.9 ppmvd) with amazingly low ammonia slip (1 ppmvd)and extremely low pressure drop (< 1.0 iwcd). The direct injection technology sprays 25% aqueous ammonia directly into thecombustion turbine exhaust duct, using the extreme velocities and high temperatures to mix and vaporize the liquids. The advantagesof this technology include cheaper capital cost, much safer and easier tuning and commissioning, better distribution of ammoniato NOx, and higher reliability.

Authors(s)

Mathew R ZedlerPE, MBA

RETROFIT

#490

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GETS 2016

COAL FLOW MEASUREMENT

Abstract:

The benefits of proper combustion and well-tuned burners can be significant for a coal-fired boiler. These can include improvedcombustion efficiency by reducing unburned carbon losses, reduced NOx emissions due to imbalanced fuel and air mixturesentering the furnace, or reduced slagging and waterwall corrosion. Extractive coal flow measurements in the burner pipes areperformed used to tune and optimize combustion in coal-fired boilers and to ensure the pulverizers are operating properly. Butthere are several techniques, various test instruments, and many possible sources of error in these coal flow measurements.

This paper will discuss best practices and test equipment for accurate, efficient, and safe coal flow measurement, focusing on thekey factors of:

• Air flow measurement in the coal pipes and mills Extractive coal flow sampling methods and equipment

• Automated versus manual testing methods, including sources of errors and data quality

• Data and results from advanced experiments at an EPRI coal flow research facility

• Example results and comparisons from actual plant testing

Authors(s)

Robert G. MudryP.E. Airflow SciencesCorporation Livonia,Michigan, USA

RETROFIT

#508

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146

RETROFIT OF SCR & NH3 STORAGE WITH HIGH CONCENTRATED AND EROSIVE ASH

Abstract:

The focus of this paper are the following topics:

• Sharing long time SCR experience in concentrated and erosive high ash application, including the comparison of honeycomband plate type catalyst

• Implementing this experience in a modern SCR system retrofitting in an old existing boiler with limited space

• Installing an ammonia system under consideration of high safety standards for people and environment

• What are the key items for a reliable and high performance SCR system

These topics are shown on case studies of plants build in Europe and Asia. Special focus will be given on an SCR systemretrofitted in Austria with an ash concentration of over 35% (in coal) and actual dust measurements of over 70 g/Nm3 if flue gas.Special attention is further given to the fly ash characteristic with about 50% of SiO2 content.

The case studies also pay attention on the retrofit challenges. These includes fitting the SCR into the existing space in the boilerisland and strategies to minimize the shutdown period during the SCR retrofit. Further a comparison of solutions is given, how toadjust the flue gas temperature before the catalyst, if the ECO outlet temperature is too low for a safe catalyst operation.

As the catalyst and the ammonia injection system are the key items for a high performance SCR system, the case studies payspecial attention on these equipment's.

In addition, Yara as one of the world largest Ammonia producer, will share case studies for ammonia systems build all over theworld considering the highest European and American safety standards. Special attention is given on designing a system which iseasy and safe to operate.

Authors(s)

Richard [email protected] Hauptstrasse1-7, A-1210 Vienna, Austria

Christian [email protected] Hauptstrasse1-7, A-1210 Vienna, Austria

RETROFIT

#520

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GETS 2016

RENOVATION & MODERNISATION OF COMPRESSED AIR SYSTEM

INSTALLATION OF OIL FREE SCREW COMPRESSOR

Abstract:

Captive power plant, PP-2, 74MW, Bhilai had service and instrument air requirement of 270 lit per sec which was met by kirloskarpneumatic, Model -2HA2TERT (formerly khosla-capelle) reciprocating horizontal mounted opposed and balanced air compressors.Three Compressors were installed each with capacity of 135 lit/ sec with the view of 02 compressors in operation and one stand-by. These compressors along with air intake inter & after coolers, discharge air pipes, air dryer units, panels were installed in PP-2 in a room with floor space of 100 sq. m. When air demand in the plant was increased due to dry ash evacuation system, otherpneumatic valves in boiler fuel lines etc., R&M was thought of by TMD engineers and state of the art machine of Atlas Copco make,model: ZR 132 FF was procured. It could be installed on floor space of maximum 20m2 and this single machine has free airdelivery of 367 lit/sec. This paper discusses the dramatic improvement in operational reliability, capacity augmentation, machineavailability, improved maintenance offered by new compressor with the help of R&M study and also innovative steps taken toconserve cooling water for this compressor.

Authors(s)

Srinivasarao PerumallaSupdt. (TMD),PP-2, NSPCL, Bhilai

RETROFIT

#530

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148

ROTARY AIR PREHEATER AND DRAFT FAN PERFORMANCE EFFECT ON UNIT HEAT RATE,

AVAILABILITY AND EMISSIONS CONTROL PLANT

Abstract:

In all coal fired plant, the combined performance of both the air preheaters and the boiler draft fans can have a dramatic effect onboth the boiler heat rate and unit availability. Excessive leakage can occur through many rotary air preheaters as their conditiondeteriorates during long term operation, thereby increasing the required draft fan flow and associated power requirements potentiallylimiting the exported power capacity. To minimise the associated availability loss, most boiler draft fans have typically been sizedto suit the most onerous operating conditions that may be experienced over the lifetime of the generating plant, including marginsto encompass maximum associated flow rates and fouling conditions through the boiler, air preheater and gas cleaning equipment(such as SCR or bag filters). These higher gas flowrates also affect the size of any FGD plant and future Carbon Capture Plant andtheir capital and operational costs and should be addressed prior to installation of emissions reduction equipment.

In most cases, the resultant fans are too large for the operating conditions experienced over 90% of their lifetime. Different types offans have been used, axial, centrifugal and mixed flow with different performance characteristics that can be used to partiallyoffset the divergent needs of the plant. However, each has limitations that may cause significant additional parasitic powerconsumption in the draft plant that can amount to a large cost imposition over the life of the boiler plant.

This paper addresses the most critical factors and design alternatives that should be considered to improve availability and reducethe unit heat rate when specifying or reviewing the performance of both the air preheaters and associated draft equipment.

Authors(s)

D. HoggHeavy Fans & Heaters,Howden Group Limited, UK

L. SalvestroHowden Australia, Australia

RETROFIT

#532

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149

GETS 2016

MITIGATION OF IMPLEMENTATION CHALLENGES IN RETROFITTING AIR QUALITY

CONTROL EQUIPMENT

Abstract:

Environmental retrofit projects have significant challenges because of the wide variety of technical options coupled with unique,site-specific challenges. To mitigate the effect of retrofit complications, a comprehensive implementation project methodology thatstarts with technology selection to understand all potential impacts leading to conceptual engineering design should be implemented.The overall objective of this systematic process is to ensure the development of a solution for meeting the project's multipleobjectives, namely, costs, schedule, and ultimately compliance with emission limits.

This paper highlights Black & Veatch's experience in air quality control retrofit projects which demonstrates key elements forsuccessful implementation of retrofit projects. It also presents case studies that offer a wide range of perspectives on potential airquality control implementation challenges.

Authors(s)

Pratik MehtaBlack & Veatch

Daniel ChangBlack & Veatch

RETROFIT

#546

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150

RETROFIT OF A WET LIMESTONE FGD AT POWER PLANT TURCENI (4 X 330 MW)

IN ROMANIA - EXPERIENCE IN CONSTRUCTION AND OPERATION

Abstract:

In February 2008, ANDRITZ was awarded by SC Complexul Energetic Turceni SA to build an FGD plant for 4 boilers with 330 MW.The Turceni power plant is the largest power station in Romania with a total production capacity of 6 x 330 MW. The Benson boilerswhich were constructed between 1972 and 1987 are fired with lignite from local area. The Turceni FGD plant is built turnkey andcomprises four flue gas absorbers, a complete limestone and gypsum treatment plant and all auxiliary systems. The flue gasabsorbers are equipped with a mounted wet stack. In 2011, the first two absorber lines as well as the limestone and gypsum plantwere completed and handed over to the customer in early 2012. The third absorber line started operations at the end of 2012. Thelast absorber line finally started operation by August 2016, after the boiler modification of unit 7 was finalized

Processing of the first flue gas in Lines 4 and 5 in 2011 revealed that raw flue gas did not comply with the originally specifiedgeneral conditions. Evaluation showed that the volumetric flow rate of flue gas deviated by 25% from the agreed amount and theSO2 concentration in the raw gas was significantly exceeded. To study the behavior of the FGD at this high flue gas flow rate andSO2 concentration, a comprehensive measuring campaign was carried out.

Authors(s)

Dr. Klaus BaernthalerANDRITZ AG

RETROFIT

#552

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GETS 2016

HIGH DUST SCR - A PROJECT REVIEW OF RECENT PROJECTS IN GUACOLDA, CHILE AND

COLUMBIA, USA WITH CHALLENGING ASH QUALITIES USING CONVENTIONAL AND DIRECT

AMMONIA INJECTION TECHNOLOGY

Abstract:

High Dust SCR application for Pulverized Coal Boilers is state of the art, however difficult coal qualities with high erosion potentialsand sticking behavior, are challenging boundary condition to reach good plant performance and long catalyst lifetime. In thisprojects different ammonia injection technologies - the so called" conventional pre-evaporated - NH3 Injection" and the so called"NH4OH Direct Injection" are used and comparison on advantages/disadvantages are discussed. Discussion of CFD- and Physicalmodelling results show that physical modelling is a mandatory analysis for high dust SCR applications.

Authors(s)

Dr. Harald ReissnerANDRITZ AG

RETROFIT

#553

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152

FURNACE WATER CLEANING TO IMPROVE BOILER OPERATION

Abstract:

On-load, automatically-controlled furnace water cleaning (HydroJets, waterlances, and water cannons) is critical to the boileroperation of many units burning tenacious slagging coals. This is especially likely when the unit was built to burn a higher qualitycoal, and is operated at a high capacity factor with sustained high loads.

Furnace water cleaning has been applied around the world, and state of the art systems maintain a clean furnace with water toobtain optimal efficiency while still protecting the furnace walls from excessive thermal fatigue damage. Many units rely exclusivelyon their on-line water cleaning system for furnace cleaning today, whether the equipment is water lances, water cannons, or HydroJets.

As power plant owners and operators around the world, including in India, search for lower cost, more environmentally friendlycoals, their original furnace cleaning systems may not clean effectively. This may lead to difficult boiler operational problems.This paper will provide guidance on how you can determine if your unit may operate more reliably or efficiently with a furnace watercleaning system if you are burning a coal blend. Case History results of applying these systems and improving unit operation willalso be discussed.

Authors(s)

Joel H. Booher, PESolutions Consultant, Boiler PerformanceCompany:Babcock and Wilcox / Diamond Power International Inc.

RETROFIT

#561

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GETS 2016

NON-LEAKAGE GGH (GAS-TO-GAS HEATER) TECHNOLOGY FOR IMPROVING FGD

PERFORMANCE

Abstract:

Recently, India goverment adopted a new environmental emissions regulation to take effect on January 2017 that the concentationsof sulfur oxides (SOx), nitrogen oxides (NOx), and particulate matter are limited within 35 ppm, 40 ppm, 30 mg/Nm3, respectively.It is more rigious than the regulation that is effective at present. Second chemical and optical reactions of SOx and NOx inatmosphere are considered another great potential of fine particulate matters geneation under submicron. These matters can giveadverse effeccts on human health and enviroment fatally. Non-leakage GGH installation in coal-firing thermal power plant has beenstrongly recommended to cope with environmental emissions limitation intensification of fine particulate matters into the atmosphere.Non-leakage GGH, unlike leakage GGH, brings minimizing fine particulate matters generation and improving wet FGD performancebecause of minimizing untreated flue gas leakage into the atmosphere without mixing with treated flue gas after a FGD process. Incase of leakage GGH with a rotating type, 2 ~ 5 % of total flue gas from coal combustion is untreatedly leaked into the atmosphere,and as a thermal power plant becomes superannuated the leakage amount increases, which leads to deteriorating the currentenvironmental status.

In this paper, we introduce the non-leakage GGH design technolgoy developed by Doosan Heavy Industries & Construction in orderto improve wet FGD efficiency and to efficiently control flue gas emissions into the atmosphere. The GGH is composed of a GGHCooler upstream of FGD and a GGH Reheater downstream of FGD, and employs finned-tube heat exchangers.

But, bare (unfinned) tubes in the GGH Reheater are situated right after the mist eliminator to efficiently remove slurry dropletsflowing together with the treated flue gas. The water circulates through tubes of the GGH such that it absorbes heat from the GGHCooler swept by the hight-temperture untreated flue gas and heats from the GGH Reheater swept by the low-temperatue treatedflue gas to a required temperature at the stack. The flue gas velocity is properly determined based on particle erosion and pressureloss on the non-leakage GGH. The developed design program calculates important design valeus such as fin pitch, tubes pitch,and bundle size, etc., in accordance with required capacities of thermal power plant.

Authors(s)

Jaedal LeeDoosan Heavy Industries& Construction, South Korea

Jinwoon LeeDoosan Heavy Industries& Construction, South Korea

RETROFIT

#563

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154

DEVELOPMENT AND USE OF MODERN REACTION STAGES TECHNOLOGY FOR TURBINE

RETROFITS

Abstract:

An intensive research work for development of modern reaction stages technology has been done in the DOOSAN SKODA POWERcompany. New bladings and related technology have been developed with the application of CFD (Computational Fluid Dynamics)simulations and tested in experimental cascade and turbine tunnels. A new unique approach for 3D blade design provides flexibilityin the flow path design with the target of high efficiency. A final in-house steam turbine test has verified whole design chain,manufacturing, assembly and also performance of the new reaction stage technology.

Modern reaction stages are applied for turbine Retrofits and Modernization achieving excellent performance of upgraded turbines.Modernized turbines normally reach efficiencies as high as brand new turbines. This presentation further focuses on new reactionflow path design with respect of original outer casing reusing. Furthermore the development of solutions for specific types ofsteam turbines will be approached and reference R&M projects will be presented.

Authors(s)

Pavel HusHead of R&MProduct Development,Doosan Skoda PowerCzech Republic

Petr MilcákHead of Flow Path Design,R&D, Doosan Skoda Power

RETROFIT

#578

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155

GETS 2016

CHALLENGES ASSOCIATED WITH RETROFIT OF SELECTIVE CATALYTIC REDUCTION AND

FLUE GAS DESULFURIZATION PLANT

Abstract:

Environment (Protection) Amendment Rules 2015 issued by Ministry of Environment, Forests and Climate Change has set the newemission standards for coal based thermal power plants. This amended rule has classified the control of emissions for sulfurdioxide, nitrogen oxides, particulate matters and mercury based on the commissioning date and power generating capacity of coalbased thermal power plant. With this amended emission standards, many coal based thermal power plant shall be retrofitted withFlue Gas Desulphurization (FGD) and Selective Catalytic Reduction (SCR) technology to meet the emission of sulfur dioxides andnitrogen oxides. Retrofit of coal based thermal power plant with FGD and SCR technology will pose many challenges with respectto layouts and necessary modifications to existing systems. This paper discusses in brief aspects of retrofit plant like boiler draft,boiler layout, utility consumption, electric auxiliary power, flue liners etc.

Authors(s)

Yogendra MishraSr. DGM and Head - MechanicalEngineering,L&T-Sargent &Lundy LtdL&T-Knowledge City,Vadodara

Hardik BhavsarManager - Mechanical EngineeringL&T-Sargent & Lundy LtdL&T-Knowledge City,Vadodara

RETROFIT

#587

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156

RETROFITTING OF EXISTING EXTERNAL COAL HANDLING SYSTEM (ECHS) WITH INSTAL-

LATION OF PIPE CONVEYOR TO REDUCE DUST EMISSION TO NEAR-BY VILLAGE IN

MUNDRA, UMPP

Abstract:

This paper elaborates one of the experiences of retrofitting the coal handling system with a portion of conveyor converting to pipeconveyor system. The existing system for coal transfer from ECHS to ICHS at CGPL Mundra includes belt conveyors, of which, 03belt conveyors BCN-26, 27 and 28 are in close vicinity of Vandh village. Tata Power as a long term permanent measure, to preventdust nuisance to villages, converted a portion of the belt conveyor system to pipe conveyor- The scheme for India's first retrofit of4500TPH coal pipe conveyor is designed such that the existing assets are used to the extent possible and the parallel beltconveyors can also be used in case of any failures in pipe conveyor stream. Design installation and engineering experiences of thesame are detailed in this paper.

Authors(s)

RETROFIT

Nilima SaoTata Power

Debasish BiswalTata Power

Rakesh PatilTata Power

Srinivasa Murthy GotetiTata Power

#602

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157

GETS 2016

REDUCING POLLUTION – RETROFITTING THE ESP OF THERMAL UNIT TO THE NEW ENVI-

RONMENTAL STANDARDS

Abstract:

Retrofitting the ESP of the thermal units to meet the new environmental norms is a real challenge for the designer. The designer hasto implement the latest technologies/assess the condition of the equipment, decide upon the replacements needed, estimate theperformance, understand the site, cabling, layout, electrical constraints. Experience of retrofitting ESP of one of the units andchallenges being faced by the designer are illustrated in the paper for the benefit of the largesse.

Authors(s)

RETROFIT

Srinivasa Murthy GotetiTata Power

Shintre Rajendra STata Power

Dipankar DasTata Power

Sanjay Kumar RautTata Power

#603

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158

RETROFIT SCHEMES FOR WATER SYSTEM DESIGN IN COAL BASED THERMAL

POWER PLANTS IN INDIA

Abstract:

Ministry of Environment Forest and Climate Change (MOEF& CC) Government of India, has released new environmental regulationsapplicable to coal fired thermal power plants in the country on 7thDecember 2015. As per this norm, emission limits of SPM, SO2,NOx and mercury from coal based thermal power plants (TPP) are modified and it limits the specific water consumption to 3.5m3/MWhr for existing plants. New plant to be commissioned after 1st of January 2017 shall limit the consumption to 2.5m3/MWhrand achieve zero liquid discharge. The norm also mandates the conversions of once through systems cooling systems to recirculating type cooling systems.

The specific water consumption of existing TPPs in the country using fresh water as source varies from 6.0 m3/MWhr to 2.8 m3/MWhr without considering water consumption by air quality control systems (AQCS). The additional water requirements by AQCShas to be accounted for arriving specific water consumption by the TPPs.

