1. MBA Internship
On
“Stock and Inventory Flow Analysis for Chemicals at
PTPS Stores”
At
UPRVUNL Panki Thermal
Power Station
(Institute Of Management)
Submitted by: Saurabh Vishal
Roll No.:16614176
2. ACKNOWLEDGEMENT
On completing this project it is my pleasure to
thank to acknowledge and extend my heartfelt
gratitude to the following people who made the
completion of this project possible:
My Mentor
Er. Vivek Asthana
(Executive Engineer,MPD, PTPS,UPRVUNL.)
Er. Harish Awasthi
(Assistant Engineer,Central Stores Division,PTPS,UPRVUNL)
Mr. Mathur
(Chemist,OG,PTPS,UPRVUNL)
for their invaluable contribution and support.
And last but not the least I would like to thank
Christ University Institute Of Management,
Bangalore for giving me the opportunity to
learn and explore various fields.
3. Power Consumption In India
The energy sector holds the key in accelerating the economic growth of India. The energy
demands for developing country like India keep on continuously growing. Energy is a driving
force behind rapid economic growth of the country. India ranks tenth in the world in total
energy consumption. It is first requirement of energy to accelerate the development of the
sector to meet its growth aspirations. Ø The pattern of energy production put coal and oil
again on top. These account for 65% of the entire generation. Renewable energy ranks
bottom of the total production just before the Nuclear energy. The distribution of energy
resource like hydro power is skewed towards North-eastern states of the country as 70 % of
the total hydro potential is located in the Northern and North-eastern region.
Figure Of Power Generation
4. In India there is a very long chain of thermal power project including the project in UP. Uttar
Pradesh Rajya Vidyut Utpadan Nigam Ltd. is the company handling thermal power stations
in the Indian state of Uttar Pradesh. UPRVUNL is wholly owned state thermal power utility
with present[when?] generating capacity of 4933 MW, operating 5 Thermal Power Stations
within Uttar Pradesh.
History
· Uttar Pradesh Rajya Vidyut Utpadan Nigam Limited (UPRVUNL) was constituted on
dated 25.08.1980 under the Companies' Act 1956 for construction of new thermal power
projects in the state sector.
· On 14 January 2000, in accordance to U.P. State Electricity Reforms Acts 1999 and
operation of U.P. Electricity Reforms Transfer Scheme 2000, U.P. State Electricity Board
(U.P.S.E.B.), till then responsible for generation, transmission and distribution of power
within the state of Uttar Pradesh, was unbundled and operations of the state sector thermal
power stations were handed over to UPRVUNL
· Unchahar Thermal Power Station - 420 MW (2X210) & Tanda Thermal Power Station
440 MW (4X110) were transferred to NTPC in year 1992 & year 2000 respectively before
unbundling of U.P. State Electricity Board (U.P.S.E.B.) into;
1. Uttar Pradesh Rajya Vidyut Utpadan Nigam Limited (UPRVUNL),
2. Uttar Pradesh Power Corporation Limited (UPPCL),
3. UP Power Transmission Corporation Limited (UPPTCL),
4. UP Jal Vidyut Nigam Limited (UPJVNL).
Power plants
Past Transitions- (860 MW)
Erstwhile U.P.S.E.B. transferred its two thermal power stations among others to NTPC
Limited against payment overdue. These power stations are;
· Unchahar Thermal Power Station 420 MW (now Feroze Gandhi Unchahar Thermal
Power Plant)
· Tanda Thermal Power Station 440 MW (now Tanda Thermal Power Plant)
5. Present Installations- (5933 MW)
At present,As of 2014 UPRVUNL is looking after generations of power of five thermal power
plants located in different parts of Uttar Pradesh, with a total installed generation capacity of
4933 MW.
· Anpara Thermal Power Station 2630 MW
· Obra Thermal Power Station 1288 MW
· Panki Thermal Power Station 210 MW
· Parichha Thermal Power Station 1140 MW [1]
· Harduaganj Thermal Power Station 665 MW [2]
Though installed capacity is 5933 MW but UPRVUNL is not able to utilize its full capacity
ever due poor maintenance, lack of funds, aging plants & frequent units tripping.
