This document discusses the potential for installing energy conservation turbines (ECTs) at NTPC Tanda to capture wasted steam energy. ECTs can be installed on existing pressure reducing valves and utilize the steam's pressure energy to generate electricity. The document analyzes three opportunities for ECTs at NTPC Tanda: the HP bypass valve, LP bypass valve, and APRDS control valve. Installing ECTs at these locations could generate 11.76 MW, 21.25 MW, and 2.7 MW respectively. The document also presents a case study of installing an ECT on the APRDS MS or CRH line, estimating annual savings of Rs. 1.08 crore and Rs. 35.04

2. VARIABLE COST OF UP & UTTARAKHAND
SL NO. Station Paisa/ Unit Station Paisa/ Unit
1 SALAL HPS 48.00 CHIBRO (YAMUNA) 27.00
2 URI HEP 81.00 KHATIMA HPS 30.00
3 CHAMERA HEP 107.00 KULHAL HPS 31.00
4 TANAKPUR HEP 115.00 CHILLA HPS 34.00
5 SASAN 128.50 KHODRI HPS 34.00
6 SINGARAULI STPS 131.00 DHAKRANI HPS 36.00
7 SIGARAULI STAGE III 136.60 RAMGANGA HPS 37.00
8 VISHUNUPRAYAG 140.00 DHALIPUR HPS 40.00
9 RIHAND STAGE II 143.70 SALAL HPS 102.00
10 DHAULI GANGA HEP 145.00 SINGARAULI STPS 131.00
11 NATHPA JHAKRI (SJVNT) 146.00 MANERI BHALI-II 134.00
12 CHAMERA -II HEP 169.90 RIHAND STAGE -III 136.60
13 URI-II HEP 169.90 RIHAND STAGE -II 143.70
14 SEWA HEP 170.00 URI HEP 169.00
15 OBRA B 171.50 CHAMERA HEP 169.90
16 ANPARA B 181.50 RIHAND 184.60
17 OBRA A 184.30 KAHALGAON-II 249.50
18 RIHAND-I 184.60 UNCHAHAR-III TPS 252.10
19 ANPARA A 213.00 UNCHAHAR-II TPS 252.20
20 CHAMERA-III 220.00 UNCHAHAR-I TPS 257.20
21 KOTESHWAR HEP 220.00 NARORA APS 259.00
22 KAHALGAON-II 249.50 TANAKPUR HEP 260.00
23 UNCHAHAR-III TPS 252.10 NAPTHA JHAKRI (SJVNL) 283.00
24 UNCHAHAR-II TPS 252.20 CHAMERA -II HEP 294.00
25 UNCHAHAR-I TPS 257.20 DHAULI GANGA HEP 306.00
26 KAHALGAON 257.40 ANTA G 314.00
27 ANPARA-C (Lanco) 258.00 URI-II HEP 326.00
28 TEHRI HYDRO 260.00 DADRI STAGE -II 327.00
29 FARAKKA 261.40 DADRI G 327.30
30 NARORA APS 277.40 RAPP © 340.40
31 TANDA 278.60 KOTESHWAR HEP 342.00
32 HARDUAGANJ Ext 295.30 JHAJJAR 361.80
33 DILHASTI HEP 306.40 CHAMERA-III HEP 373.00
34 RAPP (B) 306.40 AURAIYA G 373.30
35 NATA G 314.00 RAPP (B) 373.90
36 DADRI STAGE - II 327.20 SEWA HEP 453.00
37 DADRI G 327.30 TEHRI HYDRO 538.00
38 DADRI NCTPS 348.90 DULHASTI HEP 560.00
39 PARICCHA Ext 361.30 DADRI L 706.20
40 JHAJJAR 361.80 ANTA L 808.20