The paper outlines the design and actual water consumption patterns of existing TPPs, investigates cost effective reuse options tolimit the specific water consumption and recommends various reuse schemes for retrofit in existing TPPs. It also covers themeasures to be adopted for TPPs commissioned after January 2017. The study is carried out for both sub critical and supercritical TPPs operating on both sea water and fresh water.

Authors(s)

Subhramanyan EdamanaTata Consulting Engineers Ltd. (TCE)Bangalore

Jithin GopinathanTata Consulting Engineers Ltd. (TCE)Bangalore

RETROFIT

#607

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159

GETS 2016

CONTINUED OPERATION OF EXISTING POWER STATION CHIMNEYS FOLLOWING A

RETROFIT OF FGD EQUIPMENT

Abstract:

As a result of newly established government regulations, coal fired power stations in India will have, in years to come, have toretrofit flue gas desulphurization equipment to ensure continued, compliant operation. As a result, the flue gas emitted through thechimneys of the retrofitted stations will be below its sulphuric acid dewpoint temperature and, in case of highly economical "wetstack" operation, saturated with water. Existing chimneys, either with steel or ceramic brick flues, are unsuitable for this environment.As an alternative to the demolition and replacement of these chimneys, this paper will discuss the possibility to modify existingchimneys using Pennguard borosilicate glass block linings.

The first part of the paper will show the practical aspects of preparing and lining steel flues in an existing chimney, using as anexample a four flue, h = 250 m chimney at a coal fired power station in Hong Kong.

The second part of the paper will show the modification of a chimney with a ceramic brick flue and it will place special emphasison the specific design approach that is used to prevent the reentrainment ("spitting") of acid droplets into the environment surroundingthe power station, using standards and practices issued by US EPRI for wet stack operation.

The third and final part of the paper will present a new and highly economical approach to wet stack operation, combining theproperties of power saving wet booster fans with the thermally insulating properties of the borosilicate glass block lining system.This concept will allow for both enhanced operational safety as well as improved unit efficiency.

Authors(s)

Albert de KreijHadek Protective Systems bv

Bastiaan van der WoudeHadek Protective Systems bv

RETROFIT

#610

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160

SIMPLE AND SAFE UREA DECOMPOSITION PROCESS FOR SCR APPLICATIONS

Abstract:

Urea, safe and widely used as a fertilizer, is also the reagent of choice for small to large Selective Catalytic Reduction (SCR)systems where chemical safety is a major concern. SCR systems are installed to reduce high levels of NOx from large coal firedutility plants, industrial Co-gen plants, and other processes. In populated areas where rapid evacuation is difficult, Fuel Tech'ssimple, safe and cost-effective urea to ammonia conversion system, the ULTRA® process, is preferred over traditional SCRreagent (anhydrous or aqueous ammonia) and urea to ammonia hydolyzing processes. ULTRA installations are growing innumber around the world.

The single greatest benefit of the ULTRA process for supplying SCR reagent is safety. The urea can be from solutionized granularor prill urea stored on site in large, safe, atmospheric storage tanks. The aqueous urea solution, simply a dissolved salt, is verysafe and is commonly used in agricultural applications as a fertilizer. A heated stream of carrier air is supplied to the ULTRAchamber, or generated with an attached burner, and the aqueous urea is sprayed in a controlled pattern to promote effective dropletevaporation. The urea is quickly decomposed to useful SCR reagent and the entire stream is sent to the ammonia injection grid(AIG) with up to about 4% NH3-equivalent. There is no high-pressure nor residual ammonia at any point in the process. Thisessentially eliminates the possibility of a dangerous accidental ammonia release.

These safety and economic benefits will be fully realized in India's large coal fired utility boilers to be equipped with SCR systemsto reduce NOx. This paper and presentation will discuss the latest advances in the ULTRA process, including alternate heat sourcesand the wide range of supply rates possible.

Primary Author & Presenter

James FerriganDirector Worldwide BusinessDevelopment - Fuel Tech, Inc.

Co-Authors

William H. SunPh.D. - VP Worldwide ProductManagement - Fuel Tech, Inc.

John M Boyle, Ph.D.Sr. Director TechnologyDevelopment - Fuel Tech, Inc.

RETROFIT

#613

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161

GETS 2016

MODERNIZATION OF STEAM TURBINES FOR HIGH EFFICIENCY UNDER FLEXIBLE

LOAD CONDITIONS

Abstract:

In the power generation market in India a steadily growing percentage of fluctuating renewables are noticeably changing the loadrelated requirements of modern steam power plants. Whereas the past has seen mainly coal- fired units being operated in baseload now highly efficient part load behaviour becomes more and more important as well as quickly responding frequency supportat minimized investment costs.

In the presentation various approaches will be identified, discussed and evaluated under economic criteria focused on the abovedescribed challenges for future power generating technologies. One central idea is to shift the pure sliding pressure mode down toan intermediate load range where the upper limit is reached at around 70% and optimize the blade path efficiency according to thispoint. Along with this strategy concepts are presented which allow frequency support from primary to hour- reserve of maximizedload steps. Moreover it shall be explained how it is principally possible to use the same cycle conditions for load steps andincreasing part load efficiency at the same time. Another idea is to improve the plant performance at lower load ranges by raisingthe main and reheat steam temperature accompanied by special maintenance concepts. The ideas presented in this article aremainly derived from a steam turbine point of view. Nevertheless some requirements and effects on the overall plant are taken intoaccount additionally.

Authors(s)

Thorsten StrunkSales and Marketing Manager -Steam PlantModernizationSiemens AGPower Generation Services -Power and [email protected]

Amrish MaheshwariManager - Customer SupportSiemens Ltd IndiaPower Generation Services -Power & [email protected]

RETROFIT

#615

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162

THE RAPID GROWTH OF FIBERGLASS REINFORCED PLASTIC (FRP) IN FGD SYSTEMS

Abstract:

Regulatory agencies are aggressively implementing air pollution control (APC) standards, which require sophisticated scrubbingequipment for flue gases emitted by energy generating systems. The environment in these air pollution control systems is highlycorrosive to stainless steel and even higher nickel alloys. As a result, fiberglass reinforced plastic (FRP) composites made fromepoxy vinyl ester resins have become the preferred material of construction in many facets of air pollution control equipment froma performance perspective.

The demand for corrosion resistant composites made from epoxy vinyl ester resins increased significantly in 2006. While pricingfor nickel and its related alloys has abated significantly since this time, these materials of construction continue to command apremium over FRP. With a 60-year reputation for low maintenance and relatively stable cost, FRP provides design engineers witha reliable, cost-effective alternative that can be employed in numerous FGD applications from scrubbers to ductings and stackliners to piping and wastewater treatment. Although other materials may be cost competitive with FRP, their use typically results inhigher life cycle costs due to required maintenance. This paper will compare FRP with high nickel alloy and stainless steel in "wetprocess" Flue Gas Desulfurization (FGD) environments. Relative cost and corrosion performance data will be presented and anoverview of the various applications where FRP has been used will be shown.

Authors(s)

Guy SchneiderAshland

RETROFIT

#618

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163

GETS 2016

MODIFICATION OF POWER PLANT CONDENSER WITH HEAT PIPES

Abstract:

This paper explores the feasibility of using heat pipes for power plant condenser. Power Plant Condenser, which is a vital componentin the power plant, consists of thousands of non-ferrous tubes. A huge number of tubes are required to condense steam enteringinto the power plant condenser. Numerous operational and maintenance problems are occurring because of these huge number ofcondenser tubes. In this paper an attempt is made to reduce number of tubes to half of present number of condenser tubes . Thisis achieved by replacing conventional tubes by "Heat Pipes". This paper describes comparison between, the conventional condenserand heat pipe condenser for condensing the given amount of steam.

The heat pipe is a highly effective two phase heat transfer device. The advantage of using a heat pipe over other conventionalmethods is that large quantities of heat can be transported through a small cross sectional area over a considerable distance withno additional power input to the system. The heat pipe is a highly effective two phase heat transfer device. This paper explores theusage of this highly efficient heat pipe for usage in the regular steam condensers used in the power plants.

This paper is also describes the design details of heat pipe in terms of material composition, length, diameter for condensationpurpose. Mathematical calculations are presented for heat transfer coefficients . The feasibility study was carried out for smoothoperation of the heat pipe without ceasing during operation. Experimental setup for laboratory model heat pipe condenser ispresented . Some of the experimental results which are conducted on the laboratory are also presented and discussed.

A description is also presented on the method of "retrofitting the heat pipes" into an existing power plant condenser.

Authors(s)

T. Mallikharjuna RaoCentral Power Research InstituteBangaluru

RETROFIT

#633

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164

RETROFITTING OF FGD AND ESP SYSTEM - A CASE STUDY BY MHPS AND APPLICATION

OF EXPERIENCE FOR INDIAN POWER PLANTS FOR INDIAN THERMAL POWER PLANTS

Abstract:

There is a growing need for Air Quality Control System (AQCS) under the situation that regulation on emission has become morestringent all over the world.

MHPS have developed and improved the FGD, ESP and related technologies continuously and provide the robust solutions to thenew trends of AQCS technologies in the areas of Flue Gas Desulphurization (FGD), Ultra High Efficiency PM removal systemintegrating ESP & FGD, Moving Electrode Electrostatic Precipitator (MEEP) a unique technology best suited for retrofitting andwater saving technology for FGD system. As a result, MHPS group has delivered more than 3000 units of ESP and 300 units ofFGD all over the world and holds the leading market share.

Regulation on emission is applied to existing power plants as well as newly-built power plants. When FGD and ESP technologiesare applied to existing power plants, it is necessary to design the system with many restrictions especially space constraints whilefixing the layout. Space-saving design is one of the key technologies to retrofit FGD in the existing power plants. MHPS has appliedtheir wide experience in successfully retrofitting of FGD in many of the existing thermal power plants.

In this paper, MHPS shares their FGD and ESP retrofit technologies and experiences for existing thermal power plants discussingspecific cases.

Authors(s)

Yoshito TanakaMitusbishi Hitachi Power Systems

Tetsu UshikuMitusbishi Hitachi Power Systems

RETROFIT

#648

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165

GETS 2016

DRY FGDS AS TECHNOLOGY OF CHOICE OVER CONVENTIONAL WET FGD SYSTEMS

Abstract:

Meeting stringent emission compliance requirement creates serious challenges for power plants today. Existing power plants havefootprint constraints to accommodate air quality control systems (AQCS) compliant with the modern and future requirements. Dryflue gas desulphurization (DFGD) technologies are increasingly replacing Wet flue gas Desulfurization (WFGD) world over as thechosen technology for the many benefits they bring to the utilities. This paper covers GE's experience of NID dry flue gasdesulphurization (DFGD) systems allowing utilization of limited available footprint for power units, hence accommodating spaceconstraints for large capacity applications and the benefits they bring to the table in terms of evaluated costs. The new generationof integrated dry FGD with modular design utilizes GE's experience with high dust laden gases and provides simultaneous dust andSOx removal reaching emission level lower than 15 mg/Nm3for dust and less than 100 mg/Nm3 for SOx pollutants.

Authors(s)

RETROFIT

Ray GansleySenior Engineer-Process atAlstom Power Inc., Knoxville, [email protected]

Venkatesh RaoCommercial Proposals Leader atGE Power India Ltd., Noida, [email protected]

Jiangtian ZhangEngineering Manager -Processat GE Power, Beijing, [email protected]

#651

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166

RECENT TECHNOLOGY ADVANCEMENTS IN GE'S WET FGD TECHNOLOGIES

Abstract:

Limestone wet flue gas desulfurization (WFGD) continues to be the technology of choice in the power industry. Over the pastdecade, GE has been developing various products and technologies around WFGD systems to make them more efficient and toprovide substantial benefits to customers. Recent developments include the introduction of improved oxidation air control usingGE's sulfite analyzer. This system reduces power consumption, helps in the control of mercury emissions, and provides improvementsfor other trace elements in the WFGD purge stream. Another key advancement is the introduction of Spray Dryer Evaporators. GE'spatented and proprietary approach for disposal of power plant waste water using direct evaporation offers several benefits overconventional Zero Liquid Discharge (ZLD) systems in terms of lifecycle cost, operational simplicity and performance.

Authors(s)

RETROFIT

Ray GansleySenior Engineer-Process atAlstom Power Inc., Knoxville, [email protected]

Venkatesh RaoCommercial Proposals Leader atGE Power India Ltd., Noida, [email protected]

Jiangtian ZhangEngineering Manager -Processat GE Power, Beijing, [email protected]

#652

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167

GETS 2016

STRUCTURE EFFECTED BY COAL SLURRY AND RETROFITTING AND PREVENTIVE

MEASURES

Abstract:

INDIA has more than 35% of thermal plants with age more than 10 year. Structure steel play a key role in construction of powerplant. Steel loses its strength due to corrosion with time. Recently it is observed major failure of the structure is due to corrosionof the steel which was safe in past. It is urgent need to explore the ways to retrofit these structure for smooth operation of plant.Coal conveyor gallery is one of the structure which very prone to corrosion. This structure is very vital for power plant operation.In Korba one of the near miss accident taken place due to this phenomena. This paper throws light over the corrosion effect due tocoal over the structure related to coal handling and remedial measure for Retrofitting aging structure.

Authors(s)

Vijender SinghManager PE Civil NTPC;

Gaurav VijayDy Manager PE Civil NTPC

RETROFIT

#662

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168

CATALYTIC ACTIVATED DUST FILTER (CERAMIC OR BAG) - A NEW TECHNOLOGY FOR

COMBINED REMOVAL OF DUST, NOX, DIOXIN, VOCS AND SOX FROM FLUE GASES

Abstract:

In recent years there has been increasing concern worldwide and also in India for air pollution caused by industry off gases andvehicular emission. Sulfur Oxides, Nitrogen Oxides, Volatile organic compounds/ Hazardous Air pollutants (VOCs or HAPs) andParticulate Matter (PM)are major pollutants, which are generally believed to have substantial damaging effects on our health andenvironment. NOx also reacts in the atmosphere to form ground- level Ozone, bringing yellow smog in urban areas. In modernIndia there is huge demand of, Power, Fuel and Petrochemical products for meeting the day today requirements. Capacity augmentationor addition of new plants is foreseen in all areas. To meet the product demand, Industry is adopting state of art technologies & up-gradation of existing operation, along with measures for reduction of Air pollutants. Such solutions constraint of finances forCAPEX & OPEX. HALDOR TOPSOE has developed a unique way of removal of dust, Dioxin, VOCs/ HAPs and acid gases (like Sox)from off-gases through catalytic activated dust filter (ceramic or Fibre) in one step. Catalytically active filter bags or ceramic filtersare marketed by Haldor Topsoe under the names CataFlex filter bags and TopFrax ceramic filters. The CataFlex and TopFraxproducts are relevant when the flue gas contains particulates, and the plant is equipped with a bag filter house or part retrofit ofexisting ESP with bag filter.

This type of filters can be used in the temperature interval of 160°C to 400°C. Removal efficiencies of NOx & Sox can be up to 90-95% and PM 99% depending on operating conditions, especially temperature.

Authors(s)

Anders Rooma Nielsen, (Phd)Haldor Topsoe A/s, Denmark

Sachin PanwarHaldor Tposoe India Pvt. Ltd

RETROFIT

#681

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169

GETS 2016

A REVOLUTIONARY MDBFP SYSTEM BASED ON VARIABLE FREQUENCY DRIVE (VFD)

Abstract:

Motor-Driven Boiler Feed-Water Pump (MDBFP) is one of the most crucial equipment in the coal-fired power plant, meanwhile it isalso the largest power consumption unit that greatly dictates the auxiliary power consumption ratio. How to improve the efficiencyof MDBFP system and ensure the reliability in operation as well is an important issue to study in power industry. With the developmentof inverter technology to be more mature and reliable, the paper presents a revolutionary MDBFP system based on VariableFrequency Drive (VFD). The system adopts VFD to drive the MDBFP motor and uses gearbox to replace the fluid coupling to ensurethe system has sufficient speed range. Compared with the traditional line frequency MDBFP system, the innovative system hasobvious advantages. The new system has been applied in a certain thermal power plant in Shanxi province and many others withan obvious energy saving being more than 30%. Meanwhile, it has been running for more than two and half years without anyfailure, which reliability is proved and could be promoted widely.

Authors(s)

RETROFIT

Qi Liang with the doctor's degree and professionaltitle of senior engineer is the Chief Engineer ofShanghai Electric Fuji Electric Power TechnologyCo., Ltd.

Qi Minglong is the director of Engineer of ShanghaiElectric Fuji Electric Power Technology Co., Ltd.

#693

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170

ENERGY-SAVING TRANSFORMATION SCHEME OF FEED PUMP SYSTEM USED IN

THERMAL POWER PLANT

Abstract:

With regard to the complete electric pump unit, energy consumption of electric boiler feed pump, as the most important auxiliaryunit equipment inside the plant, takes up a remarkable ratio among auxiliary units of the power plant compared with other auxiliaryunit equipment, which has direct impact over economic and technical indicators and energy-saving benefit of the complete plant.Therefore, improving efficiency of the electric pump unit has practical and great significance.

There are a variety of energy-saving measures for the boiler feed pump. How to decide an economically feasible transformationscheme based on actual conditions is a quite important subject. Common energy-saving transformation manners in the marketare followings: frequency conversion transformation of electric pump unit; optimization design of feed pump impeller and guidevane; change from electric feed pump to steam-driven feed pump; optimization design of feed pump unit, etc.

Authors(s)

Suwei QuPowerchina Spem Company Limited

RETROFIT

#694

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171

GETS 2016

IN-HOUS DESIGN AND DEVELOPMENT OF BOTTOM CONSEP ASSEMBLY OF ARU

VESSEL OF CPU

Abstract:

The Condensate polishing unit is commonly used as part of a power plant's condensate system, it prevents premature chemicalfailure and deposition within the power cycle..The regeneration units of Condensate Polishing system are rubber lined pressurevessels, each complete with a header and lateral distribution system. The 500MW NTPC FARAKKA CPU ARU was supplied withflanged bottom CONSEP assembly .Due to failure of CONSEP assembly of ARUthe resin started coming out in the drain line duringregeneration which in turn led to shutdown of entire CPU regeneration system .In this paper author explains how this failure hashappened ,what were the failure repurcations and how this entire CONSEP was redesigned and developed inhouse for the first timein NTPC and huge financial implication could be avoided in terms of spares cost and unit availability.