Future Expansions
Upcoming Projects
Construction Stage- (3300 MW) Meja Stage I Meja Thermal Power Station, Meja Urja Nigam
Private Limited (In 50:50 equity JV with NTPC Limited) - 2X660 (1320 MW)
· Karchana Thermal Power Station - 2×660 (1320MW)
· Harduaganj Extn.2 - 1×660 (660 MW)
Planning Stage- (6600 MW)
· Panki - 1x660 (660 MW)
· Obra Stage C - 2x660 (1320 MW)
· Meja Stage II - 2x660 (1320 MW)
· Ghatampur Thermal Power Station - 3×660 (1980 MW) - a Neyveli Uttar Pradesh
Power Limited (In 49:51 equity JV with Neyveli Lignite Corporation Ltd.)
· Jawaharpur Super Thermal Power Station, Etah district --2x660 MW [3]
6. PankiThermalPower Station
Panki Thermal Power Station(PTPS), Kanpur[U.P] Ø Panki Thermal Power Station is a
Electricity Generation Station where Electricity Generated through the steam operation on
Turbine & Steam is Generated by Coal Firing so it is a Typical Coal fired Electricity
Generation Station. Ø It is Located about 16 Kms Away from Kanpur Railway Station ,was
Started with two units(1st & 2nd) of 32 MW each.it was established in 1968. Ø After
Generating Power for about 28-29 years,2*32 MW units had completed their Rated Life So
they were closed on 30th November 1995 & 18th April 1997 respectively. Ø So In 1976-77
,Two Units (3rd & 4th of 2*110 MW each) Manufactured ,Installed Bharat Heavy Electronics
Ltd. These units were established in 1976 & 1977 respectively. Ø Unit 3rd & 4th have been
derated to 105 MW each by the Central Electricity Authority(C.E.A) on 11th January 1990.
So Presently there are two units (3rd & 4th of 105 MW each) working at PTPS.
Water TreatmentPlant
The Water Treatment plant is required at the water from canal can’t be directly Used in
Boiler for Thermal Electricity Generator water is converted into steam at High Pressure & It
is allowed to force Turbine Rotated and the electricity is Generated. Therefore water is the
basic requirement to the thermal Power plant. Generally in the Thermal Power Plant Is
Employed to Refine the Water. Necessity of Water Treatment:- Natural Water Contains
Solid,Liquid & Gasseous Impurities and Therefore this water can’t Be used for Generation of
Steam in the Boiler ,The different Effect introduced due to use Of Unrated Water in the
boiler.So the water impurities should be removed before its used as a stream.The following
procedure is used in WTP for minimizing the hardness & removing the impurities:-
Flocculate Plant:- Here Alum is added is added to water to Precipitate Dust Particles In
Water.Aluminium in Alum neutralizes Charge Dust Particle & this gives Result to a heavy
Complex Compound Which is settled Water Treatment Plant (W.T.P)
Auxiliaries of W.T.P Sand Filter
- These Stages of sand filter are putt across the flow so as to remove other Suspended
Particle, If any.
Activated Carbon filter- This Filter is employed for removal of Bacteria and organic
material. Here anthracite(Coal) is uses for Filter
Cation Exchanger- At this stage ions are observed by ion exchnanger method,HCl and
negative resin are principle ingredient of this chemical filter
Anion Exchanger:- Here Negative Ions are observed by Carefully Formulated by positive
resin. Mixed Bed Exchanger:- Here Remaining a negative ion is removed that is extracted
through resin.
7. The D.M(De mineralized)water is now ready which has some properties-
Conductivity-0.03 to 0.5 (micro/cm2)
PH-6.5
Silica-0.002ppm
Hardness-NIL
8. Stock and Inventory flow analysis of Main
Chemicals in PTPS Stores
Some of the Major Chemicals and their Uses in the Plant are as follows
Naoh-
Essential chemical for preparing D.M. water. Used for regeneration of strong Base
Anion Exchange Resins in various Beds of D.M. Plant.
HCL-
Cation Resin in various beds of strong acid of D.M. Plant.
NH4OH-
Ph of D.M. water we produce is slightly acidic (6.5-6.8). To increase it’s pH
for the value of 8.5-8.8. NH4OH is used.
T.S.P-
Used for maintaining boiler water . pH to the limit of 9.4-9.7
H.H-
Used for removal of residual dissolved oxygen in filtered water by chemical means .
SBP-
Used in clariflourator ( P.T. Plant) for removal of organic matter in Raw water.
N.F.A & P.A.C
To convert colloidal impurities ( especially during rainy season to suspended form &
thereby removing them).
PAC- High turbidity water.
NFA- Low turbidity water.
9. Lime-
For removal of Temporary hardness in raw water. Used especially when Total hardness
(temporary+permanent) is high.