3. NTPC TANDA OUTAGE
PROFITABILITY
A CHALLENGE
INTRODUCTION ECT DESCRIPTION TANDA POTENTIAL PRDS CASE STUDY LIMITATIONS CONCLUSION
UNIT#1 OUT FOR 94 DAYS, UNIT#2 OUT FOR 90 DAYS-NTPC MAUDA
349.438 MUS LOST DUE TO BACKING DOWN/RESERVE SHUT DOWN-NTPC TANDA
32.983 % OF TOTAL LOSS DUE TO BACKING DOWN/RESERVE SHUT DOWN-NTPC DADRI
17.66% OF TOTAL LOSS DUE TO BACKING DOWN/RESERVE SHUT DOWN-NTPC UNCHAHAR
FROM 01ST APRIL 2015 TO 30TH MARCH 2016

4. PC SHARP
UNDER THE GUIDANCE OF
SHRI RAKESH BAJAJ (AGM MM)
TEAM
T RAMCHANDRAN (SR MGR-FQA)
AMIT KR NAYAK (MGR-TMD)
PRAVEEN PRAJAPATI (DY MGR-BMD)
RAVI PAL SINGH (DY MGR-OPN)

5. KNOWLEDGE SHARING BY SHARP
SL. NO TIME THEME/TOPIC SPEAKER EVENT
1
SEPTEMBER, 2015 ENERGY EFFICIENT CARTRIDGE AMIT NAYAK तकनिकी गोष्ठी
2
APRIL, 2015 THERMO DYNAMICS AND THERMAL ENGINEERING RAVI PAL SINGH KNOWLEDEG SHARING
3
FRBRUARY, 2015 BREAKDOWN IN ROTARY PART PRAVEEN PRAJAPATI BOILER KT MEET
4 NOVEMBER, 2015 UT AND DPT TECHNOLOGY T RAMCHANDRAN KNOWLEDGE SHARING
5 FEBRUARY, 2016 STUDY OF 03 MW BACK PRESSURE TURBINE ALL 04 MEMBERS BABHNAN CHINI MILL
INTRODUCTION ECT DESCRIPTION TANDA POTENTIAL PRDS CASE STUDY LIMITATIONS CONCLUSION

6. ACCOLADES OF SHARP
INTRODUCTION ECT DESCRIPTION TANDA POTENTIAL PRDS CASE STUDY LIMITATIONS CONCLUSION
FOUNDED IN JANUARY, 2011.
FIRST POSITION IN NOCET-2011, STATION LEVEL.
FIRST RUNNER UP IN NOCET-2011, REGIONAL LEVEL.
FIRST POSITION IN PC-2012, STATION LEVEL.
FIRST RUNNER UP IN PC-2012, REGIONAL LEVEL.
FIRST POSITION IN Q4E-2013, STATION LEVEL.
FIRST POSITION IN Q4E-2013, REGIONAL LEVEL.
SECOND RUNNER UP IN Q4E-2013, COMPANY LEVEL.
FIRST POSITION IN Q4E-2014, STATION LEVEL.
FIRST RUNNER UP IN Q4E-2014, REGIONAL LEVEL.

7. INTRODUCTION ECT DESCRIPTION TANDA POTENTIAL PRDS CASE STUDY LIMITATIONS CONCLUSION
THE SOLUTION
MAKE THE PLANT AS ENERGY
EFFICIENT AS POSSIBLE,
PREFERABLY USING
EXISTING RESOURCES

8. INTRODUCTION ECT DESCRIPTION TANDA POTENTIAL PRDS CASE STUDY LIMITATIONS CONCLUSION
PRESSURE REDUCING VALVES
THE PRESSURE ENERGY (POTENTIAL ENERGY) IS
CONVERTED TO USELESS TURBULENCE & NOISE IN THE
PRV.
POTENTIAL OF ABOUT 3000 MW IN INDIA ITSELF,
WHICH IS 1.2 % OF THE TOTAL INSTALLED CAPACITY
BY BUREAU OF ENERGY EFFICIENCY