Authors(s)

Jai Inder SharmaManager (MM )NTPC LimitedFarakka Super Thermal Power Station

Ujjwal SarkarSr. ManagerNTPC LimitedFarakka Super Thermal Power Station

RETROFIT

#715

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172

ELECTROSTATIC PRECIPITATOR UPGRADE STRATEGIES FOR IMPROVED

PARTICULATE EMISSIONS

Abstract:

Due to governmental legislation, allowable particulate emission from thermal power stations have been reduced considerably thanin the 1970-2011 time period. However there are a great number of utility electrostatic precipitators (ESPs) installed in that era.This "aging fleet" of ESPs is now about 25-40 years old, and are often the highest emitting sources (in terms of particulate matter)within utility systems. These older units were designed (and are Grand-Fathered) to achieve 100-150 mg/Nm3 of particulatematter, instead of modern performance levels of 30-50 mg/Nm3. Many of the units are experiencing problems with the internalelectrodes corroding or sustaining rapper damage, to the point of failure. Additionally the rapping and electricals installed on thesedated ESPs are inadequate for modern day compliance requirements. Lastly many of the collecting plate designs used at that timedid not fully utilize the casing volume as collecting electrode volume. Thus it is possible to rebuild, enlarge, and improve theseexisting ESPs, while not changing the "foot-print" of the installation. In this paper a number of strategies will be discussed for theserebuilds. These include:

1) rebuilds to better utilize casing length and height,

2) benefits of increasing the collecting plate height vs. detriment of poorer aspect ratio,

3) higher reliability electrode designs,

4) high frequency transformer-rectifiers

Authors(s)

Sankar ThakurKC Cottrell India Pvt. Ltd.

RETROFIT

#717

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173

GETS 2016

INTEGRATED NOX REDUCTION USING ASCRTM TO REDUCE CAPITAL COST VS.

CONVENTIONAL SCR TECHNOLOGY

Abstract:

I-NOxTM systems employs the combination of multiple NOx reduction technologies. The three technologies are: staged combustionconsisting of Low NOx burners (LNBs) and Over-Fire Air (OFA); Selective Non-Catalytic Reduction (SNCR); and Selective CatalyticReduction (SCR). The concept derives its advantages from the synergies that exist between these technologies. The key designtool for the Fuel Tech Advanced SCR ASCRTM layer of an I-NOx system is Computational Fluid Dynamics. The considerable costsavings arise from using a single-layer SCR catalyst installed within existing ductwork, suitably modified, and the utilization ofexisting external structural supports. The pressure drop of a single layer is much lower compared to a full-size SCR. The existingID-fan can be utilized, and the overall capital cost savings are significant and can exceed 50%.

The paper will present design guidelines for the SCR technology, which are specific to the coals fired in India, domestic, importedand blended coals. The design guidelines address erosion, ash accumulation, plugging and catalyst poisoning. The specificchallenges and solutions for the mitigation of the coal specific challenges will be presented.

The paper will also present case studies of Fuel Tech projects where I-NOx and the ASCR approach for the SCR layer was thecorrect process selection over a more traditional SCR. It will focus on the key design components which enable the catalyst toperform in a duct section which has higher than normal flue gas velocities. The paper will also go into some detail regarding theoptimization of the SNCR system component which is critical to the overall performance of the ASCR process.

Primary Author & Presenter

Volker RummenhohlBusiness Development Consultant -Fuel Tech, Inc.

Co-Authors

Penelope StamatakisDirector Process Engineering -Fuel Tech, Inc. Reid Thomas -Sr. Process Engineer - Fuel Tech, Inc.

RETROFIT

#724

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174

CASE STUDY ON ZERO LIQUID DISCHARGE ON FGD SCRUBBER WASTEWATER FROM

A COAL FIRED POWER PLANT

Abstract:

Recycle reuse and Zero Liquid Discharge (ZLD) technologies are increasingly beingemployed in the power, oil & gas and otherindustries. In many instances the use of these technologies is driven by environmental mandates, in others it may be economicbenefit from water reuse and/or social responsibility.

The removal of sulfur from flue gas using Flue Gas Desulfurization (FGD) generates a high TDS purge (blowdown) stream thatcontains various environmental pollutants such as heavy metals, arsenic, selenium, boron and is highly saline. Historically FGDpurge streams have centered on conventional physical, chemical and biological methods. However, even after treatment there willremain a residual concentration of the pollutants and a highly saline stream that must be discharged. ZLD solutions eliminate theliquid discharge and produce a high quality distillate that is reused.

In 2006 Aquatech was awarded a contract for the supply, installation, commissioning, operation and maintenance of five (5) ZLDsystems for five (5) power plants operated by ENEL in Italy. This paper presents a report on the operational feedback of these ZLDsystems.

Authors(s)

J. Michael MarlettPE, P.Eng, Aqua-chem ICD, Aquatech International Corp.www.aquatech.com, email: [email protected]

Daniel BjorklundVice President of Industrial concentration and desalination AquatechInternational Corp. www.aquatech.com, email: [email protected]

Deepak KachruHead Sales & BD of Industrial solutions, Aquatech India,[email protected]

RETROFIT

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GETS 2016

RETROFITTING OF SWITCHYARD PROTECTION SYSTEM: CHALLENGES IN

PLANNING & EXECUTION

Abstract:

Use of Intelligent Electronic Devices (IED) has changed how Control & Protection of electrical breakers used to be in past. Therehave been continuous enhancements in capabilities of these IEDs. International standard & publications has changed the era ofelectrical protection.

Retrofitting jobs for thermal power plants poses multiple challenges. Electrical Control & Protection Systems have developed fromConventional Electromechanical relays to Digital Relays to Numerical Relays. Present system includes IEC 61850 compliant IEDs.We intend to see these from the point of view of EHV electrical system's availability, criticality, economics and extent of modernizationplanned. Impact of IEC 61850 compliant Numerical Relays vis-a-vis non-availability of spares & support for old electromechanicalrelays forces the requirement of retrofitting. Effect of existing scheme of switchyard, type of protection scheme, extent of retrofitting,numbers of bays in switchyard, shutdown planning etc. are key constraints involved. Another critical challenge is the amount oftime required for completing the retrofitting job. Then, there are number of conventional electromechanical relays required forprotection of electrical equipment in any EHV Switchyard. Number of cables required and complexity involved are huge for conventionalcontrol of electrical systems. With many of its inherent complications, conventional system has disadvantages. Few of them beinghuge amount of cable required, greater amount of panel wiring, complexity of logics, difficult maintenance, more number ofpanels, more control room space, non-availability of spares etc. Under retrofit in this paper, we will be presenting the challengesenvisaged during planning and execution of retrofitting of old protection systems in Switchyard.

Paper addresses the networking of relays under retrofitting forming the engineering local area network of modern relays. With aneye on retrofitting of control system for switchyard bays, we envisage the use IEC 61850 protocol in completely new system.

Authors(s)

Arun Kumar SharmaNTPC Limited

Balaji Malepati

RETROFIT

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176

LARGE SCALE SCR RETROFIT ON COAL FIRED UTILITY BOILERS, A SUCCESFUL

EXPERIENCE

Abstract:

Termokimik Corporation has retrofitted a significant number of coal fired with SCR (Selective Catalytic Reduction) systems for thereduction of Nitrogen Oxides, cumulating an experience now exceeding 30.000 MW worldwide. The paper reviews the recentexperience, focusing the attention on process design and project execution issues. Two case studies are analysed, describing thedevelopment of the project from initial concept to the successful operation. The first case is relevant to the installation of an SCRsystem in the frame of a conversion from Coal to Biomass of a Utility Boiler. The second is relevant to an SCR retrofit of a 600 MWCoal Fired Boiler, necessary to allow the Power Plant to fulfil the most recent European emission limits.

Authors(s)

Paolo CavezzaleTermokimik Corporation

Matteo TritellaTermokimik Corporation

RETROFIT

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177

GETS 2016

OPTIMISATION OF DOWNTIME OF BOILER DURING ESP RETROFIT

Abstract:

The accurate planning, execution and safety standards has brought the experience of completion of 2 x 500 MW ESP retrofit as perthe schedule without hampering Boiler Operation and existing plant equipment such as MCC , PLC etc.

The part shutdown of MCC and ACP and changing them to new one and charging with new feeders and connecting to new ESP isa critical and new method adopted by us and achieved good results.

The major benefits includes :-

• No Boiler stoppage.

• Partial down time of common electrical

• Decrease of ESP Shutdown from 90 Days to 45 Days

This paper also talks about how the methods adopted in planning and tools and plants selected to .make the Project completed ontime.

Authors(s)

P. SudhakarThermax Ltd.

RETROFIT

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178

STEAM TURBINE RENOVATION: EFFICIENCY IMPROVEMENT, EMISSION REDUCTION

AND RENEWABLE INTEGRATION

Abstract:

The key challenges plaguing the ageing coal plants presently in India is to remain competitive with the modern machines at thispivotal time in the Indian Power Sector, where the average Plant Load Factor (PLF) is in the tune of 55 to 60% which is expectedto settle at this level going forward. Coupled with increasing demand, the influx of the Renewables will also be one of the keyreasons for lower PLFs staring at Coal plants.

Efficient, Reliable and Cost Effective Cycling, Low Load Operation (LLO), load ramp and start/shut capabilities with compliance toemissions would require selective renovation across coal plant equipment, including Steam Turbines.

• The Steam Turbine retrofit provides significant benefits to the utility:

• Improve thermal performance of the steam turbine thereby reducing coal consumption and corresponding emission

• Significantly contribute to utilities competitiveness under merit order and also contribute to reduce emissions from thermalpower plants

• Potential to regain the parasitic load on account of implementation of emission equipment (DeSOx, DeNOx, SPM)

• Design features incorporated for Flexible operation (efficient Low Load Operation and faster ramp ups/ ramp downs)

• Monitoring during such operations

• Implementation involves managing a lower scope and less execution risk

• Shorter installation time on site with manageable scope

It is techno economically attractive to renovate/ retrofit ageing units where lower PLFs/ lower utilisation put stress on thecompetitiveness and revenue streams of utilities. This paper discusses the requirements for ageing 210 MW and 500 MW SteamTurbine and related plant equipment modification options to enable coal plant meet the above challenges.

Authors(s)

Chinmoy MohantyGE Power India Ltd

RETROFIT

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GETS 2016

Dr. Gerard RileyRJM International

PRIMARY NOX REDUCTION TECHNOLOGY DEVELOPMENT - A SHORT CUT FOR LOW COST

EMISSIONS COMPLIANCE IN INDIA

Abstract:

This paper will outline progress made from the original first generation Low NOx burners (LNBs) to the current, state-of-the-art,Ultra-Low NOx Burners (ULNBs) that are achieving IED-compliance or near-compliance using primary NOx-reduction methodsonly, when firing Coal, Biomass, Oil or Gas.

For many years, the limit to NOx reduction by primary means was around 400-450mg/Nm3 for coal-fired plants. This was far toohigh to achieve IED-compliance when coupled with any secondary NOx-reduction technology other than Selective Catalytic Reduction(SCR). SCR is such an expensive option that it is thought to be uneconomic by many generators. However, with the advent ofRJM's Ultra low NOx technology, SCR is no longer the only option for IED compliance.

Real life results from new and older power plants, such as AES's Kilroot and Maritza, SSE's Ferrybridge C, Engie/Mitsui's (formerly,GDF Suez's) Rugeley and others, will demonstrate that major capital expenditure on costly secondary measures is no longer theonly way to achieve a significant reduction in NOx emissions. When secondary measures are required, simple NOx "polishing" bySelective Non-Catalytic Reduction (SNCR) systems or in-duct or mini SCR ensures final IED compliance at reduced ammoniaconsumption.

Authors(s)

RETROFIT

Barry CohenRJM International

John GoldringRJM International

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GETS 2016

REBUILD

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182

AIR COOLED CONDENSER - A SUSTAINABLE WATER CONSERVATION APPROACH FORPOWER INDUSTRY

Abstract:

Water is prominent on the list of global crisis that are predicted to present major challenges to human populations at scalesranging from local to global. As an essential resource for life, sustainable growth and healthy ecosystems, water has been high onthe industrial requirement. The water requirement for industries especially power sector is substantial high and in many cases thepower plants are not able to get the desired quantum of fresh water due to limitation of the fresh water availability in the watercourses. Further the dumping of sewage municipal and industrial waste into the river bodies is polluting the freshwater resources.This pollution load is forcing industries to continuously revamp its processes & technology upgradation is becoming the need ofthe hour. Presently continuous R&D in industrial market is bringing variety of technologies but the cost implications is lagging it tomaterialize as the technology cost is increasing the ECR merit order rating of industry thereby making it unviable. Besides, latestEnvironment Protection Amendment Rules 2015 has made it mandatory to existing CT based power plants to bring down thespecific water consumption to less than 3.5 CuM / MWHr and for plants after 1st Jan 2017 to reduce the water consumption toless than 2.5 CuM/ MWhr.

Authors(s)

Prag SoodNTPC Ltd

REBUILD

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183

GETS 2016

UPGRADED INSULATION SYSTEMRECENT DEVELOPMENTS IN THERMAL INSULATIONSYSTEM IN INDUSTRY

Abstract:

Designing of Thermal Insulation System for various applications in a Power Plant is very challenging. Presently the Power Plantgeneration capacity has increased up to 800 MW in the country and accordingly the operating temperature condition have alsogreatly increased. Previously the insulation material mainly used was Mineralwool, but now the concept of combination insulationutilizing a soft refractory Ceramic Fibre insulation material as initial layer followed by Mineralwool is a common practice recommendedfor more efficiency.

Authors(s)

K.K. MitraLloyd Insulations (India) Ltd.

REBUILD

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184

FITTING-IN OF GREEN AND SUSTAINABLE BUILDINGS IN COAL-FIRED POWER PLANTS

Abstract:

Buildings are one of the major consumer of world's energy. Reduction of CO2 can be met globally by constructing green andsustainable buildings. In order to accommodate the global climate change, the awareness of constructing low carbon greenbuildings has become inevitable and revolutionized the building design in many countries. Green buildings afford high level ofenvironmental, economic, and engineering performance. Theseinclude energy efficiency, conservation, improved indoor air quality,resourceand material efficiency, and occupant's health and productivity. This Paperfocuses on defining and fitting of green buildingin Thermal power plant setup and elaborating their interaction with the environment and energy. The energyconsumption in thebuildings can be reduced substantially by designing proper layout. In terms of green benefits, the buildings having plenty ofnaturallight and ventilation, which both cut down on artificial lighting andcooling, use of energy efficientappliances and application ofenergy conserving practices synergies with use of renewable energy and water harvestingtechniques makes low- energy buildings.

Authors(s)

Nipun PharliaNTPC Ltd.

REBUILD

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GETS 2016

RECENT DEVELOPMENTS IN USE OF NATURAL DRAFT COOLING TOWER AS CHIMNEY &DRY COOLING SYSTEMS

Abstract:

A cooling tower is a heat rejection device, which extracts waste heat to the atmosphere though the cooling of a water stream to alower temperature. Cooling towers are vital equipment for the better plant performance. Hence, all the efforts are to be deployed toincrease its efficiency.

On the other hand, if durability and long-term performance criteria are incorporated in the design of cooling towers right from theoutset, structural deterioration will progress more slowly than would normally be the case and the need for close monitoring wouldbecome necessary only at an advanced stage in the life of the structure. This thinking is already reflected in some of the largestcooling towers constructed in the very recent past.

Authors(s)

Somnath BhattacharjeeAGM (BMD), NCPS-Dadri

REBUILD

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186

BHEL'S INTEGRATED PLANT DESIGN SYSTEM: REBUILDING PROJECT ENGINEERINGPROCESS

Abstract:

In BHEL, the integrated power plant solution provider of the Nation, Integration of main constituent plants and equipment of plant iscarried out by its plant engineering & design center, Project Engineering Management (PEM). In 2009, as a strategic engineeringprocess rebuilding initiative, PEM took up integration of its engineering processes by deploying a world class data-centric engineeringsystem. The paper discusses the salient learnings from contract formulation, execution and project engineering for live projectsand challenges of such a major IT-based change initiative.

Authors(s)

REBUILD

Rajeev TivariBharat Heavy Electricals Ltd.

Jacob JamesAdditional General Manager/MPL& IPDS BHEL-PEM, NOIDA

Anil JoshiGeneral Manager/Mechanical& IPDS BHEL-PEM, NOIDA

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187

GETS 2016

STRUCTURAL DESIGNS FOR FLOATING SOLAR POWER PLANTS

Abstract:

Floating structure design for dams (1D movement), lakes & for river traffic control with structural module having two buoyantchambers one upright & other angled. The angled one can inflate & deflate making the module to sink & afloat by rotating over thehinge of previous module acting as a cantilever beam.

Authors(s)

Arjun RajNational Institute of Technology - Trichy

REBUILD

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188

BASED DESIGN PRINCIPLES OF BOILER FEED PUMPS STATIONS(SIGMA DIZ + DOOSAN ŠKODA POWER)

Abstract:

A. TECHNICAL OVERVIEW

• Boiler Feed Pump stations with variable speed

• Drive Turbines Details

• Boiler Feed Pumps Details

• Based design principles of Boiler Feed Pumps stations (SIGMA DIZ + Doosan Škoda Power)

Authors(s)

Tomas KahounDoosan Škoda Power

REBUILD

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189

GETS 2016

HIGH VOLTAGE MIXED TECHNOLOGY (HYBRID) SWITCHGEAR - STEPS UP TO 400KV

Abstract:

For many, the world of high-voltage equipment has always been divided between air-insulated switchgear (AIS) and gas-insulatedswitchgear (GIS). Previously, space requirements usually predicated which option was chosen - with GIS allowing a far morecompact, though more expensive, substation footprint. Stated simplistically: AIS was the preferred choice in rural areas while GISwas usually chosen in urban settings. This picture changed dramatically some years ago with introduction of High Voltage HybridSwitchgear's.