Q. Sand-
Filtering medium. Used for removal of suspended impurities in clarified water.
A/C-
Used for removal of residual CL2 gas in clarified water.
SBA- Strong base Anion Resin .
WBA- Weak base Anion Resin.
10. Statement of Chemical issued from three years
Sl.no. Name of Chemical 04/12 to
03/13
04/13 to
03/14
04/14 to
03/15
04/15 to
03/16
Qty.
(KG/Ltr.)
Qty.
(KG/Ltr.)
Qty.
(KG/Ltr.)
Qty.
(KG/Ltr.)
1 Try Sodium Phosphate 5800 5250 8100 5650
2 Caustic Soda (Flakes) 54600 51400 61750 44050
3 Alum (N/F) 67120 152980 59305 92545
4 Bleaching Powder 11475 12975 11100 8300
5 Liquid Ammonia (LR) 1295 1550 1885 1550
6 Hydrochloric Acid 471840 403950 514565 364310
7 Hydrazine Hydrate 1450 1400 2000 1400
8 Poly Al. Chloride 15000 30000 30000 25000
9 Indian Strong Cation Resin 1200 5100 1800 1250
10 Indian Strong base Anion Resin 1350 2850 1000 850
11 Indian Weak Base Anion Resin 750 500 700 0
12 Activated Carbon Course Grade 4/8 ------------- 1500 ------------- 1000
13 Activated Carbon Fine Grade 8/30 ------------- 2000 ------------- 2000
11. Stock and Inventory flow analysis of Main
Chemicals in PTPS Stores along year 2015-16
w.r.t Demineralized Water Produced and Consumed
Chemical ConsumptionFor the monthof April 2015
S.No.
Chemical Name with previous
Balance Unit
Previous
Balance
Total
Received Total Consumed
Opening
Balance
1 NaOH Kg 115 4200 3670 645
2 HCl MT 36.015 58.265 42.65 51.63
3 NH4OH Lit 10 110 115 5
4 TSP Kg 50 400 350 100
5 HH Kg 180 - 110 70
6 SBP Kg 200 - 200 0
7 NFA MT 20 - 8.5 11.5
8 PAC MT 3.5 0.5 - 4
9 Lime Kg 400 - 200 200
10 Q Sand - -
11 A/C MT
C 0.2 MT +
0.6 MT - -
12 SBA Lit 850 - - 850
13 WBA - -
14 SAC Lit 900 - 150 750
15 NaCl Kg 105 - - 105
DM Water
Preparation 22837 MT
DM Water
Consumed 23047 MT
12. Chemical ConsumptionFor the monthof May 2015
S.No.
Chemical Name with
previousBalance Unit
Previous
Balance
Total
Received
Total
Consumed OpeningBalance
1 NaOH Kg 645 5200 5125 720
2 HCl MT 51.63 29.235 54.79 26.075
3 NH4OH Lit 5 150 150 5
4 TSP Kg 100 600 600 100
5 HH Kg 70 200 145 125
6 SBP Kg Nil 1000 850 150
7 NFA MT 11.5 15.225 11.5 15.225
8 PAC MT 4 4
9 Lime Kg 200 - 200
10 Q Sand Nil
c 7.0+ F
4.0 MT - c 7.0+ F 4.0 MT
11 A/C MT
C 0.2 MT + F
0.6 MT
C 10 + F
20 MT - C 1.2 + F 2.6 MT
12 SBA Lit 850 - - 850
13 WBA - -
14 SAC Lit 750 - 750
15 NaCl Kg 105 - - 105
DM Water
Preparation
31030
MT
DM Water
Consumed
30750
MT
13. Chemical ConsumptionFor the monthof June 2015
S.No.
Chemical Name with
previousBalance Unit
Previous
Balance
Total
Received Total Consumed
Opening
Balance
1 NaOH Kg 720 6000 5200 1520
2 HCl MT 26.075 49.64 47.99 27.725
3 NH4OH Lit 5 150 140 15
4 TSP Kg 100 600 550 150
5 HH Kg 125 75 50
6 SBP Kg 150 1000 750 400
7 NFA MT 15.225 11.5 3.725
8 PAC MT 4 4
9 Lime Kg 200 - 200
10 Q Sand MT c 7.0+ F 4.0 MT -
c 7.0+ F 4.0
MT
11 A/C MT
C 1.2 MT + F
2.6 MT
C 10 + F
20 MT -
C 1.2 + F
2.6 MT
12 SBA Lit 850 - 50 800
13 WBA - -
14 SAC Lit 750 - 750
15 NaCl Kg 105 - - 105
DM Water
Preparation 30570 MT
DM Water
Consumed 30710 MT
14. Chemical ConsumptionFor the monthof July 2015
S.No.