9. ENERGY CONSERVATION TURBINE

10. INTRODUCTION ECT DESCRIPTION TANDA POTENTIAL PRDS CASE STUDY LIMITATIONS CONCLUSION
ENERGY
CONSERVATION TURBINE
LOSS
KW

11. INTRODUCTION ECT DESCRIPTION TANDA POTENTIAL PRDS CASE STUDY LIMITATIONS CONCLUSION
ENERGY
CONSERVATION TURBINE
• ECT IS A SMALL COGENERATION SYSTEM CATERING
TO STEAM FLOW RATES FROM 1.5 T/HR AND
UPWARDS.
• BACK PRESSURE STEAM TURBINE USED IN PARALLEL
TO AN EXISTING PRESSURE REDUCING VALVE (PRV).
• STEAM IS EXPANDED IN THE ECT, THUS CONVERTING
HEAT ENERGY (OF STEAM ) TO ELECTRICAL POWER.

12. INTRODUCTION ECT DESCRIPTION TANDA POTENTIAL PRDS CASE STUDY LIMITATIONS CONCLUSION
ENERGY
CONSERVATION TURBINE
ANTI
VIBRATION
MOUNTS
GENERATOR
LUBE OIL FILTER
TURBINE
LUBE OIL COOLER

13. INTRODUCTION ECT DESCRIPTION TANDA POTENTIAL PRDS CASE STUDY LIMITATIONS CONCLUSION
ENERGY
CONSERVATION TURBINE
• ALLOW THE STEAM FLOW VARIATION WHILE
KEEPING THE PROCESS PRESSURE CONSTANT.
• INDUCTION GENERATORS CONTINUE TO
OPERATE IN SPITE OF LARGE FLUCTUATIONS IN
INLET PRESSURE.
• GREATER THAN 80% TURBINE EFFICIENCY.
• COMPACT POWER PACKAGE
• FITS IN CONGESTED EQUIPMENT ROOMS.

14. NTPC TANDA POTENTIAL
HP BY PASS VALVE
LP BY PASS VALVE
APRDS CONTROL VALVE

15. INTRODUCTION ECT DESCRIPTION TANDA POTENTIAL PRDS CASE STUDY LIMITATIONS CONCLUSION
HP BY PASS VALVE
INLET PRESSURE : 90 KG/CM2, 500 DEG C
OUTLET PRESSURE : 6 KG/CM2, 300 DEG C
STEAM FLOW : 130 T/H
POWER POTENTIAL
11.76 MW

16. INTRODUCTION ECT DESCRIPTION TANDA POTENTIAL PRDS CASE STUDY LIMITATIONS CONCLUSION
LP BY PASS VALVE
INLET PRESSURE : 6 KG/CM2, 300 DEG C
OUTLET PRESSURE : 0.08KG/CM2, 40 DEG C,
90% DF
STEAM FLOW : 150 T/HR
POWER POTENTIAL
21.25 MW

17. INTRODUCTION ECT DESCRIPTION TANDA POTENTIAL PRDS CASE STUDY LIMITATIONS CONCLUSION
APRDS CONTROL VALVE
INLET PRESSURE : 150 KG/CM2, 500 DEG C
OUTLET PRESSURE : 13 KG/CM2, 350 DEG C
STEAM FLOW : 60 T/HR
POWER POTENTIAL
2.7 MW

18. INTRODUCTION ECT DESCRIPTION TANDA POTENTIAL PRDS CASE STUDY LIMITATIONS CONCLUSION
VALVE
HP BYPASS
VALVE
LP BYPASS
VALVE
APRDS CONTROL
VALVE
POWER IN MW 11.76 21.25 2.70
DURATION IN
MINUTES
10 10 60 X24X365
(5 TPH TO SJAE)
FEASABILITY