Authors(s)

Anurag PanditABB India Ltd

Amit SinhaABB India Limited

REBUILD

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COMPACT AND RELIABLE SWITCHINGSMALLER, MORE EFFICIENT AND SIMPLERGAS-INSULATED SWITCHGEAR (GIS)

Abstract:

One of the greatest achievements of modern society is the electrical power grid. When the Westinghouse Electrical Company builtthe first workable AC (alternating current) generating unit in 1895 in Niagara Falls, electricity turned from a scientific curiosity intoa useful application for society. It also quickly became clear that electricity could only be economically transmitted over longdistances at high voltages. This was the only way to connect the large power plants that were usually located near fuel sources likecoal mines to load centers that needed the electricity, such as towns, cities and today's megacities. Finally, development of high-voltage switching devices made it possible to safely connect several generation units and multiple loads to the same electrical line,which has resulted in the complicated but efficient meshed arrangement that is today's electricity grid.

Authors(s)

Anurag PanditABB India Ltd

Amit SinhaABB India Limited

REBUILD

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GETS 2016

MATCHING THE '5 R' CONCEPT: FLEXIBLE OPERATION OF FOSSIL FIRED POWERPLANTS - THE NEW CHALLENGE

Abstract:

Worldwide the energy market is changing and a shift from fossil based to renewable based generation is happening. The resultingneed for flexible operation creates a major challenge to the installed fleet of coal-fired boilers, both for the materials used as well asthe stability of the combustion process.

Fossil-based power generation is set to stay, however its overall share will be reduced, which also reduces the power generation'senvironmental impact. As a result of the shift the challenges to boilers originally designed for full-load operation and now requiredto operate in alternating mode at medium- or even low-load levels is significant. To be able to cope with these challenges Renovationand/or Rebuilding (redesigning) of existing coal-fired boilers is required.

Authors(s)

Roland ZepeckDirector Global Marketing,Durag Sales & MarketingGmbH & Co. KG, Hamburg

REBUILD

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192

DESIGN OF POWER BOILER FURNACE WALL SUPPORTING STRUCTURE

Abstract:

Nowadays it is the trends to increase the capacity of power plant unit, and operating condition becomes more severe. Power boilerfurance wall stiffening system is also influenced by these facts. It is no loger valid to use the design concept of old unit because ofenlarged furance size and incrased design value of furance gas pressure.

Authors(s)

Jae Cheol KimCorporate R&D InstituteDoosan Heavy Industries &Construction

Dr. Tae Wan KimCorporate R&D InstituteDoosan Heavy Industries &Construction

REBUILD

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193

GETS 2016

WATER TREATMENT AND REUTILIZATION AT COAL FIRED POWER STATION

Abstract:

In India, "Environment (Protection) Amendment Rules 2015" was enacted in December 2015. Among them, the upper limit of theamount of water used, and the upper limit of atmospheric emissions concentration of PM, SO2, NOx, mercury has been defined forthermal power plant. In addition, wastewater from thermal power plant is prohibited under the act. In order to be compliant with thenew environmental norms, it is urgent for utilities to enhancement their environmental measures through improving ESP, installingdesulfurization/denitrification equipment. With wet-type desulfurization equipment that is currently prevalent, wastewater treatmentis absolutely required. In view of the stringently regulated value of the amount of water use and that of wastewater, how utilitiescope with the situation through management of wastewater reutilization is quite crucial.

Authors(s)

Masahiro OzawaJapan Coal Energy Center

REBUILD

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194

WASTE HEAT RECOVERY SYSTEM USING SUPER CRITICAL CARBON DIOXIDE ASWORKING FLUID

Abstract:

Doosan Heavy Industries (DHIs) is now developing advanced Rankine cycles using super critical carbon dioxide (sCO2) forcomposing waste heat recovery system. The concerned system is an advanced eco-friendly technology, converting waste heatgenerated from various industrial processes to electricity. Compared to other working fluids such as organic and steam, the sCO2heat engine has the potential for higher power density with no phase change. Also, the sCO2 system has lower installation,operation and maintenance (O&M) costs than other heat recovery systems. DHIs targeting high-efficiency waste heat recoverysystems and related services, applicable across cement, steel, and diesel generation, etc. Among those categories, the focus ofthis paper is based on the cement process so that we present the current status and future prospect of the sCO2 waste heatrecovery system.

Authors(s)

Gonjoo LeeBoiler R&D Centre - SupercriticalCO2 Development Team,Doosan Heavy Industries, S Korea

Hwachang SungBoiler R&D Centre - supercriticalCO2 Development Team,Doosan Heavy Industries, S Korea

REBUILD

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GETS 2016

TOWNSHIP PLANNING - INTEGRATION OF LIFESTYLE AND TECHNOLOGY IN TODAY'SCONTEXT

Abstract:

The traditional way of designing townships involves the construction of buildings as per the type of occupancies with an isolatedapproach.With changing trends and focus on a better work life balance, the design of inclusive buildings with interactive facades,integrated facilities, green terraces, with more emphasis on the open/public spaces would enhance the lifestyle satisfaction andcreate a healthier environment for the inhabitants of the Township. The aim of the paper is to explore this aspect keeping in mind thesmart, sustainable solutions for the Township.

Authors(s)

C.R. IndumathiTata Consulting Engineers

REBUILD

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STUDY ON THE REMOVING FINE PARTICLES OF WET ELECTROSTATIC PRECIPITATOR ATHIGH GAS VELOCITY

Abstract:

Wet electrostatic precipitator has a significant removal for fine particulate matter like PM2.5. By improving its structure andcombined with experiments to explore a new type wet electrostatic precipitator which could handle a lot of smoke is the purposeof the article. Experimental results show that the new type wet electrostatic precipitator with 9m long tube at 60kV voltage and 4m/s wind velocity for PM2.5 removal efficiency reached 85%, it's a new way for coal-fired power plants to reduce emissions of fineparticulate matter.

Authors(s)

REBUILD

Shi ChaolinEngineer, SEC-PGEPE

Yang ZaitaoEngineer, SEC-PGEPE

Guo ShiyiSenior Engineer, SEC-PGEPE

Ding ChenggangSenior Engineer, SEC-PGEPE

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GETS 2016

A CASE STUDY ON USE OF PRECAST TECHNOLOGY FOR CONSTRUCTION OFHIGHRISE BUILDINGS

Abstract:

Housing, the basic need of every human being. Primitive houses were built of simply mud & straw blocks heated in the sun. TheRomans were the pioneers in construction technology to experiment blending of lime and volcanic rock to create sublime and awe-inspiring structure like Pantheon in Rome, still the largest unreinforced concrete dome on the planet. Use of precast in constructionis not new. Ancient Romans made the use of moulds to cast their mind-boggling system of tunnels & aqueducts. With everincreasing demand for housing, a need to automate and modernize the construction industry was deemed. In the present scenario,engineering and architectural innovation & improvisation has enabled the construction world to explore the neo-arena of prefabtechnology.

Authors(s)

Ram KumarProject Director Amrapali Group, India

Manoj PattersonAssistant Vice President Amrapali Precast Infrastructure

Sandeep JainAssistant Manager Amrapali Precast Infrastructure

REBUILD

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198

ESTIMATION OF POTENTIAL ENERGY SAVINGS BY ALGORITHM BASED ROLLER SHADECONTROL FOR VISUAL COMFORT

Abstract:

Office buildings are usually operational during day-lit hours and thus exhibit a large potential of utilizing daylight for reducinglighting energy demand along with intangible benefits like health, well-being and productivity of the occupants. This study analysesthe energy savings potential of an east facing office building located in New Delhi, India through utilization of daylight. The salientfeatures of the present study include analysis led design concept of using drafting tool Rhinoceros 3D 5.0 and simulation tool DIVA4.0 for evaluating the energy savings potential of a roller blind. The study holistically estimates the effect of day-lighting characteristicson the roller shade performance by adopting glare control strategies for all weather conditions. Glare control strategies that helpin maintaining occupant's visual comfort and consequently estimates potential energy savings through lighting is the USP of thestudy. An algorithm has been developed to iteratively alter and analyse set of roller shade blind positions and suggests parametricappropriateness of their positions.

Authors(s)

Dibakar RakshitIndian Institute of Technology Delhi

Lakshya SharmaIndian Institute of Technology Delhi

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GETS 2016

HEALTH EFFECTS OF FINE PARTICULATE MATTER IN JAIPUR CITY

Abstract:

Fine particulate matter here refers to particles present in the atmosphere both as solid particles and liquid droplets including dust,smoke, fumes and aerosols of size less than 2.5 μm in aerodynamic diameter. The major man made sources are vehicular,industrial, coal burning and biomass emissions. In the recent years, the concentration of fine particulate matter has increasedexponentially in the entire major Indian city. For health impacts and regulatory purpose, PM is significantly classified as respiratoryparticles (?PM10), fine particulates (?PM2.5) and ultrafine particles (?PM1). Among the different size range, ultrafine particlesare highly potent than the coarser particles as their size is 10 times smaller than PM10. These particles can stay in the atmospherefor days to weeks and thus can be transported over long distances in the atmosphere. Due to small size, particulate matter less orequal to 2.5 μm deeply penetrates into human respiratory system.

Authors(s)

Shaurya Johari

Dr. Rai Singh

Dr. Shailendra P. Singh

(Environment Department, Consulting Engineers Group Ltd)

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USING DRONES/UNMANNED AERIAL VEHICLES (UAV) FOR SURVEY WORKS:UNIQUE CONSTRUCTION TECHNOLOGIES

Abstract:

During last five decades surveying and engineering measurements have seen multifold technological advancements. Higheraccuracy of survey results, faster availability of survey data, lucid representation like 3D modelling of topography, real time dataavailability and ability to survey even inaccessible areas are some of the major challenges, key concern and basic requirements oftoday's projects. This papers details about all key benefits, differentiation of Survey using drones/UAV and conventional Surveyand highlights a way ahead for adoption of this new technology. It also covers key regulatory issues and evolving guidelines inIndia regarding the operation of drone for industrial purposes.

Authors(s)

C M VermaNTPC Ltd.

Abuzar AhmadNTPC Ltd.

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Pallavi ShuklaNTPC Ltd.

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GETS 2016

ON USE OF DUCTILE IRON PIPES IN CROSS-COUNTRY APPLICATIONS

Abstract:

The comparative analysis of use of Ductile Iron pipes and Mild Steel pipes in cross-country applications have been studied to bringhome the conclusive points of various advantages and disadvantages of using the different kinds of pipe materials in cross-country applications. The article also contains breathtaking photographs of Ductile Iron Pipelines in various stretches of cross-country application.

Authors(s)

Sabarna RoyVice President & Head -Business Development,Electrosteel Castings Limited,Kolkata.

REBUILD

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202

TECHNOLOGIES TO UTILIZE THE EXISTING PILE FOUNDATIONS FOR NEW STRUCTURES

Abstract:

Old running plants may be founded on the pile foundations and while proposing new plant structures in place of existing plantstructures, it is usual perception/assumption that these pile foundations need to be exhumed. However, these piles can be utilizedfor the new structures either by augmenting its load carrying capacity (i.e. lateral capacity) or by integrating them into newfoundations system by performing proper soil structure interaction analysis. If not integrated within the pile cap, these existingpiles still can be utilized as settlement reducing elements for the foundation designs. Typical cases already implemented in theindustry highlights how such situations can be addressed utilizing the advancements made in the field of geotechnical engineeringand design. Methods for enhancing the lateral pile capacity, integration of old and new piles in a pile group, analysis of pile rafts,and approaches for settlement reducing piles already exist and can be implemented for new plant structures.

Authors(s)

Jaykumar ShuklaL&T-S&L, Vadodara

Soumen SenguptaL&T-S&L, Vadodara

REBUILD

#709

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PRECAST BUILDING SYSTEMS - AN ALTERNATIVE TECHNOLOGY FOR MULTISTORYTOWNSHIPS

Abstract:

Our world is changing fast, not only by widely spreading information, new thoughts and values, but also physically. Changinglandscapes, new cities, newly built surroundings for new kind of living. So wherever we go, we will meet a need for buildingconstruction. And these all needs to be produced economically, fast, safely, with high quality, and of course without forgetting thesustainability and aesthetic aspects of it. There is increasing demand for construction options that will contribute to achievingsustainable development.

Authors(s)

Sunil ModiL&T-Sargent and Lundy Ltd.Vadodara

Mitesh PunjaniL&T-Sargent and Lundy Ltd.Vadodara

REBUILD

#713

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ECONOMICS OF CLEAN TECHNOLOGY IN INDIA

Abstract:

A global transformation to a low carbon economy is under way, fundamentally changing the conventional technology of production,distribution, storage, management and consumption to cleaner and greener technologies. As conventional technologies are showinginherent limitations and negative externalities, only clean technologies can help in achieving the global goals of sustainabledevelopment. This paper review and analyse the economic aspects of this transition to clean technology development in India. Thebenefit Indian Economy will reap from clean technology, the approaches government and corporates are taking and the businessand financial opportunities available for clean technology development are also analysed in relevancy.

Authors(s)

REBUILD

Kalipada AdhikaryNLC India Ltd.

Gobinath M.NLC India Ltd

Teddy PungropeNLC India Ltd.

#734

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PPS MICRO FIBER BAG FILTER FOR LOWERING DUST EMISSION FOR COAL FIREDPOWER PLANTS

Abstract:

Using PPS micro fiber bag filter is an effective method to achieve less than 20mg/N? dust emission in coal fired power plants.Toray's PPS has 40% world market share and wellknown as No.1 PPS brand due to its excellent quality and reliability. We introducethe effectiveness of PPS micro fiber to the market.

Authors(s)

Yuta HasegawaToray International Inc

REBUILD

#737

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HCSD FOR LESSER POLLUTION AND MANAGEMENT OF LAND,WATER AND ENERGY

Abstract:

As the name suggests, High Concentrated Slurry Transportation system, is about transferring slurries containing relatively highproportion of particulate matters. High Concentrated Slurry Transportation is common practice in a number of industrial applicationssuch as long distance ore transportation, feeding autoclaves/ digesters/ gasifiers, tailing disposal etc. High Concentrated SlurryDisposal (HCSD) System is especially about high concentrated tailing for disposal or filling of lowlands.

Authors(s)

Pushpal Banerjee,Weir Minerals India Pvt. Ltd.

REBUILD

#761

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GETS 2016

ENERGY LOSS DUE TO IMPROPER FUNCTIONING OF STEAM TRAPS IN AUXILIARYSTEAM PIPE LINES

Abstract:

Steam traps are automatic valves used in every steam system to remove condensate, air, and other non-condensable gases whilepreventing or minimizing the passing of steam. If condensate is allowed to collect, it reduces the flow capacity of steam lines andthe thermal capacity of heat transfer equipment. In addition, excess condensate can lead to "water hammer," with potentiallydestructive and dangerous results. Air that remains after system startup reduces steam pressure and temperature and may alsoreduce the thermal capacity of heat transfer equipment. Non-condensable gases, such as oxygen and carbon dioxide, causecorrosion in the system. Steam lost through the trap because of improper functioning provides no heating service. This effectivelyreduces the heating capacity of the steam system or increases the amount of steam that must be generated to meet the heatingdemand. Where condensate is not returned to the system, water losses will be proportional to the energy losses associated withleaking steam.

Authors(s)

Rakesh KumarNTPC Ltd.

REBUILD

#775

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NEW APPROACH TO BUILD SMART ALARMS TO SAVE UNIT TRIPPINGS

Abstract:

Power generation companies are facing new challenges in current scenario which means increased competition, increasedexpectation of cost effective operation and reliable high plant availability. Hence there is immediate need of effective tools to avertany inadvertent tripping on sheer negligence or which can be dealt with little care. .

absolute alarms ignored by operators is turning out to be leading causes of unplanned downtime, contributing considerable lossesin production.The awareness of personnal to attend alarms in a quick way is desired; however today's adavnced DCS systemsenable us to create alarm systems that are flexible, small, and relatively inexpensive. However, this has resulted in alarm overload& result into tripping equipment, system and/or worse plant failure.

Authors(s)

Kushalkumar L BhosikarNTPC Limited

REBUILD

#777

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#787

ADVANCED ULTRA-SUPERCRITICAL STEAM POWER PLANTS-BOILERS

Abstract:

GE's development of advanced Ultra-Supercritical Steam Power Plants is provided with a future view of the design & configurationof such plants. The current state-of-the-art USC steam power plants with the most advanced steam conditions worldwide areexplained. Looking into the future, A-USC power plants are significantly more efficient and will reduce use of scarce fuel resourceswhile maximizing power generation with reduced environmental impact. GE is the world leader in advancing USC and A-USCsteam power plant technology & has on-going developments for the boiler & steam turbine components & optimized integratedplant. Achieving high steam temperature requires new materials & new fabrication techniques. GE is a founding member of theEuropean EMAX consortium & USA USC Materials Consortium. GE continues active involvement in materials validation in laboratoryenvironments & in field testing in test loops in operating utility boilers in Germany & USA.

Authors(s)

Sanjay DeganGE Power India Limited

REBUILD

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"BUILD, DISMANTLE AND BUILD" REPLACEMENT AT COAL FIRED POWER STATION

Abstract:

The Environment (Protection) Amendment Rules issued in December 2015 more stringently regulates amount of water utilizationand emissions of PM, SO2, NOxand mercury. Well before the new norms came in place, developing a power station on a greenfield,regardless of the fuel it may use, has been getting more and more difficult as the local community tends to be concerned that therewould be impacts on land use and environment on the site and land acquisition process accordingly may be prolonged.

The foregoing circumstances have brought in changes in the landscape of the powersector in India; Replacement has come up asone of the potential options to address the growing demand and environmental as well as economic requirements. However, quitea few stakeholders hesitate to proceed as a. Replacement may incur the disadvantage of interrupted power supply, b. Method andprocess are unclear as there is no precedent in India.

J-POWER’s Isogo Coal Fired Power Station (New Isogo) of 2x600MW, constitutes a preeminent model that many may like to learnfrom and follow. The story and current status of New Isogo are featured by:

a. The two USC units of New Isogo was developed from two decades-old subcritical bythe method of “Build, dismantle andbuild” replacement, which provided immense benefit to the owner utility as well as the local community by ensuring uninterruptedpower supply even during the construction period.

b. New Isogo is equipped with the latest environmental technologies; among others,MEEP (Moving-electrode type ElectrostaticPrecipitator) that has garnered attention from many stakeholders in the power sector in India after it was awarded for R&M atNTPC’s Rihand TPS.

c. O& M of New Isogo is characterized by up-to-date best practices, which also bolster the consistent operation at highestefficiency and lowest possible emissions.