Chemical Name with previous
Balance Unit
Previous
Balance
Total
Received Total Consumed
Opening
Balance
1 NaOH Kg 1520 5600 6030 1090
2 HCl MT 27.725 57.63 46.565 38.79
3 NH4OH Lit 15 200 155 60
4 TSP Kg 150 700 800 50
5 HH Kg 50 200 140 110
6 SBP Kg 400 1000 850 550
7 NFA MT 3.725 15.135 4.86 14
8 PAC MT 4 4
9 Lime Kg 200 - 200
10 Q Sand MT c 7.0+ F 4.0 MT
c 2.250 MT +f
2.75 MT
c 1.75+ F
4.250 MT
11 A/C MT C 1.2 MT + F 2.6 MT -
C 1.2 + F 2.6
MT
12 SBA Lit 800 - 800
13 WBA - -
14 SAC Lit 750 - 750
15 NaCl Kg 105 - - 105
DM Water
Preparation 32725 MT
DM Water
Consumed 32750 MT
15. Chemical Consumption For the month of August 2015
S.No.
Chemical Name with previous
Balance Unit
Previous
Balance
Total
Received Total Consumed
Opening
Balance
1 NaOH Kg 1090 4400 3955 1535
2 HCl MT 38.79 84.91 81.975 41.725
3 NH4OH Lit 60 100 140 20
4 TSP Kg 50 600 550 100
5 HH Kg 110 100 10
6 SBP Kg 550 500 50
7 NFA MT 140 21.56 7.915 27.645
8 PAC MT 10 6.5 3.5
9 Lime Kg 2 - 200
10 Q Sand MT c 1.750+ F 4.250 MT
c 1.0 MT +f 1.6
MT
c .75+ F
2.650 MT
11 A/C MT C 1.2 MT + F 2.6 MT C 1.0 + F 1.5 MT
C .2 + F 1.1
MT
12 SBA Lit 800 - 800
13 WBA - -
14 SAC Lit 750 - 750
15 NaCl Kg 105 - - 105
DM Water
Preparation 25885 MT
DM Water
Consumed 25990 MT
16. Chemical Consumption For the month of September 2015
S.No.
Chemical Name with previous
Balance Unit
Previous
Balance
Total
Received Total Consumed
Opening
Balance
1 NaOH Kg 1535 8000 3670 865
2 HCl MT 41.725 84.67 31.135 45.26
3 NH4OH Lit 20 100 100 20
4 TSP Kg 100 600 600 100
5 HH Kg 10 200 105 105
6 SBP Kg 50 1000 750 300
7 NFA MT 27.645 2.645 25
8 PAC MT 3.5 10 7.5 6
9 Lime Kg 200 - 200
10 Q Sand MT 0.75+2.65 0.75+2.65
11 A/C MT 0.2+1.1
C .2 + F 1.1
MT
12 SBA Lit 800 850 750 900
13 WBA - -
14 SAC Lit 750 1250 1750 250
15 NaCl Kg 105 - - 105
DM Water
Preparation 20930 MT
DM Water
Consumed 20780 MT
17. Chemical Consumption For the month of October 2015
S.No.
Chemical Name with previous
Balance Unit
Previous
Balance
Total
Received Total Consumed
Opening
Balance
1 NaOH Kg 865 6000 5080 1785
2 HCl MT 45.26 35.445 36.5 44.205
3 NH4OH Lit 20 500 385 135
4 TSP Kg 100 600 550 150
5 HH Kg 105 400 315 190
6 SBP Kg 300 1000 925 375
7 NFA MT 25 30.045 3.045 52
8 PAC MT 6 5.5 0.5
9 Lime Kg 500 200 300
10 Q Sand MT 0.75+2.65 0.75+2.65
11 A/C MT 0.2+1.1
C .2 + F 1.1
MT
12 SBA Lit 900 900
13 WBA - -
14 SAC Lit 250 250
15 NaCl Kg 105 - 105
DM Water
Preparation 23385 MT
DM Water
Consumed 23315 MT
18. Chemical Consumption For the month of November 2015
S.No.