19. CASE STUDY
ECT AT APRDS CHARGED FROM MS-LINE
WHAT IF CHARGED FROM CRH-LINE ??

20. INTRODUCTION ECT DESCRIPTION TANDA POTENTIAL PRDS CASE STUDY LIMITATIONS CONCLUSION
CAPACITY OF APRDS
MP STARTUP STEAM FLOW 35 T/HR
F.O AUTOMISATION STEAM FLOW 25 T/HR
HP GLAND SEALING 2 T/HR
TO STEAM JET AIR EJECTOR 5 T/HR
TO D/A PEGGING FROM 6 ATA 21 T/HR
SCAPH 5 T/HR
APH SOOT BLOWING 1.25 T/HR
L.P SEALING 2 T/HR
AT MCR 5 TPH OF PERENNIAL ENTHALPY FLOW IN APRDS

21. INTRODUCTION ECT DESCRIPTION TANDA POTENTIAL PRDS CASE STUDY LIMITATIONS CONCLUSION
ECT~
APRDS MS LINE
TO APRDS 11 ATA HDR

22. INTRODUCTION ECT DESCRIPTION TANDA POTENTIAL PRDS CASE STUDY LIMITATIONS CONCLUSION
APRDS MS LINE
STEAM FLOW : 5 TPH
INLET PRESSURE : 150 KG/CM2, 500 DEG C
OUTLET PRESSURE : 13 KG/CM2, 350 DEG C
STEAM FLOW : 5 T/HR
ECT EFFICEINCY : 95%
310 KW
@RS. 4/KWH RS. 1.08 CRORE PER ANNUM SAVINGS
HEAT RATE REDUCED BY 7.71 KCAL/KWH

23. INTRODUCTION ECT DESCRIPTION TANDA POTENTIAL PRDS CASE STUDY LIMITATIONS CONCLUSION
APRDS MS LINE-SPECS OF ECT
•DIMENSIONS : 6.5X4X3 (IN METERS)
•NO. OF STAGES : 2
•POWER PACK SET WEIGHT (KG) 4500 KG.
•TURBINE SPEED (RPM): 12000 – 14400
•OUTPUT (RPM) : 1500 / 1800
•PRECISION ROLLING ELEMENT BEARING.
•PRESSURIZED OIL CIRCULATION SYSTEM.
•FLEXIBLE COUPLING OF TURBINE AND GENERATOR.
•MOUNTING SKID WITH ANTI-VIBRATION MOUNTS.
•NO FOUNDATION REQUIRED.
BY TURBOTECH PRECISION ENGINEERING PRIVATE LIMITED BANGLORE

24. INTRODUCTION ECT DESCRIPTION TANDA POTENTIAL PRDS CASE STUDY LIMITATIONS CONCLUSION
APRDS MS LINE-PROJECT COST
BY TURBOTECH PRECISION ENGINEERING PRIVATE LIMITED
BANGLORE
DESCRIPTION (RS.IN LAKHS)
TURBINE GENERATOR 94
C.S.T(4%) 1.81
E.D(16.32%) 6.36
SUPERVISION OF ERECTION 8
FREIGHT 0.2
EXPANSION BELLOWS 0.6
TURBINE ERECTION 1
ELECTRIC CABLING 1
STEAM PIPING ETC. 2
CIVIL WORK 0.5
MISCELLANEOUS 1
LESS MODVAT 6.36
INVESTMENT 1.20 CRORE

25. INTRODUCTION ECT DESCRIPTION TANDA POTENTIAL PRDS CASE STUDY LIMITATIONS CONCLUSION
APRDS CRH LINE
TO APRDS 11 ATA HDR
ECT~

26. INTRODUCTION ECT DESCRIPTION TANDA POTENTIAL PRDS CASE STUDY LIMITATIONS CONCLUSION
APRDS CRH LINE
STEAM FLOW : 5 T/HR
INLET PRESSURE : 35 KG/CM2, 380 DEG C
OUTLET PRESSURE : 13 KG/CM2, 350 DEG C
STEAM FLOW : 5 T/HR
ECT EFFICEINCY : 95%
100 KW
@RS. 4/KWH RS. 35.04 LAKH PER ANNUM SAVINGS
HEAT RATE REDUCED BY 11.78 KCAL/KWH