Authors(s)

Masahiro OzawaJapan Coal Energy Center

Yamada FumikoJapan Coal Energy Center

REBUILD

#595

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THE INSTALLATION OF A CORROSION RESISTANT FIBERGLASS CHIMNEY LINER INA CONCRETE CHIMNEY

Abstract:

A major energy group in Poland heavily invested in environmentally friendly equipment and in modernization of its power stations.They have therefore ordered three new flue gas desulfurization units, based on spraying of lime-stone suspension into flue gas(wet FGD). The units were designed for the lignite and biomass fueled units 4, 5 and 6 of the Turow power plant in Bogatynia.

Each unit is designed for a maximum flue gas flow of 1,280,000 Nm3/h with a maximum SO2 concentration of 2,500 mg/m3 anda removal of = 97.5%. After installation of the three lines the flue gas desulphurization unit will work at a temperature of 70 °C andnormal circumstances. However, during the construction period the flue gas desulphurization of unit 4 and 6 will NOT be operative,but will be operated under bypass conditions. As soon as the last unit (5) has been installed the total system will be operational forflue gas desulfurization.

During by-pass operation (Unit 4, 2 years) the temperature of the system can reach temperatures up to max 160°C (for 2 hours,normal 141°C) and under maximum SO2 concentration.

The three existing chimney liners, consisting out of borosilicate blocks, needed to be replaced as this lining material wasn’t theright choice for the flue gas desulphurization unit of this new power plant. The engineers of PGE decided to use fiberglass for theconstruction of the 700 meter of chimney liners and ducts due to the wet circumstances and the huge differences in temperature(20 – 160 °C)

The real challenge on this project was the short construction time. PGE insisted in demolishing the brick chimney liner andinstalling the new fiberglass chimney liner within a time frame of 40 days. At that point Plasticon Composites only had 25 days toinstall a new chimney liner of 5,300 mm in diameter and 120 meters high.

This paper will describe the realization of this challenging installation job Plasticon Composites executed, as well as the possibilitiesof fiberglass and the construction method of a fiberglass chimney liner and duct.

Authors(s)

Jacco KroezePlasticon Composites

#788

REBUILD

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EXPERIMENTAL INVESTIGATION ON GASIFICATION OF COAL AND WOODY BIOMASSBLENDS IN A FLUIDIZED BED PLANT

Abstract:

Gasification technology, as an efficient technology for solid fuel utilization, is used to convert carbonaceous materials includingcoal, biomass, petroleum coke, etc. into syngas or producer gas that can be used to produce electricity, hydrogen, chemicals andliquid transport fuels. The cogasification of woody biomass with coal, could contribute to the reduction of the fossil fuels dependencyand CO2 emissions, as biomass is known to be neutral as regards CO2 emissions [1]. The cogasification of woody biomass andcoal have been reported by several researchers, including the reduction in the production of tar when coal is co-gasified withbiomass, which can produce large amounts of tar when gasified alone [1, 2-4]. The co-gasification of woody biomass and coalwas studied experimentally in a pilot scale bubbling fluidized bed gasifier. The pilot plant is capable to process 1.2 tpd of feed andoperates up to 10200C at 1.2 bar pressure. The effect of woody biomass and coal contents on gasifier performance parameterssuch as carbon conversion efficiency, cold gas efficiency, low heating value and syngas yield during air blown co-gasification ofa woody biomass and coal were experimentally determined. The results indicate that, the carbon conversion, calorific value, coldgas efficiency and syngas yield increases due to the synergistic interactions between coal and woody biomass blends whenwoody biomass percentage increases in coal blend.

Authors(s)

Siva Rama Krishna NakkaBHEL

REBUILD

#789

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Abstract:

In addition to profitability, responsible handling and consumption of elements remain high priority in power generation with carbonbased fuels. Efforts in CO2 reduction were undertaken in the past focusing on the state of the art large steam power plants in thehigher output classes. As a result, measures for high efficiency and flexibility were mainly developed for large units since they weremost beneficial. The Organisation for Economic Co-operation and Development (OECD) recently addressed the environmentalrequirements as a precondition for export financing for the entire range of coal fired power plants. Going forward, good experiencesof the existing high end ultra super critical (USC) coal fired power plants need to be transferred to the power plants of the 350MWsize. Innovative products are required to face this market segment in the most beneficial way for power plant owners. Siemens hasmodified its core components addressing the new requirements. The Siemens steam turbine shows how technologies for (U)SCapplication from larger types have been introduced in proven turbine designs of subcritical applications. For the steam turbinegenerator, Siemens is leading the way with an innovative mix of proven components and technologies to reduce initial, operationaland service costs as well as provide top performance with operational flexibility.

Authors(s)

Thomas AchterSiemens

Dr. Rainer QuinkertzSiemens

Mayuresh JoshiSiemens

REBUILD

#790

INCREASED EFFICIENCY AND FLEXIBILITY OF LARGE COAL FIRED POWER PLANTSAPPLIED TO THE 350MW CLASS

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SPECIAL SESSIONS

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GETS 2016

POWERING THE GROWTH

Abstract:

Weir Flow Control India is the wholly owned subsidiary of Weir Group, UK who are the pioneers in the field of flow control. In 2010,Weir Group acquired BDK valves in Hubballi, Karnataka and established a world class manufacturing facility for industrial valves.The Weir group has a range of innovative products for power sector, especially to handle high pressure steam. Hopkinsons valvesare particularly very popular in power plants across the world. With the modern facility set up in India, the Weir Group transferredthe technology to manufacture ` Pressure seal bonnet -Parallel slide Gate valves' and `Bonnet less Globe valves'. The focus wason to start manufacturing pressure classes 900 and above upto 4500 keeping in mind the requirements of the super critical &ultra-super critical power plants coming up in India.

These valves provide leak tight, trouble free operation for a longer period of time compared to conventional wedge gate valves andare easy to maintain. The unique concept of utilising the line pressure itself to get the sealing for both bonnet and the body seatingis very effective in this type of design. The technology transfer involved a series of well-established procedures to be followed forproper handing over of the technical knowledge.

This paper will bring out the process of technology transfer, features and benefits of the products, manufacturing & quality systemsput in place to meet the stringent requirements and how we plan to go forward in meeting the challenges in high pressure valvesrequired for power sector in future.

Authors(s)

Narayan GhatikarWeir BDK ValvesPvt. Ltd.(a unit of Weir India Pvt. Ltd.)

MAKE IN INDIA

#541

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INDIGENIZATION OF POWER SECTOR MATERIALS A JOURNEY TOWARDS

MAKING INDIA PROUD

Abstract:

Star Wire (India) Limited is one of the leading special steel plant engaged in manufacturing of sophisticated High Alloy Steels,Super Alloys and Stainless Steels for Creep , Corrosion, fatigue, wear and cryogenic applications meeting national and internationalspecifications in various strategic sectors such as Aviation & Space, Automobile, Energy, Defense,Oil and Gas, Tool & Die in shapeof castings, forgings and rolled products in semi & finished machined condition.

Indigenous Product Range:

Focus on import substitution for Auto components, Defence, Power & other sectors.Pioneered indigenous development of EngineValve Steel, Armor Steel, SteamTurbine Castings and rolled, forged steel for Super Critical TemperatureTurbine and Generators &several other sectors.

Developed LargeWeight Critical Castings up to 65 MT single pc for 500 & 660/800MW SteamTurbine for NTPC Projects.ESR &Non ESR grades of Turbine Blade Steel for Steam / Compressor / Gas Turbines and NonMagnetic Steel for Turbo Generators suchas Tension Bolt & Finger Material.

Authors(s)

Dr. S.K. GoelExecutive DirectorM/s Star Wire (India) Ltd

Mukesh PundirJoint General Manager -Marketing

MAKE IN INDIA

#567

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INDIGENIZATION OF CRITICAL EQUIPMENT FOR POWER SECTOR

Abstract:

REMI PROCESS PLANT & MACHINERY LTD: India's largest manufacturer with a technical tie up of STC Engineering of Germany forIndigenization of FGD agitators.

Efficient Agitators starting from limestone preparation tank, Absorber bottom tank (reaction tank), Feed water tank, Waste watertank, Auxiliary absorbent tank, Neutralization tank, Drain sumps etc. at every Stage perform an important role in FGD system. Atthe core of FGD system the flue gas passes through the absorber spray zone, where absorber slurry spraying countercurrent to theflue gas flow completes the sulfur dioxide removal process. The absorber slurry & mist eliminator wash water that are sprayed intothe absorber pass down through the absorber & collected in the lower section of the absorber which is referred to as the Absorberreaction tank. Four side entering agitators on each absorber reaction tank keep the absorber slurry solids in suspension. LikewiseAgitator does the function of preparation of absorber slurry.

Improper selection of Agitators or failure of Agitators to achieve the process parameters will force the whole FGD system to bebypassed.

Authors(s)

Detlef KlattREMI - STC Engineering of Germany.

MAKE IN INDIA

#568

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TURBINE BLADE MACHINING CENTER

Abstract:

In a world that has an ever-increasing demand for customization and precision, AZAD is at the forefront of a new wave of qualitysuppliers of engineering solutions. Sustainable engineering and manufacturing gets a new meaning with Azad's worldclass CNCshop - a 'one-stop shop' where the entire production process is done under one roof. This is testimony to AZAD's collaborativeculture that is built on reliability, quality and occupational safety.

We started our activities in 2008, and by now AZAD, through its technical know-how and an amazing infrastructure has made itsmark in manufacturing Gas and Steam Turbine Parts with an eminent degree of precision to meet highly customized blueprints formajor OEMs across the Globe. AZAD facilities include:

• Forge Shop

• Hi-tech CNC machines

• State of art inspection facility

• Laboratory

• Manufacturing software's

• Dedicated Team

• Technical Expertise

Our parts are therefore set to have the right perspective in meeting the client's demands. Earlier these parts were imported, nowbeing "MADE IN AZAD".

Authors(s)

Rakesh ChopdarOwner & Managing Director

MAKE IN INDIA

#574

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BOSCH REXROTH - MAKE IN INDIA

Abstract:

• Company brief

• Highlights of manufacturing and testing infrastructure developed

• List of critical items being indigenously manufactured

• Markets / customers / projects from Indian manufacturing unit.

• Issues and challenges being faced

Brief Abstract Content

• About Bosch Rexroth in India, its spread, products and solutions offered to Indian customers.

• Highlights of processes, products manufactured and tested at Sanand plant.

• Successfully executed projects in key segments.

• Issues and challenges while doing localization.

Authors(s)

MAKE IN INDIA

Kaushik Bandyopadhyay

Johnson P R

Jignesh Soni

#579

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A PREMIER VALE MANUFACTURER'S MAKE IN INDIA JOURNEY

Abstract:

Velan is a Premier Valve Manufacturing Organization headquartered out of Montreal, Canada. We are leaders in Valve design withmany first to market Innovations. Velan has a proven ability to satisfy special project requirements through its extensive engineering,R&D, and in-house manufacturing capabilities using state of the art machinery.

Velan's India manufacturing plant in Coimbatore is a proof of its commitment to bring world class products to India and providecost effective solutions to the customers. The Manufacturing plant is situated in Coimbatore and has a capability to deliver nichevalves in the High Pressure/ High Temperature lines. Valves produced out of this facility are in use in many NTPC run super criticalplants across the country. Velan India also manufactures Hi Pressure Drain Valves (a patented Velan product) for the power marketin India.

The presentation in the conference is focused on Velan's Journey in bringing superior Engineering & Manufacturing technology toIndia and its ability to offer cost effective solutions to the Indian user Industry both in Power and Refining verticals.

Authors(s)

R Ramesh BabuVelan Canada

MAKE IN INDIA

#582

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M/S FLOWSERVE OVERVIEW AND CAPABILITIES

Abstract:

1) Company Introduction- Flowserve India & Flowserve Spain

2) Critical items indigenously manufactured in Flowserve India

3) Product profile & Product volumes shipped from Flowserve India

4) Major Projects Executed

5) Flowserve India manufacturing capabilities

6) Flowserve India testing capabilities

7) Package photographs

8) Engineering capabilities

9) ISO certificates

Authors(s)

Amit BakshiRegional Director-Commercial Operations,EPO-APAC & Middle East

Sachin PatilGeneral Manager -Commercial Operations -EPO India

MAKE IN INDIA

Vijay Raman BhanProject Sales Manager India

#584

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RATNAMANI METALS & TUBES LTD

Abstract:

Ratnamani Metals & Tubes Ltd, the largest manufacturers of Stainless Steel Seamless / Welded Tubes & Pipes, Nickel AlloySeamless Tubes, Titanium Welded Tubes and Carbon Steel Welded Pipes with facility for Coating of pipes.

Ratnamani has three manufacturing facilities situated Indrad, Chhatral and Kutch in the state of Gujarat, India. Ratnamani has itsown Hot Extrusion facility for manufacturing Seamless mother hollows, which is a pre-material for further cold finishing andproducing of High Pressure Feed water Heater tubes, Low Pressure Feed water tubes, Heat Exchanger Tubes and Instrumentationtubes. The usage of hot extruded mother pipes gives a distinct advantage as compared to the technology such as hot piercing.

Our manufacturing facilities are equipped with latest generation High Speed Cold Pilger Mills, Cold draw Benches, Off-line BrightAnnealing Furnaces for manufacturing Seamless Tubes - Heat Exchanger and Instrumentation. Similarly our Welded Tube mills areequipped with Online Eddy Current Testing, Bright Annealing, laser guided online dimensional controls. The tubes can be suppliedin both straight and U-Bend condition.

The SS Plants are equipped with inspection and testing facilities viz., Eddy Current Testing, latest generation

Ultrasonic Testing machines capable of checking wall thickness variation along the length of tube, Hydro Testing, Air Under WaterTesting and Laboratories for conducting in-house Mechanical, Corrosion and Chemical tests. We also have Real Time RadioscopyTesting (Digital Radiography), Film Radiography (X-Ray) to ensure consistent quality

Authors(s)

Jigar Sanghvi

Vijay Kaul

MAKE IN INDIA

#597

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MAKE IN INDIA IN TRANSMISSION SECTOR

Abstract:

The 'Make in India' campaign is aimed at making India a manufacturing hub with focus on 25 sectors. Even today manufacturing(16 per cent of GDP) pays more excise duty than services (60 per cent of GDP) pays service taxes.

Power Sector being one of the major industry. To create jobs, the country needs to move away from the services-driven growthmodel to labor-intensive manufacturing-driven growth.

Imports of electrical equipment in the country have assumed very threatening proportions and have now captured over 35% of themarket for electrical equipment in India, whereas there is significant under utilization of installed domestic capacity, resulting inloss of employment. The Indian electrical equipment industry comprises of two segments - generation equipment (boilers, turbines,generators) and transmission & distribution (T&D) and allied equipment like transformers, cables, rotating machines, etc.

India transmission grid has gone for 765kV network and due to scarcity of land GIS is the solution for faster implementation oftransmission projects. Since the voltage and the product is available only in East Asian countries players from these countryparticipated.

Disproportionate reliance on imported power equipment, with uncertain quality and lifecycle, and with no domestic manufacturingfacility to provide emergency repairs, spares, replacements, etc. especially for heavy equipment, is fraught with long term risks

Authors(s)

Sanjay BhambhaniGE T&D India Limited

MAKE IN INDIA

#604

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END TO END MANUFACTURING SOLUTIONS TO POWER SECTOR COMPONENTS:

CASE STUDIES

Abstract:

Kalyani Group of companies is actively involved in indigenization of parts, especially for high end applications, with the help of theirtechnological advantages in manufacturing practices and metallurgical know-how. This paper talks about successful developmentof some key components for power plant applications with end-to-end manufacturing from steelmaking to final finishing of theproduct. The challenges and solutions in manufacturing of components of critical grades like F91, F92, duplex stainless steels,rotor grade steels, alloy steels, ST 12 T etc. are discussed. This includes the success story of replacing cast coal crusher hammerwith forged hammer, with customized material

specifications to tackle different coal conditions. With the help of state of art testing and material characterization facilities at in-house R&D centre, including SEM, EBSD, EDAX, High and Low Cycle Fatigue, Creep, High Temperature Tensile and compressiontests, fracture toughness tests, the innovative solutions provided to the sector are discussed.

Authors(s)

Ajitkumar GaikwadR&D, Bharat Forge Ltd., Pune

Naresh SharmaAVP, Sales and Marketing

MAKE IN INDIA

#605

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INDIGENIZATION OF BOILER FEED PUMPS, CONDENSATE EXTRACTION PUMPS & HIGH

PRESSURE VALVES FOR SUPERCRITICAL POWER PLANTS KSB

Abstract:

Modern pump technology from Germany made inroads into India when KSB AG, Germany established its presence with the settingup of the first factory at Pimpri, Pune. The evolution of KSB in India has been in line with the development plans of the country'seconomy.

In 1960, the Irrigation and Process Division was set up at Pimpri in Pune followed by KSB foundry which was set up in 1974 atVambori, Ahmednagar.

The only certified facility in India to manufacture and test primary heat transport pumps for nuclear power plants was set up atChinchwad near Pimpri in 1978. High capacity, high head multi-stage pumps and condensate extraction pumps for the powersector are currently produced at the Power Projects Division.

And now, to address our endeavor to supply pumps for the supercritical power plants & nuclear plants, KSB in India is in theprocess of setting up a focus plant addressing these needs in Shirwal about 60 km from Pune.

Authors(s)

Rajesh Arora

MAKE IN INDIA

#606

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LARGEST SINGLE PIECE CASTING OF 53 MT FOR 660 MW SUPERCRITICAL TURBINE,

CASE STUDY

Abstract:

L&T MHPS Turbine Generators Pvt Ltd established Heavy Casting Unit (HCU) with an investment of Rs 120 Cr. to cater to therequirements of Steam and Hydro Turbine Heavy Weight Steel Castings. Equipped with state of art manufacturing facility, HCU canproduce 6 MT to 70 MT single piece weight casting in Carbon Steel, Low-Alloy and High Alloy Steel grades.

In short span of 4 years since inception, HCU has successfully supplied 14 Sets of Turbine Casings for Super Critical, CombinedCycle & Industrial Steam Turbines in Low Alloy & High Alloy Steels.

HCU is striving ahead to supply Heavy Weight Casings for Supercritical Turbine as an Import substitution for Indian OEMs. AlsoHCU have supplied Turbine Casings for 6 - Export Projects.

• Largest Single Piece Steam Turbine Casing - HP & IP combined design Outer Casing of 53 MT.