Chemical Name with previous
Balance Unit
Previous
Balance
Total
Received Total Consumed
Opening
Balance
1 NaOH Kg 1785 3000 3650 1185
2 HCl MT 44.205 32.32 31.8 44.205
3 NH4OH Lit 135 100 155 80
4 TSP Kg 150 500 550 100
5 HH Kg 190 200 150 240
6 SBP Kg 375 1000 775 600
7 NFA MT 52 7.5 44.5
8 PAC MT 6 5.5 0.5
9 Lime Kg 300 300
10 Q Sand MT 0.75+2.65 0.75+2.65
11 A/C MT 0.2+1.1
C .2 + F 1.1
MT
12 SBA Lit 900 900
13 WBA - -
14 SAC Lit 200 200
15 NaCl Kg -
DM Water
Preparation 19130 MT
DM Water
Consumed 19170 MT
19. Chemical ConsumptionFor the monthof December 2015
S.No.
Chemical Name with previous
Balance Unit
Previous
Balance
Total
Received Total Consumed
Opening
Balance
1 NaOH Kg 1135 1200 620 1715
2 HCl MT 44.725 34.85 41.24
3 NH4OH Lit 80 30 50
4 TSP Kg 100 50 50
5 HH Kg 240 20 220
6 SBP Kg 600 300 300
7 NFA MT 44.5 10.64 3.14 52
8 PAC MT 5.5 5.5
9 Lime Kg 300 100 200
10 Q Sand MT 0.75+2.65 0.75+2.65
11 A/C MT 0.2+1.1
C .2 + F 1.1
MT
12 SBA Lit 900 50 850
13 WBA - -
14 SAC Lit 200 50 150
15 NaCl Kg -
DM Water
Preparation 2140 MT
DM Water
Consumed 2370 MT
20. Chemical ConsumptionFor the monthof January 2016
S.No.
Chemical Name with previous
Balance Unit
Previous
Balance
Total
Received Total Consumed
Opening
Balance
1 NaOH Kg 1715 600 640 1675
2 HCl MT 41.24 6.5 34.74
3 NH4OH Lit 50 150 130 70
4 TSP Kg 50 50
5 HH Kg 220 200 100 320
6 SBP Kg 800 1000 550 750
7 NFA MT 52 5 47
8 PAC MT 5.5 5.5
9 Lime Kg 200 100 100
10 Q Sand MT 0.75+2.65 0.75+2.65
11 A/C MT 0.2+1.1
C .2 + F 1.1
MT
12 SBA Lit 250 250
13 WBA - -
14 SAC Lit 150 150
15 NaCl Kg -
DM Water
Preparation 2035 MT
DM Water
Consumed 875 MT
21. Chemical ConsumptionFor the monthof February 2016
S.No.
Chemical Name with previous
Balance Unit
Previous
Balance
Total
Received Total Consumed
Opening
Balance
1 NaOH Kg 1675 520 1155
2 HCl MT 34.79 4.2 30.54
3 NH4OH Lit 70 70
4 TSP Kg 50 50
5 HH Kg 320 320
6 SBP Kg 750 500 250
7 NFA MT 47 5.5 41.5
8 PAC MT 5.5 5.5
9 Lime Kg 100 50 50
10 Q Sand MT 0.75+2.6 0.75+2.6
11 A/C MT 0.2+1.1
C .2 + F 1.1
MT
12 SBA Lit 850 850
13 WBA - -
14 SAC Lit 150 150
15 NaCl Kg -
DM Water
Preparation Nil
DM Water
Consumed 315 MT
22. Chemical ConsumptionFor the monthof March2016
S.No.
Chemical Name with previous
Balance Unit
Previous
Balance
Total
Received Total Consumed
Opening
Balance
1 NaOH Kg 1155 3000 3490 365
2 HCl MT 30.54 32.195 28.725 34.01
3 NH4OH Lit 70 100 100+50 20
4 TSP Kg 50 400 250 200
5 HH Kg 320 130 190
6 SBP Kg 250 1000 950 190
7 NFA MT 41.5 11.5 30
8 PAC MT 5.5 5.5
9 Lime Kg 50 500 200 350
10 Q Sand MT 0.75+2.6 0.4 0.35+2.6
11 A/C MT 0.2+1.1
C .2 + F 1.1
MT
12 SBA Lit 850 850
13 WBA - -
14 SAC Lit 150 150
15 NaCl Kg -
DM Water
Preparation 17215 MT
DM Water
Consumed 16035 MT