27. INTRODUCTION ECT DESCRIPTION TANDA POTENTIAL PRDS CASE STUDY LIMITATIONS CONCLUSION
APRDS CRH LINE-SPECS OF ECT
• SINGLE STAGE IMPULSE TYPE
• DIMENSIONS : 5X4X4(IN METERS)
• HIGH SPEED FLEXIBLE COUPLING
• FREQUENCY: 50 HZ
• VOLTAGE: 380V / 415V
• INDUCTION GENERATOR WITH GRID EXCITATION SYSTEM
• CONFIGURATION: BACK PRESSURE
• POWER SET WEIGHT : 2000 KG
BY KESSELS TURBINE NEW DELHI

28. INTRODUCTION ECT DESCRIPTION TANDA POTENTIAL PRDS CASE STUDY LIMITATIONS CONCLUSION
APRDS CRH LINE-PROJECT COST
BY KESSELS TURBINE NEW DELHI
DESCRIPTION (RS.IN LAKHS)
TURBINE GENERATOR 43.5
PANEL, SWITCH & CABLING 2.5
ERECTION , MODIFICATION 2.5
INVESTMENT 48.5

29. V ECT IN INDIA
• 300KW AT AMRUT DISTILLARIES LTD, KUMBALGOLD, BANGLORE
BY TURBOTECH PRECISION ENGINEERING.
• 340 KW AT UNITED SPIRITS, POONAMALLEE, CHENNAI BY
TURBOTECH PRECISION ENGINEERING.
• 1600 KW AT PHARMACEUTICAL INDUSTRY, HIMANCHAL BY
SIEMENS.
INTRODUCTION ECT DESCRIPTION TANDA POTENTIAL PRDS CASE STUDY LIMITATIONS CONCLUSION

30. V COMPARISON
• @ RS 2 CRORE, BFP ENERGY EFFICIENT
CARTRIDGE, SAVINGS 300 KW PER BFP.
• @2.5 CRORE TG ROOF TOP SOLAR 450
KW FOR ONLY ~04 HRS PER DAY
@ RS 48 LAKH, 100 KW
USING ECT AT APRDS
ECT AT APRDS
INTRODUCTION ECT DESCRIPTION TANDA POTENTIAL PRDS CASE STUDY LIMITATIONS CONCLUSION

31. V
INTRODUCTION ECT DESCRIPTION TANDA POTENTIAL PRDS CASE STUDY LIMITATIONS CONCLUSION
LIMITATIONS
OBLIVIOUS TO INSIGNIFICANT YET
PERINNIAL LOSS IN PRVS.
FINANCIALLY NOT VIABLE FOR ALL
PRVS.
APREHENSION TOWARDS RELIABILITY
OF UNCHARTED INNOVATION.

32. V CONCLUSION
INTRODUCTION ECT DESCRIPTION TANDA POTENTIAL PRDS CASE STUDY LIMITATIONS CONCLUSION
•GROWING DEMAND AND RISING PRICES
MAKE INVESTMENT IN SMALL-SCALE
TURBINES ECONOMICALLY VIABLE.
•USE PROVEN AND ESTABLISHED
TECHNOLOGY AND CONSISTS OF
CONTINUOUS TECHNICAL
IMPROVEMENTS.
•RELIABLE SMALL-SCALE TURBINE WILL BE
A PROFITABLE AND LASTING DECISION.

33. BABHNAN SUGAR MILLS LTD
GONDA
3MW BACKPRESSURE TURBINE
FLOW :30 TPH
30 KG, 350 DEG C TO 2 KG 165 DEG C

38. Thank You
Transforming lives
“Our most basic common link is that we all inhabit this small planet. We all breathe the same air.
We all cherish our children's future. And we are all mortal.” John F. Kennedy