• Development of Steam Turbine Casing - IP Outer single piece weight 60 MT for 1000 MW.

Successful development of 9 % Cr (GX12CrMoVNbN9-1) Super Critical Turbine Inner Casings.

Authors(s)

Anjan BanerjeeHeavy Casting Unit

MAKE IN INDIA

#621

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229

GETS 2016

MANUFACTURING TECHNOLOGY OF CREEP-RESISTANCE STEEL FOR POWER INDUSTRY

Abstract:

L&T Piping Centre (a part of L&T Heavy Engineering) operates at the upper end of the technology spectrum, and has been at theforefront of introducing new processes, products and materials in the manufacturing sector. As part of Make in India new technologieshave been recently developed in-house such as for HSLA, 9Cr-1Mo-V and 9Cr-2W steels for the Power Piping sector meetingstringent quality and NDT requirements during cutting, fabrication, welding, bending and Heat treatment.

This paper describes the manufacturing technology details of P36, P91 & P92 materials and associated precautions duringfabrication.

Authors(s)

Ravi R JaniL&T Piping [email protected]

Binoy ShawL&T Piping [email protected]

MAKE IN INDIA

#623

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230

L&T'S JOURNEY FOR SUPERCRITICAL POWER PLANT STATIC EQUIPMENT

Abstract:

L&T Heavy Engineering, a part of the L&T Group has been manufacturing feedwater equipment for power plants for more than 2decades. These equipment are manufactured in our globally benchmarked workshops in Powai and Hazira. The designs arecarried out at our Powai Facility backed by our world class Technology Centre.

Under the Make in India drive, the Surface Condensers, Feed water HP & LP Heaters are now designed and indigenously manufacturedin L&T India and being supplied to NTPC projects.

L&T is also supplying globally to all major turbine players overcoming challenges on quality, technical competency, reliability andcultural issues. Currently,L&T is executing condensers and feed water heater for super critical projects in Indonesia and UAE.

The critical raw material like tubesheet forgings are also developed in house to help reduce dependency on Imports and meetproject schedules. The titanium tube to tubesheet welding procedure developed in house is 100% automated with zero defects.

Authors(s)

Suman Bakshi

MAKE IN INDIA

#627

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GETS 2016

L&T- MHPS TURBINE GENERATORS PRIVATE LIMITED

Abstract:

Ten years back in 2006, Government of India unveiled its grand plans to meet the burgeoning demand of power, with a singlesource of supply of power equipment, country was struggling to meet the demand. To mitigate the constraints, Larsen & Toubro

Limited collaborated with the Mitsubishi Heavy Industries of Japan and Mitsubishi Electric Corporation, Japan to manufacture hightechnology super-critical and ultra-super-critical Turbine & Generators in India for domestic market and established factory atHazira ,Surat Gujarat.

The factory was formally inaugurated on 11th of January 2011 . The Turbine & Generator Shops are part of one of the world'slargest and most advanced hubs for manufacturing the complete range of equipment for supercritical power plants.

LMTG is a Safety First Company with state-of-the-art facility and is acknowledged as one of the Best in the world. LMTG today isan established and respected player in the Indian Power Market and have international clientele spread across the Americas,Middle East and the Far East .

LMTG has the record distinction of achieving 95% of localization within this short time, a unique achievement by any standard andis the true pioneer to Make in India movement in the country. LMTG remains a true success story of Indo-Japanese Collaboration.

Authors(s)

Aloke SarkarVice President & Head - OperationsL&T- MHPS Turbine GeneratorsPrivate Limited

MAKE IN INDIA

#631

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232

U P STEELS

Abstract:

Formerly known as U.P. Steels, Isgec - Castings is one of the premier Heavy Steel Foundries in the world serving the PowerIndustry globally for last 3 decades.

It has large experience in making critical castings in various grades of Steel, Alloy Steel, SG iron & Alloy Iron used by the PowerIndustry all over the World, including Critical Metallurgies like P91 and Duplex Steel.

Castings are made in piece weight range of 100 kg to 60000 Kg.

Facilities:

1. Steel Refining by LRF/ AOD/ VD/ VOD after melting by Arc / Induction routes to make superior metal

2. Pattern: CNC Pattern making with large storage

3. Simulation: In-house MAGMASOFT & Pro-Cast softwares

4. Testing: State-of-the-art well equipped Laboratory with Gas analyzer, NDT & RT facilities.

Key Strengths:

1. Good updated infrastructure in the self-sufficient large integrated facility

2. Strong Metallurgy Knowledge with qualified & experienced team

3. Welding Technology

4. Collaborative support to customers with technical inputs using its qualified & experienced team

5. Well diversified portfolio (Power, Valves, Pumps, Steel, Cement, Mining etc) to bring knowledge & learning's acquired acrosssectors.

Authors(s)

Mahesh GuptaCOO & Business HeadISGEC Heavy Engineering Ltd.

MAKE IN INDIA

#635

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GETS 2016

SUPER CRITICAL STEAM TURBINE AND GENERATOR ISLAND FOR INDIAN MARKET

Abstract:

With the ever increasing concerns to build best-in-class manufacturing infrastructure including foster innovation, protect intellectualproperty and to enhance skill development, a major initiative "Make in India" is designed. Original equipment manufacturers(OEMs') are constantly striving to develop new local sources for cost improvement and best resources utilization. Indigenization ofcomponents is only possible once proper knowledge transferred and best practice implemented. This article seeks to demonstratethe influence of Make in India and the impacts on future growths.

Authors(s)

Akhilesh BahadurAlstom Bharat Forge PowerPvt Limited - [email protected]

Dharmesh SaveAlstom Bharat ForgePower Pvt Limited - [email protected]

MAKE IN INDIA

#641

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234

POWERING THE GROWTH

Abstract:

The ABFPPL, a joint venture of GE and Bharat Forge was setup for engineering, manufacturing and supply of Super-critical SteamTurbine and Generator Units to address the Indian requirement of STG Island based on advanced technology. In addition to theSteam turbine and Generators, a high efficiency and enhanced engineered balance of plant components to STG Island such asCondensers and Feed Water heaters were identified as key to the comprehensive local solution to be offered. To meet the aboverequirement, the technology for engineering, manufacturing and supply the state of the art Condensers and Feed Water heaterswere transferred from GE global lead centers to ABFPPL. The ABFPPL engineering center in Noida has the capability to completelyengineer these Condensers and Feed Water heaters with focus to increase the local content of the materials to be used in thisequipment at the same time enhancing the engineering to meet the specific Indian requirements. The best manufacturing processwithin GE to manufacture these Condensers and Feed Water heaters is being implemented in various manufacturing facilities inIndia - thereby ensuring that these locally engineered, manufactured and supplied product are world class and encompasses thegovernment's "Make in India" vision.

Authors(s)

Sandip [email protected]

Pawan Kumar [email protected]

MAKE IN INDIA

#642

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235

GETS 2016

LMB - A PIONEER OF MAKE IN INDIA IN INDIAN POWER SECTOR

Abstract:

L&T-MHPS Boilers (LMB) is a Joint Venture company of Larsen & Toubro Ltd. India with 51% equity and Mitsubishi Hitachi PowerSystems Ltd. Japan with 49% equity and was incorporated on April 18, 2007. LMB offers Supercritical & Ultra-supercritical Boilersover 500 MW and Coal Pulverizers on EPC basis covering complete Design, Engineering, Procurement, Manufacturing, ProjectManagement, Erection & Commissioning and After

Sales services. LMB has completed the technology absorption for Supercritical and UltraSupercritical Boilers. It has establishedinternational benchmark in boiler engineering industry using an integrated advanced 3 D modelling software with in-house capabilityand has validated design with firing Indian coal for the first time. Six units of boilers supplied by LMB have achieved commercialoperation and are successfully running.

LMB was the first private equipment manufacturer to establish super critical capability in India and strives to become the mostpreferred coal fired equipment supplier contributing to nation's power generation capacity in an eco-friendly manner. Within a shortspan of 6 years, LMB has successfully manufactured over 70,000MT of Boiler Pressure Parts and over 70 Pulverisers making itpioneer in 'Make in India' for power sector.

Authors(s)

Siddharth Gupta

MAKE IN INDIA

#654

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236

MAKING CONTROL SOLUTIONS IN INDIA

Abstract:

While for GE A&C, the manufacturing of the hardware may happen in USA, the products and solutions offered are more than justhardware. We have a strong engineering team working on current and future product lines and technologies which power theseController's logic. The Noida center is Center of Excellence for DCS & Excitation System . The teams work on the firmware,execution environment and custom solutions for projects and drives these product lines in association with the globally distributedteams. In addition to the product offerings, we have a very strong Projects team which has many noteworthy accomplishments toits credit.

Authors(s)

Manish SharmaMarketing Leader-GE Energy Connections

MAKE IN INDIA

#659

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237

GETS 2016

MAKE IN INDIA - ABB PERSPECTIVE

Abstract:

ABB India with its 49 manufacturing facilities located across 12 locations is one of the major players in the field of power andautomation. With a workforce of ~ 9000 employees, 3000+ resources in R&D, and close collaboration with local suppliers, ABBIndia is not only catering to Indian customers' requirements, but also exporting to 100 countries.

The "Make in India" concept has been ABB's core strategy to achieve business competitiveness for serving the customers locallyas well as globally. World's highest voltage 1200 kV power transformer and circuit breaker designed and made in India; pilot of firsturban multi-source microgrid in heart of Delhi; key partner in NE Agra - the World's first multi-terminal UHVDC transmission link;almost 50 % of solar power generated in India going through ABB equipments; and executed one of the first and the largest SCADAproject in India.

This article showcases some of the important ABB's contributions towards "Make in India" initiative, specifically in power andautomation domain. A collaborative and multi-disciplinary approach is, therefore, required across the value chain to successfullyachieve this target.

Authors(s)

C H Prahallad

Shrikant Bhat

MAKE IN INDIA

#664

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238

TOSHIBA JSW POWER SYSTEMS PRIVATE LIMITED - LIVING UP TO THE PROMISE OF A

BRIGHT FUTURE

Abstract:

Toshiba JSW Power Systems Private Limited (TJPS) is a 75:25 Joint Venture between Toshiba Corporation, Japan and JSW Group,India.

Since 2011, TJPS's 3000MW per annum, integrated manufacturing and test facility at Chennai, is supplying Steam Turbine andGenerator parts worldwide along with its parent company Toshiba. Toshiba to reinforce its commitment towards the growth ofIndian Power Sector, and also to ensure reliable after sales service and prompt technical support to its Customers has signedtechnology transfer agreement with TJPS. Key employees of TJPS have undergone rigorous class room and on the job training atToshiba operations at Japan. To supply "Japanese quality products and services" at Indian Market Price, Quality systems andstandards at TJPS are same as of Toshiba Corporation, Japan. TJPS, is committed towards "Make in India" has progressivelymoved up in value chain from only Steam Turbine and Generator manufacturer to a Complete Turnkey Solution provider to buildThermal Power projects on Engineering, Manufacturing, Procurement, Construction and Services (EMPCS) basis. TJPS will haveseamless access to the latest technology available at Toshiba Corporation, Japan. Toshiba JSW is an initiative of putting this greatnation, India on a world map as a Manufacturing hub.

Authors(s)

Jyotirmoy Mukherjee

MAKE IN INDIA

#671

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239

GETS 2016

EVALUATION OF AODV FOR QOS METRICS USING NS-2 SIMULATOR

Abstract:

The real time applications and multimedia consume lot of network resources, hence high flow rates and very less delay arerequired. The MANETs are not able to satisfy the QoS requirements. Therefore researchers have performed number of researchesin order to improve the QoS. The routing phase in mobile ad hoc networks play a vital role in improving the QoS. There are numberof existing routing protocols such as AODV, DSR, DSDV, TORA, etc. Here in this paper, AODV is taken into the consideration. TheQoS routing protocol based on AODV(MAODV) suggests that the discovery operation for the reconstruction of the path should bedone from the source node. In this paper, QoS routing protocol based on AODV(MAODV) gives better results than the existingAODV protocol with respect to the QoS metrics such as throughput, delay, pdr, energy, bandwidth etc. The Simulations were donein NS-2.34 in order to validate our proposed QoS routing protocol which is based on AODV.

Authors(s)

Spriha JohariMinistry of Law & Justice

Charu Wahi

MAKE IN INDIA

#695

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240

TECHNOLOGY TRANSFER: GERMANY >> INDIA KUHME INDIA'S FAST TRACK APPROACH

BOOSTED THRU MAKE IN INDIA

Abstract:

KÜHME Armaturen GmbH as a midsized company based in Bochum, Germany is serving the international power generatingindustry with special valve skid technology for safe isolation and control of fuel flow. Because of the rapid growth in the Indianpower generating market and the continuous request addressed by Indian customers KÜHME decided to establish the new productionplant KUHME Valves India Pvt. Ltd. (KVI) in Pune. KÜHME Germany participated in a special supporting program launched by theIndian Embassy in Berlin, Germany. This program is dedicated for German midsized technology providers - so called hiddenchampions - and is part of the MAKE IN INDIA initiative launched by the Indian Government. In March 2016 KUHME Valves Indiawas awarded to manufacture and to deliver 120 nos. of fully integrated Burner Valve Skids for NTPCs Mega Power Project BARH- Stage I. This paper covers the entire process of technology transfer from Germany to India. It also covers the managementdecision process including selection of optimum production place in India. This paper includes detailed inside views with regard tothe support granted by the Indian Embassy as part of the MAKE IN INDIA program. Finally this paper will conclude with a summaryas well as an outlook regarding the strategic next steps on the agenda to further develop and grow this particular new Indiancompany KV.

Authors(s)

Stephan SIMONBochum - [email protected]

MAKE IN INDIA

#696

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241

GETS 2016

TECHNOLOGY TRENDS IN RECIPROCATING STEM CONTROL VALVES

Abstract:

Traditionally Control Valve designs have evolved over a period of time, taking care to address the problems being faced by the end-users with existing valves in high pressure drop applications. With advent of supercritical power plants, the parameters likepressure/temperature of water/steam has increased over the years. In high pressure drop feed water applications like Boiler FeedPump Min. Recirculaton; Cavitation damage, low flow throttling damage to the seat, damage from foreign material are the mostpredominant causes of premature valve failures. After careful evaluation of all aspects involved, new range of high pressure dropcontrol valve solutions have been developed ingeniously addressing all the listed concerns. Internationally research is going on totest the material used in control valves for elevated temperatures and thermal cycling arising out of the upcoming Ultra SuperCritical Plants and the envisaged higher cyclic operations. From the environment perspective (more predominantly in Oil & Gassegment), fugitive emission from Control Valves is a major pollutant contributing to environmental degradation. State-of the ar tsolutions in Control Valve Gland Sealing has been developed jointly with internationally reputed gland sealing material suppliers, togive gland leak tightness of the gland almost equal to a Bellows sealed gland. The manufacturing facility is established with anintention to maximize the product performance and minimize impact to environment. The paper will cover the non-confidentialaspects of above.

Authors(s)

Biju SimonDGM (Sales & Marketing)MIL Controls Limited, Kerala

Sivaprakash. SDy. Manager - R&DMIL Controls Limited, Kerala

MAKE IN INDIA

#701

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242

THE NEXT GENERATION EDI FOR HIGH PURITY WATER – US INVENTION

Abstract:

The conductivity and low silica content for feed water requirements for high pressure boilers for the Power Industry are becomingmore and more stringent. Conventional mixed bed technology though meets these requirements; consistency in the permeatequality has always been the question. The resultant loss of energy through boiler blow downs, and storage and handling of harshchemicals, is the biggest drawbacks of the conventional system. The treatment of the waste generated and water wastage areother drawbacks. EDI overcomes all these disadvantages and with lower operating costs, has become the most popular technologyin power industry globally.

With patented dual voltage technology, QUA's FEDI (Fractional Electro-Deionization) technology is the next generation of EDI. FEDIimproves upon the reliability of EDI system. FEDI stacks are able to tolerate higher hardness in the feed water. As a result, FEDI canbe used after single pass RO without the need for softening or second pass RO. FEDI is a green technology which reduces theenvironmental foot print, it eliminates the use of chemicals and treatment of wastewater as required by MB.

With the manufacturing plant located in India, serving all the global requirements, QUA is able to assure the required technicalsupport and service, the two major deterrents for the promotion of EDI technology in India. We will present case studies onoperational data and economics.

Authors(s)

Abhijeet Puranik

MAKE IN INDIA

#721

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243

GETS 2016

ENGINEERING PIPING SYSTEMS AND PREFABRICATION OF SPOOLS FOR CONSTRUCTION

PRODUCTIVITY AND QUALITY

Abstract:

In chemical or Power plant construction Piping forms a very important component. Piping erection can start only after equipmentsare erected. Piping layout can be finalized only after receiving details from equipment manufacturer. In view of this Piping erectionbecomes Critical activity in plant construction.

By evaluating the layout in PDMS software and prefabricating spools the construction time can be considerably reduced. Also byprefabricating critical piping like P91/P92 materials 50% joints can be done in shop floor in controlled condition.

This presentation describes the details and advantages of this methodology based on our experience in this field.

Authors(s)

Muthiah KannappanDEE Piping Systems, India

MAKE IN INDIA

#736

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244

BHEL'S JOURNEY TOWARDS DESIGN AND MANUFACTURE OF STEAM TURBINES

Abstract:

BHEL Hyderabad with decades of experience and supply of more than 1100 steam turbines, has the know-how and know-why ofsteam turbines and is in a position to meet any plant specific requirement for captive industry, power plants and process industries.BHEL is fully equipped to provide comprehensive service to clients covering system design, engineering, manufacturing, turnkey,erection & commissioning and civil works. BHEL Hyderabad star ted manufacturing impulse type steam turbines in mid-3;82Óu"ykvj"vgejpqnqi{"htqo"Umqfc (Czech Republic) and First Brno (Czeck Republic). BHEL entered into collaboration withSiemens (Germany) in 1975 for industrial as well as utility sets (up to 120 MW) and started manufacturing reaction turbines sincethen. Collaboration with Siemens for Industrial range of steam turbines ended in 2011. BHEL has absorbed the technology, andsince 2011, has been taking and executing orders for steam turbines from various customers meeting their specific requirements.BHEL Hyderabad is now capable to design and manufacture steam turbines up to 200 MW and speed up to 15000 rpm. Steamturbines are designed as per the international standards IEC-45 and API612. BHEL is continuously striving for increasing theefficiency of steam turbines and to meet domestic customer requirement. BHEL Hyderabad is equipped for import substitution ofsteam turbines for various applications.

Authors(s)

Dr. G. Raghavender RaoDGM (BHEL Hyderabad)

MAKE IN INDIA

#748

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GETS 2016

STUDENTS' SECTION

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247

GETS 2016

MOLECULAR DYNAMICS STUDY ON THE EXTRACTION OF 1-BUTANOL FROM AQUEOUS

PHASE USING IMIDAZOLIUM BASED IONIC LIQUIDS

Abstract:

The gradual decrease of fossil fuel resources and ever increasing environmental pollution has led us to focus on alternative energyresources such as biomass. Due to its good calorific value biomass derived 1-butanol is gaining importance recently as analternative fuel. In our work, Molecular Dynamics (MD) Studies were performed to recover 1-butanol from aqueous phase presentin the biomass fermentation broth using four different Ionic Liquids (IL's). The IL's are based on 1-alkyl-3-n-octylimidazoliumbis(trifluoromethylsulfonyl) imide ([RMIM][Tf2N]), where R=ethyl, butyl, hexyl and octyl chains. The hydrophobicity of these IL's isknown to be controlled by the alkyl chain length. In the Liquid- Liquid Extraction studies, two clear phases were observed with eachof these solvents. Initially MD simulation was performed with [OMIM][Tf2N] to validate the reported experimental results. Resultsfrom extract and raffinate phases were then compared with the Liquid-Liquid Equilibrium (LLE) experimental studies for [OMIM][Tf2N]-butanol-water to explain the effectiveness of the solvent. Further the simulations were carried out for all the four solvents byvarying the solvent molecules or the composition of the feed. Simulations were run for a time period of 40 ns using OPLS-AA forcefield. A type II phase behaviour with a large immiscible region was observed for all compositions at T=300K. The selectivity valuecomputed was the highest (3583.73) for [OMIM][Tf2N] among the different Ionic Liquids. The distribution coefficient was found tobe greater than unity for all the IL's. It indicates an easier dispersion of solute from aqueous phase to extract phase. Greaterhydrophobicity of [OMIM] and [Tf2N] led to an absence of IL in aqueous phase. Radial distribution function and running coordinationnumber computation were done to provide a microscopic structure of the extract phase. From these two computational analysis itwas confirmed that a higher cation concentration was found to solvate the butanol molecules.

Authors(s)

Upasana MahantaIIT, Guwahati

Dr.Tamal Banerjee

STUDENTS' SECTION

#482

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248

PEIZOTECHENERGY - UTILISING WASTED ENERGY

Abstract:

Is nature available with sufficient stuff in its magical box? We the humans have used our natural resources to their infinite sincetime immemorial. But is it still found caught as puppet amidst our selfish desires? Yes or no. Let's give it a sight. As a result of theirincreased use, lots of energy resources have got exhausted. Now, it's time to strengthen our nerves and present nature a 'reward'in itself in the form of ENERGY CONSERVATION. Ranging from walking on our feet, how energy is found trapped once we roam all-around the world with 'CARS.' How the motion of electric cars gets possible with embedded crystals (PIEZOELECTRIC CRYSTAL)in its tires as a result of piezoelectric effect? The output due to deformation of tires is converted to d.c signal by an array of PZTbenders. Each PZT bender will act as single piezo-generator (PZT crystal surrounded by two metal electrodes). PZT crystals areused as it offers higher flexibility, reduces electrical impedance and high deformation areas of tires could not be covered and in turnoffers higher sensitivity upto 10db.The static motion of cars produces the force of M*g (where M is the total of mass of car plusmass of people sitting on it) whereas the dynamic motion of car produces the force of M*(g+a) (a is the acceleration of car).

Authors(s)

Harita UppalEE 4th yr, Jss Academy of Technical EducationNOIDAEmail id: [email protected]

Tripti MittalEE 4th yr, Jss Academy of Technical EducationNOIDAEmail id: [email protected]

Anshika DalalEE 4th yr, Jss Academy of Technical EducationNOIDA

STUDENTS' SECTION

#493

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249

GETS 2016

FLAMELESS COMBUSTION: A REVIEW

Abstract:

This review paper presents the characteristics of flameless oxidation/FLOX. In this present paper, combustion characteristics andpollutant emissions are studied for various types of fuels, both liquid and gaseous fuels. For some fuels, oxygen enrichment hadbeen done and its effect has been compared with the results without oxygen enrichment. For each case, pollutants emissions likeNOx, CO and HC have been studied and tried to reduce it further. This review paper also focuses on the efficiency of the combustion.

Authors(s)

Rohit RajDepartment of Mechanical EngineeringJSS Academy of Technical EducationNoida

Aman ChaurasiaDepartment of Mechanical EngineeringMeerut Institute of engineering and TechnologyMeerut

STUDENTS' SECTION

#500

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250

OPTIMIZATION OF WIND TURBINE BLADES

Abstract:

Renewable Energy Sources are the most widely used sources of energy nowadays. Solar and wind are frequently used for thegeneration of electricity. Solar energy is only available in day time but wind energy is available 24 hours that is why our main focusis to develop electrical energy from wind energy. We are planning to optimize the blades of the windmill in order to obtain aconsummate degree of rotation which we generally obtain in normal windmills and compare the data of production of electricitywith the general norms. We will collect the data for different composite materials and analyse the blade using the topologyoptimization technique followed by comparison of the results obtained with the material which is currently used. The main objectiveof this study is to use a material for the turbine blade which reduces the cost and increases the efficiency.

Authors(s)

STUDENTS' SECTION

Siddharth KesarwaniDepartment of MechanicalEngineering, JSS Academy ofTechnical Education

Tarun KulshresthaDepartment of MechanicalEngineering, JSS Academy ofTechnical Education

Tanush TripathiDepartment of MechanicalEngineering, JSS Academy ofTechnical Education

#509

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251

GETS 2016

INVERTED ROAD TRANSPORTATION

Abstract:

The present road transportation system has got very exhausted and is causing serious problems to the environment, thus there isa need for an up gradation in the system. The roads and vehicles used presently would be completely inverted in their working. Theroads would be made to move with the help of motors instead of the present technology where motors in vehicles help in moving.This methodology would reduce the burden on non-renewable resources and would help in making of a cleaner mode oftransportation. This idea will help people in a lot of ways, all the vehicles will be well aligned and thus, traffic problems will bereduced to a great extent, pollution levels would be greatly reduced, the accidents and crime activities will also be reduced. Thesystem would run independently without the need of non-renewable resources or electricity from grid. Thus, this makes it an idealup gradation required in the present road transportation system.

Authors(s)

Abhishek Matlotia

STUDENTS' SECTION

#572

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252

PINCH ANALYSIS OF TURBO DRYER FOR SLUDGE

Abstract:

Turbo dryer is extensively used in sludge drying because of its capability to dry sludge uniformly with high rate of moistureremoval. The main objective of this paper is to focus on reduction of energy consumption in continuous dryers for a given processrequirement. As continuous turbo dryers are enclosed, they keep surrounding environment relatively dustless and odourless.However, disadvantage of these dryers are of consuming marginally higher power. Generally, in these dryers, hot air and/orthermic oil is used to remove the moisture from the sludge by convection and conduction. The hot air exhausted from the dryer isat comparatively higher temperature and appropriate heat recovery may be possible. This problem may be better targeted forminimum utility requirement by pinch analysis. In this paper, problem is formulated based according to the pinch analysis byappropriate modifications of streams to satisfy mass and energy balance equations for individual streams as well.

Authors(s)

Sanjay Kumar PatelPh.D. ScholarSardar Vallabhbhai NationalInstitute of TechnologySurat, Gujarat, IndiaEmail: [email protected]

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#626

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253

GETS 2016

OPTIMAL AERODYNAMIC DESIGN OF NEW GENERATION SMALL-SCALE HORIZONTAL

AXIS WIND TURBINE

Abstract:

In this paper, optimal aerodynamic design of new generation small-scale horizontal axis wind turbine (HAWT) has been presented.The aerodynamic analysis has been performed using blade element momentum (BEM) theory to predict the aerodynamicperformance for 5 m rotor radius wind turbine. The NACA 63-415 airfoil has been utilized and optimized for design tip speed ratio(TSR) values for all turbines rotors. Moreover, a comparative study of turbine geometry has been performed at different TSR tooptimal design of turbine rotors and the pitch angle is considered to be zero. Here, annual energy yields of the small-scale HAWThas been also calculated as a function of average wind speed. In this study, curve fitting approximation has been utilized for tip lossfactor, chord and twist angle distribution. It is used for the design of any small-scale HAWT instead of tedious and iterative methodin MATLAB, which reduces plentiful computational time. It is observed that the results gives very small error against computationalresults of small-scale HAWT for lower wind applications.

Authors(s)

Umesh Chaudhary

Received the B.E. degree in electrical engineering from the Bhagalpur College of Engineering Bhagalpur,Bihar, India, in 2009, and the M.E. degree in electrical engineering from the Indian Institute of Science,Bangaluru, India, in 2011. He is currently working toward the Ph.D. degree in the Department of Electronicsand Electrical Engineering from Indian Institute of Technology Guwahati, India.

Dr. Praveen Tripathy

Received his Ph.D. in Electrical Engineering from Indian Institute of Technology Kanpur, India in 2011. Heis presently working as Assistant Professor in EEE at IITG.

Dr. Sisir Kumar Nayak

Received the M.Sc. (Engg.) and Ph.D. degrees from the IISc, Bengaluru, India, in 2003 and 2009, respectively.He is presently working as Assistant Professor in EEE at IITG

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#655

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254

OPTIMAL DESIGN AND ECONOMICAL ASSESSMENT OF SMALL-SCALE HAWT FOR

INDIAN SCENARIO

Abstract:

In this paper, a new generation small-scale horizontal axis wind turbine (HAWT) aerodynamic design and economical assessmentof 22 kW or less power rating turbine has been presented for Indian scenarios. The aerodynamic analysis is performed using bladeelement momentum (BEM) theory to calculate the total annual power generation for three different rotors. Moreover, the cost ofpower generation and payback period of complete wind energy system (WES) for all turbine rotor have been calculated andanalyzed based on overall efficiency. It found that, the initial cost of WES is approximately high but for long-term aspects andpayback period, it is good option. Finally, the technical and financial aspects of small-scale HAWT has been presented for lowerwind applications.

Authors(s)

JayshreeBanasthali Vidyapith

Umesh ChaudharyIIT G

STUDENTS' SECTION

#656

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255

GETS 2016

CHARACTERIZATION OF FLY ASH FOR UTILIZATION AS A STOWING MATERIAL IN

COAL MINES

Abstract:

Coal is a major source of energy. It contributes approximate by 55% of total energy production. In India, about 70% electricitygeneration produced by combustion of pulverized coal in thermal power plants. The available Indian coal quality is very poor. TheIndian coal having very high ash content and low calorific value, generate large quantities of ash produced as by-products ofcombustion. During combustion of coal in the thermal power plants generate large amount of inorganic residues like bottom ash,fly ash slag and flue gas desulfurization by-products, which have low value for utilization and several environmental problemsassociated with their deposition. During the hydraulic transportation and disposal, coal ash comes with contact with water. Thetracing elements present in ash migrate to ground water, surface water and soil over a period of time. The production of the largeamount of the toxic metal elements in ash disposal system of the thermal power plants can pose negative environmental effects onhuman health and on plants. The objective of present study to investigate the physical, chemical, mineral and rheologicalcharacteristics of fly ash for their potential utilization in stowing operation. Studies were conducted with fly ash collected from ashdisposal system of Guru Nanak Dev thermal power plant, Bhatinda, Punjab, India. From the characterization of fly ash sample, it isfound that the ash sample is enriched predominantly in silica; alumina and iron oxides that fall under the category of F type fly ash.The major mineral crystalline phase identified in the ash sample is quartz and mullite. From the properties of fly ash, it can be usedas a stowing material in coal mine.

Authors(s)

Jatinder Pal SinghResearch Scholar, MEDThapar University, PatialaEmail: [email protected]

Dr. Satish KumarAssistant Professor, MEDThapar University, PatialaEmail: [email protected]

Dr. S.K. MohapatraSenior Professor, HMEDThapar University, PatialaEmail: [email protected]

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#661

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256

OVERVIEW OF ELECTROMECHANICAL ACTUATORS USED IN MORE ELECTRIC AIRCRAFT

Abstract:

This paper presents the different electric motor technologies available in the literature for the aircraft applications which canreplace the existing actuation system. Aircraft applications usually demand high power density and high reliability while achievingthe goal of reducing fuel consumption, weight, cost, and environmental impact. New electric drives can replace conventionalhydraulic, pneumatic, and mechanical actuation system by electromechanical actuation system by meeting these requirements.This paper discuss the different actuators in aircraft and also the features of induction motor, reluctance motor, and PM motors onbasis of their fault tolerant capability, reliability, complexity, cost effectiveness and suitability for actuators in aircraft.

Authors(s)

Jaideepsingh R Patil

Ritesh Kumar Keshri

STUDENTS' SECTION

#666

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257

GETS 2016

FUEL FROM PLASTIC WASTES

Abstract:

As we all know, the world is leading towards an 'Energy Crisis'. Industrial development and population explosion have coerced usto a surge in the global demand for energy. The current supply of exhaustible sources of energy such as coal and petroleum hasbecome scarce and we are in a strong need of alternative sources of energy which, apart from meeting our energy demands, arealso eco-friendly.

One way is to obtain fuel energy from plastic wastes. Plastics are non-biodegradable polymeric compounds which are veryinexpensive and durable. However, plastic causes land pollution, adversely affects wildlife and humans, waterways and oceansand undermines their beauty. Hence, obtaining fuel energy from plastic wastes will not only meet our energy demands but will alsohelp in their successful elimination and/or processing and disposal.

The paper deals with the procedure for the conversion of plastic wastes to fuel energy using pyrolysis and its scope. The techniqueis being currently used successfully in various countries like India, UK, Spain, etc. and has proved quite satisfactory. One tonplastic can be used to produce 700L diesel and 100L kerosene. One of the best examples is the Cynar fuel plants which presentlyproduce 19500 liters of usable fuel from 20 tons of plastic waste daily. With the help of further research in this field, we may beable to make this technology more efficient as it, beyond all doubts, holds a great deal of potential in present and future.

Authors(s)

STUDENTS' SECTION

Shantanu VaswaniJ.S.S Academy ofTechnical Education

Saurabh MishraJ.S.S Academy ofTechnical Education

Divyansh MishraJ.S.S Academy ofTechnical Education

Shubham BhasinJ.S.S Academy ofTechnical Education

#667

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258

REUSE OF MOISTURE CONTENT IN FLUE GASES

Abstract:

Electricity plays a prominent role in the life of a human being and plays a very prominent role in the development of a country. Soincrease in production of electricity with less extra input is actually important in the present scenario.

Water is undoubtedly the most essential element that needs to be saved or reused.

This paper deals with a common solution to the above mentioned problems. The process explained in this paper uses the moisturecontent in the flue gas that is getting wasted. We propose some changes in the present design (just before chimney) for the betterworking of proposed process.

Authors(s)

Makireddy SaliniNIT RaipurEmail: [email protected]

Gagandeep Singh KhanujaNIT RaipurEmail: [email protected]

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#672

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259

GETS 2016

INTEGRATED GASIFICATION COMBINED CYCLE (IGCC) POWER GENERATION WITH RE-

CYCLE FLUE GAS USING COAL/BIOMASS BLEND AS FUEL

Abstract:

There is a need to reduce greenhouse gas emissions in order to meet India's the INDC targets at the COP21 summit held in Paris2015. In this context, biomass co-firing is a possible option to reduce the CO2 emissions in the atmosphere. Biomass can beconsidered as "CO2-neutral" as CO2 is absorbed during the growth of biomass. Therefore, CO2 capture during co-firing can beCO2-negative which is a very attractive way of reducing overall CO2 emissions. The use of renewable energy sources is beingpromoted through the Renewable Purchase Obligation (RPO) which is expected to create certain percentage of power fromrenewable energy sources. In the present study, this aspect is explored by considering co-firing of biomass fuel with coal in theOxy-CO2-IGCC-CC (with carbon capture) power plant. Due to biomass ash agglomeration properties at high gasification temperatures,Indian coals can be co-fired with biomass up to 10% thermal output. The Oxy-CO2-IGCC-CC plant with high ash Indian coal at aflow rate of 100 kg/s to a gasifier operating at 30 bara is taken as reference. The plant produces a net electrical power output of379 MWe. In co-firing mode, the net power output should remain the same and 10% power output should come from biomassfiring so as to meet renewable purchase obligation. Detailed analysis of IGCC-CC plant is performed with iterative calculations.

Authors(s)

V.Satyam NaiduPhD Scholar at IIT Madras

Preeti AghalayamProfessor in Chemical Dept.at IIT Madras

Sreenivas JayantiProfessor in Chemical Dept.at IIT Madras

STUDENTS' SECTION

#674

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260

ELECTRICITY BILL ANALYSER (TECHNICAL APP)

Abstract:

Today when we get our electricity bill we just look at the bill amount and hardly care about how much units we have consumed andwhat is the actual importance of those equivalent units. We could have used this amount to enlighten the street lights, traffic lightsand other such appliances around us. The app will give right estimation for this problem…

Solution:

We will input basic information of the user in the beginning like number of family members, number and categorization of appliancesrunning on electricity in their house. Then, the user will enter the bill amount and total units consumed for some defined period (say1 month).The app will display the user his consumption and also enlist the importance of electricity units they consume byshowing them how many other appliances like street lights, e-rickshaw, etc… can run for hours by the equivalent units.The usercan change appliance number and hours used accordingly and calculate units by Unit Calculator and also give an analysis of theirbill according to our estimate.The app will analyse the bill and estimate approximately how much units out of total units isconsumed by which appliance whether it is AC, electric geyser, tube lights and other appliances distinctively.The app has a featureof Compare and Share, where the user can compare his bill with his friend's bill and can share it on Facebook, Twitter or othersocial media platforms.Finally this app also tells you about how many slum houses summed up to give equivalent units consumptionthan that of your one single house does.As an add-on the app will have saving tips which will help users to save and reduce theirbills in future…

Authors(s)

Yashi GuptaABES Engineering College

Shubham RawatABES Engineering College

STUDENTS' SECTION

#676

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261

GETS 2016

DIFFERENTIAL PROTECTION OF TRANSMISSION LINE USING WIRELESS COMMUNICATION

Abstract:

Pilot wire differential protection is one of the most common methods for protecting short transmission lines. The conventionalprotection scheme has drawbacks, such as malfunction due to line disconnection and limited line length. The protection algorithmis based on current signals measured at both ends of the transmission line. The data is exchanged through the wireless communicationnetwork. The relay decision is based on data sharing obtained through wireless communication network. Current differentialprotection using pilot wire is applied widely on transmission lines as the main protection. Vector difference between the measuredcurrents at the two ends of the transmission line is used for the operation of most current differential relays. The length of the linethat can be protected by the pilot wire differential protection is limited by the effect of resistance and capacitance of the pilot wire.Here PIC 16F877A controls the entire system. The PIC compares the values of both the end of the transmission line with the helpof Mikro C program. The instant value of voltage, current and frequency is measured and monitored with the help of an LCDarrangement which is connected to the port D of the microcontroller. The status of both the end is transferred with the help of awireless communication through ZigBee. The systems consist of master and slave section and the master will control the relay inboth the section. The relay arrangement which connected in the master station will trip the circuit whenever a fault occurs.

Authors(s)

STUDENTS' SECTION

#685

Gagan BatraB.Tech, Bharati Vidyapeeth'sCollege of Engineering

Shubham BaunthiyalB.Tech, Bharati Vidyapeeth's Collegeof Engineering

Himadri SinghB.Tech, Bharati Vidyapeeth'sCollege of Engineering

Vaibhav BalujaB.Tech, Bharati Vidyapeeth'sCollege of Engineering

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262

SOLAR PANEL ANGLE CALCULATOR (TECHNICAL APP)

Abstract:

To figure out the finest position and direction angle of a solar panel to capture maximum sunlight and give the optimal results allyear round.

Uniqueness:

Measure results of all possible positions and identify the pre-eminent out of it using algorithms and calculations. Further tellingapproximate amount of energy that can be generated with the position suggested.

Solution:

One solution is to angle the panels to track the sun minute by minute by using an automated solar tracker. But, the expense of atracker is more than buying additional panels to compensate. The amount of power, a solar tracker uses in order to track the sunalso reduces the efficiency of the system.As the correct angle of Photo-Voltaic panel depends upon the latitude and longitude, sousing the current GPS location or by manually feeding the latitude and longitude of the required place, the application's algorithmwould evaluate angle of photovoltaic panel on which sunlight is maximum throughout the year.Generally, the solar panels used inhomes and industries are placed considering the main factor that affects the efficiency of Photovoltaic system i.e. the amount ofsunlight captured by them. Our solution is to analyze this factor in a more dynamic manner and provide an appropriate result to theuser, so that Photovoltaic panel (Solar Panel) produces efficient results.The optimum angle which provides consistent resultthroughout the year is evaluated by the algorithm. It would also evaluate the amount of power that the solar panel can generate bythe angle provided.

Authors(s)

STUDENTS' SECTION

#686

Tarun SethiaABES Engineering College

Shubham ShuklaABES Engineering College

Shreya BhartiABES Engineering College

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263

GETS 2016

A CRITICAL REVIEW ON MANAGEMENT OF SOLID WASTE IN INDIAN SCENARIO

Abstract:

As urbanization and economic development increases in our country at a very fast rate, the adverse impact of it is generation of"detritus," or solid waste. The major problem which rises during any activity to control this is lack of awareness among people.Keeping the society clean and clear is the responsibility of every individual of society. Disposal of waste material highly dependsupon the conditions of a particular place or country. Improper solid waste management causes Air Pollution, Water Pollution andSoil Pollution. Microbial Solid Waste clogs drains, creating stagnant water for insect breeding and floods during rainy seasons.Greenhouse gases are generated from the decomposition of organic wastes in landfills. Insect and rodent vectors are attracted tothe waste and can spread diseases such as cholera and dengue fever. Waste management is one of the major problems currentlyfaced by our society. The specific technologies and mechanisms are probable solutions to India's Solis Waste Management crisis.The areas of focus are Recycling, Aerobic Composting (or Mechanical Biological Treatment), Small Scale Biogas (or Bio-methanation),Refuse Derived Fuel (RDF) and Waste-to-Energy Combustion (WTE), these technologies are selected based upon their successinside and outside India, suitability to Indian conditions, environmental impact and economics. It is beyond the scope of this paperto venture into the debate on "the limits to growth" vis-à-vis resource consumption or the negative environmental impacts that willoccur from wastes generation.

Authors(s)

Harshit Sharma

STUDENTS' SECTION

#691

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264

ANTIMATTER – UNEXPLORED ENERGY

Abstract:

In this universe, everything was created in pairs, which are exact opposites of each other. Like Yin and Yang, electron and positron,etc. Same way, for matter there is antimatter. Therefore, we can say that antimatter is the exact opposite of matter.

Antimatter is a material composed of antiparticles, which have the same mass as particles of ordinary matter but oppositecharges.

The energy density of antimatter is higher than that of conventional fuels. If matter-antimatter collisions resulted only in photonemission, the entire rest mass of the particles will be converted to kinetic energy. The energy per unit mass is about 10 orders ofmagnitude greater than chemical energy and about 3 orders of magnitude greater than the nuclear potential energy that can beliberated using nuclear fission.

We just need to think of ways to harness this energy, and make this economically feasible. The only problem in making this feasibleis that the expense of creating a small amount of antimatter is much higher.

Authors(s)

Divya Saxena

STUDENTS' SECTION

#692

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265

GETS 2016

MAKING A AMMONIA(NH3) PLANT ON OCEAN OFFSHORE BY USING ELECTRICITY GENER-

ATED FROM OTEC POWER PLANT

Abstract:

Ocean Thermal Energy Conversion (OTEC) is the use of temperature difference between the surface water of ocean and water atcertain depth, by generating electricity .In this paper we generate electricity by closed cycle OTEC power plant and the losses inhigh cost of cold water pipeline and in electricity transmission is reduced by making a floating NH3 production plant on oceanoffshore by using electricity generated by OTEC power plant .The raw material for that like air and H2O is easily available on oceansurface. Thus the final product along with byproduct H2 and O2 is shipped from the offshore plant to the required place rather thanelectricity transmission and the use of floating offshore plant reduced the cost of cold water pipeline.

Authors(s)

Shyam Kishor SharmaStudent, Mechanical EngineeringJSS Academy of Technical Education Noida

STUDENTS' SECTION

#705

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266

DESIGN OF A COST-EFFECTIVE SMALL WIND TURBINE FOR LOW WIND SPEEDS

Abstract:

Small wind turbines (SWTs) available in the country today are expensive imported units that are generally designed for higheraverage wind speeds, not prevalent in India. They are not popular due to their low efficiency and consequent long payback period.The motivation is therefore to design and develop a cost-effective, efficient, small wind turbine for direct stand-alone application inurban, coastal and rural areas.

The airfoil sections have to be optimized for the SWT for the characteristic low wind speed and Reynolds number (Re), typicallybelow 500,000. The airfoil sections conforming to this requirement namely the Aquila, Eppler, Wortman, Selig, and the SG serieswere studied resulting in the choice of the SG6043 airfoil section with high lift to drag ratios (CL/CD) and soft stall. AvailablePermanent Magnet Generators (PMGs) were studied for their favorable characteristics and a Ginlong 500 PMG was selected forpower generation output of 500W at 450 rpm with low cogging torque. An iterative code based on the Blade Element Momentumtheory was used to predict the performance of the wind turbine. The parameters of diameter, tip speed ratio, number of blades,chord, and pitch were varied, to obtain the combination with the best performance (CP, power and torque). The starting time wasalso estimated for the design. The final design has 2 blades with 2.8m diameter and rated power of 500W at a wind speed of 7 to8m/s. The choice of this wind speed is on the basis that the maximum design wind speed should be twice the average operationalprevalent wind speed. The design is applicable for stand-alone off-grid applications.

Authors(s)

Vaisakh Suresh KumarResearch ScholarDepartment of Ocean Engineering,IIT MadrasChennai 600036, India

V Anantha SubramanianProfessor, Department ofOcean Engineering,IIT Madras,Chennai 600036, India

STUDENTS' SECTION

#719

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267

GETS 2016

DEVELOPMENT OF IMPROVED SYSTEM DESIGN FOR DENSE-PHASE PNEUMATIC CONVEY-

ING OF FLY ASH

Abstract:

Typical Indian coal used in thermal power plants normally have about 35-45% of ash. About 60% of India's total power generationcomes from coal fired thermal power stations (using such high ash coal) thus making safe and reliable. Fly ash should bepreferably conveyed in dry mode (i.e. using pneumatic conveying) as per MoEF guidelines. Transportation of fly ash using fluidizeddense-phase mode has gained tremendous popularity in power plant in recent times. Lower air flow rate and gas velocity, reducedpipeline size and wear rate makes the dense-phase flow a favorable choice as compared to conventional dilute phase. However,designing such fluidized dense phase system is not a trivial task. This is due to highly turbulent, complex nature of the gas-solidsmixtures. In this work authors tried to give some insight on the fundamental phenomenon of fluidized dense-phase flow. Conveyingof power station fly ash has been studied through different pipeline configurations. Different fly ash samples were examined in afluidizing column to determine the de-aeration characteristics and fluidized bulk densities. Conservation equations for the fluidizeddense-phase flow system were developed and solved using fourth-fifth-order Runge-Kutta-Fehlberg (RKF45) method for differentfluidized bulk densities and air mass flow rates. It has been observed that the particle velocity actual gas velocity and their ratioincrease, whereas, the solids volumetric concentration decreases down the pipeline. The existing empirical models and experimentalresults are found to be in good agreement with numerical results. Improved model for solids friction factor have been developed,with the help of using existing dilutephase model which has been modified for dense-phase flow condition. The experimental andpredicted pneumatic conveying characteristics were compared to validate the solids friction factor model which is used it topredict the total pipeline pressure drop. The results show that the predicted model has shown acceptable predictions.

Authors(s)

Kapil Sharma

Baldeep Kaur

STUDENTS' SECTION

#723

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268

MODELLING OF WIND-SOLAR HYBRID SYSTEM WITH IMPLEMENTATION OF EFFICIENT

MPPT ALGORITHM USING MATLAB

Abstract:

Renewable energy source is the fast buzz of the life save alternative. Solar has received increased emphasis for the past fewdecades. Wind comparatively less, but has managed to catch the attention of researchers prevailing to the present energy scenario.To vanquish these energy crises, proper choice of renewable power sources with efficient control is an immediate need. A combinationof two or more renewable sources can prove effective in terms of cost cutting and reliability when compared to single source. Thispaper proposes a hybrid energy system implementing solar panel and wind turbine as an effective substitution for conventionalthermal and hydro power plants. Considering the low efficiency of wind and solar the key principle of the proposed work is to use maximum power point trackers (MPPTs) so as to optimize the cost and size of the solar panels and wind turbines. The studydiscusses the detailed SIMULINK modelling of solar PV panel/Array and wind turbine PMSG system. A DC-DC buck boostconverter is used to implement the MPPT algorithms successfully. An incremental conductance MPPT algorithm is incorporatedfor maximizing the output power from PV panel and a simple hill climbing search algorithm tracks the maximum power profile incase of wind. Future work includes development of a novel topology for wind and solar hybrid minimizing the use of converters.

Authors(s)

Pratik RaoM.Tech from Electrical Engineering Dept.Sardar Patel College of Engineering,Mumbai, India

B. B. PimpleAssociate Professor in Electrical Engineering Dept.Sardar Patel College of Engineering,Mumbai, India

STUDENTS' SECTION

#739

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269

GETS 2016

AUTOMATED STREET LIGHTING SYSTEM WITH INTENSITY CONTROLLER USING

PWM TECHNIQUE

Abstract:

Conventional street lighting system operates irrespective of the passerby frequency. It is used mainly for lighting purpose on roads.Since, it doesn't take into account the passerby frequency; it leads to economic losses in power systems. With the currentgovernment taking initiatives towards energy efficiency, the current power system is primarily focused on sustainability. A well-designed lighting system should be capable of performing tasks in order to achieve self-sufficiency and reduce human efforts.This problem desires a need to design a system which is automated and reliable. This work aims at introducing automation (bydetecting failure of lights and gas leakages) and flexibility (by varying the intensity levels of the light using PWM technique) in aStreet Lighting system. It will help to design an Automated Street Lighting (ASL) System which accomplishes the need of a flexiblepublic lighting and increases reliability.

Authors(s)

STUDENTS' SECTION

Vishal MittalPEC Chandigarh

Hriday KohliPEC Chandigarh

Rishabh GuptaPEC Chandigarh

Arushi SinglaPEC Chandigarh

Rahul SharmaPEC Chandigarh

#749

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270

PICO HYDRO -SOLAR HYBRID SYSTEMS – A FEASIBILITY STUDY

Abstract:

India is one of the world's most pressing environmental concerns state nd it calls for stable community-managed power. In India,the environmental degradation caused by fossil - fuel based energy generation has led the governments and policy makers toswitch to renewable and clean energy technologies. Government of India also has initiated a Ujwal Bharat programme by targetingrenewable energy capital to 1,75,000 MW by the year 2022. The use of renewable solar energy is more attractive in water pumpingsector applications in remote areas of many developing countries. Hence, solar photo voltaic (PV) water pumping has beenrecognized suitable for grid isolated rural locations and alternative to diesel operated pumps. The solar water pumps have a uniquecost structure with very high capital investment and near zero marginal cost of pumping.

In India there are around 18 million agricultural pump sets and approximately 0.5 million connections per year are being installedwith average capacity of 5 HP. Total annual consumptions in agricultural sector is about 19% of total electricity consumption. Thewater power delivered by the electrical pumps possess in the form of some energy before it irrigates the crops. The purpose of thisfeasibility study is to develop a hybrid Pico Hydro -Solar(PHS) system to generate electrical power. The pilot investigation has beenconducted at Central Water and Power Research Station (CWPRS), Pune. The system consists of a micro cross flow runnercoupled with the DC generator produces the electricity from the water pump delivery line and integrated a roof top solar panelarrangement on the existing pump house develops solar PV system. The hybrid system helps in recovering energy from the waterpower and solar energy. The energy developed can help in supporting the house hold demands considerably in the agriculturalareas which are grid dependent.

Authors(s)

STUDENTS' SECTION

Abhinav MisalkarB.Tech Final YearVishwakarma Institute of TechnologyPune

Rajan PalaiB.Tech Final YearVishwakarma Institute of TechnologyPune

Shirish YemulB.Tech Final YearVishwakarma Institute of TechnologyPune

Dr. K. KumarScientist B, CWPRS, Pune

Prof. P. S. DhaneshwarProfessor, Vishwakarma Instituteof Technology, Pune

#764

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271

GETS 2016

CONCEPTUALISING DECENTRALISED WASTE – WATER TREATMENT UNIT

Abstract:

Decentralization of waste water treatment is not a newly initiated process. Even after a lot of painstaking effort from variousresearchers we have not ensured wastewater reuse in households and communities on a larger scale. No abatement is observedin ever increasing gap between water supply and recycle. More than 80 % of the water supplied in households is used for non-potable purposes. Government spend 27 (Rs/kl) for supply of water to households and they get approximately 1.25 (Rs/kl) inreturn. There are huge losses been incurred by government on a daily basis. Whole document reflects upon the need for reuse ofwaste water than merely recycling it. Paper propose a concept design for treatment of waste water in households which canensure the reuse of water after recycle. It is not a full fledged design. Concept design proposed in the paper caters to the constraintsof cost, paucity of space, quality of treated water and reuse of treated water in the households. Septic tank has been redefined inthe proposed design to increase its efficiency in waste water treatment. Septic tank are getting obsolete from the towns. This paperinitiates the need to ponder over the decision again. Element of flexibility has been involved by in the conceptualised method bydesigning based upon the inlet BOD to the treatment plant. Special emphasis has been laid upon the importance of decentralisedtreatment units by discussing case studies of different nation and critically analysing centralised treatment units and technologycurrently involved in treatment of waste water.

Authors(s)

Rohan Sharma

STUDENTS' SECTION

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OPTIMISING ENERGY EFFICIENCY IN DELHI METRO COACHES BY INSTALLATION OF INTEL-

LIGENT LIGHTING CONTROL

Abstract:

In the times of rising issues of environmental pollution and global warming, energy conservation and energy efficiency have helda key status in the 21st century. In terms of energy use, transport sector is only next to industrial sector and accounts for 22% oftotal commercial energy consumption. To reduce the energy consumption and prevent use of exported oil, many countries haveemployed Mass Rapid Transit System (MRTS) for public transport. These Rapid Transport Systems have proved to be lesserenergy intensive than the conventional systems of road transport. With advancement of technology as well as awareness, there isa huge energy saving potential that can be explored in these Rapid transit systems.

This paper studies the potential of energy saving in India's first rapid transit system, Delhi metro by reduction of lighting load. Themechanism is to use daylight during the elevated run of the metro trains and dimming the lights while maintaining the desired luxlevels inside the metro coaches using intelligent control sensors. The same intelligent control system can be used to maintaindesired lux levels as per lighting standard during underground run of the metro trains.

The analysis shows about 1 MW lighting load in metro trains during availability of daylight. With only sunlight entering the metrotrains, the lux levels inside the metro are more than that required as per the Indian lighting code and thus a major fraction of theaforementioned lighting load can be saved. It is proposed in the paper to employ 75% dimming of lights using the optical sensors.Considering same luminaire efficiency, there is a potential of energy savings in the range of 778 MWh to 2333 MWh by efficientuse of day light. A prospective 90% saving i.e. 1244 MWh to 2800 MWh can also be achieved by efficient use of daylight andenergy efficient luminaires. Also, during the underground and night journey of metros, optimum lighting levels (lux) can be maintainedby use of optical sensors which will result in further energy savings.

Authors(s)

KajolCentre for Energy StudiesIndian Institute of Technology,Delhi, India

Deepak Kumar SahaniCentre for Energy StudiesIndian Institute of Technology,Delhi, India

STUDENTS' SECTION

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Page 274: GETS 2016 - NTPC GETS e-Compendium.pdf · 1 GETS 2016 MESSAGE Gurdeep Singh Chairman & Managing Director NTPC Limited I am delighted to be a part of GETS 2016, a confluence of technology