ptps chemical consumption report

MBA InternshipOn

“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

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.

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

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)

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]

Panki Thermal Power 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 Treatment Plant

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 FilterCation Exchanger- At this stage ions are observed by ion exchnanger method,HCl and negative resin are principle ingredient of this chemical filterAnion 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.

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

Stock and Inventory flow analysis of Main Chemicals in PTPS StoresSome 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.

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.

Statement of Chemical issued from three yearsSl.no. Name of Chemical 04/12 to

03/1304/13 to

03/1404/14 to

03/1504/15 to

03/16Qty.

(KG/Ltr.)Qty.

(KG/Ltr.)Qty.

(KG/Ltr.)Qty.

(KG/Ltr.)1 Try Sodium Phosphate 5800 5250 8100 56502 Caustic Soda (Flakes) 54600 51400 61750 440503 Alum (N/F) 67120 152980 59305 925454 Bleaching Powder 11475 12975 11100 83005 Liquid Ammonia (LR) 1295 1550 1885 15506 Hydrochloric Acid 471840 403950 514565 3643107 Hydrazine Hydrate 1450 1400 2000 14008 Poly Al. Chloride 15000 30000 30000 250009 Indian Strong Cation Resin 1200 5100 1800 125010 Indian Strong base Anion Resin 1350 2850 1000 85011 Indian Weak Base Anion Resin 750 500 700 012 Activated Carbon Course Grade 4/8 ------------- 1500 ------------- 100013 Activated Carbon Fine Grade 8/30 ------------- 2000 ------------- 2000

Stock and Inventory flow analysis of Main Chemicals in PTPS Stores along year 2015-16

w.r.t Demineralized Water Produced and Consumed

Chemical Consumption For the month of April 2015S.No.

Chemical Name with previous Balance

Unit

Previous Balance

Total Received

Total Consumed

Opening Balance

1 NaOH Kg 115 4200 3670 6452 HCl MT 36.015 58.265 42.65 51.633 NH4OH Lit 10 110 115 54 TSP Kg 50 400 350 1005 HH Kg 180 - 110 706 SBP Kg 200 - 200 07 NFA MT 20 - 8.5 11.58 PAC MT 3.5 0.5 - 49 Lime Kg 400 - 200 200

10 Q Sand - -

11 A/C MTC 0.2 MT + 0.6 MT - -

12 SBA Lit 850 - - 85013 WBA - -14 SAC Lit 900 - 150 75015 NaCl Kg 105 - - 105

DM Water Preparation 22837 MTDM Water Consumed 23047 MT

Chemical Consumption For the month of May 2015

S.No.


Unit

Previous Balance

Total Received

Total Consumed Opening Balance

1 NaOH Kg 645 5200 5125 7202 HCl MT 51.63 29.235 54.79 26.0753 NH4OH Lit 5 150 150 54 TSP Kg 100 600 600 1005 HH Kg 70 200 145 1256 SBP Kg Nil 1000 850 1507 NFA MT 11.5 15.225 11.5 15.2258 PAC MT 4 49 Lime Kg 200 - 200

10 Q Sand Nilc 7.0+ F 4.0 MT - c 7.0+ F 4.0 MT

11 A/C MTC 0.2 MT + F 0.6 MT

C 10 + F 20 MT - C 1.2 + F 2.6 MT

12 SBA Lit 850 - - 85013 WBA - -14 SAC Lit 750 - 75015 NaCl Kg 105 - - 105

DM Water Preparation

31030 MT

DM Water Consumed

30750 MT

Chemical Consumption For the month of June 2015

S.No.


Unit

Previous Balance

Total Received

Total Consumed

Opening Balance

1 NaOH Kg 720 6000 5200 15202 HCl MT 26.075 49.64 47.99 27.7253 NH4OH Lit 5 150 140 154 TSP Kg 100 600 550 1505 HH Kg 125 75 506 SBP Kg 150 1000 750 4007 NFA MT 15.225 11.5 3.7258 PAC MT 4 49 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 MTC 1.2 MT + F 2.6 MT

C 10 + F 20 MT -

C 1.2 + F 2.6 MT

12 SBA Lit 850 - 50 80013 WBA - -14 SAC Lit 750 - 75015 NaCl Kg 105 - - 105


Chemical Consumption For the month of July 2015

S.No.


Unit

Previous Balance

Total Received

Total Consumed

Opening Balance

1 NaOH Kg 1520 5600 6030 10902 HCl MT 27.725 57.63 46.565 38.793 NH4OH Lit 15 200 155 604 TSP Kg 150 700 800 505 HH Kg 50 200 140 1106 SBP Kg 400 1000 850 5507 NFA MT 3.725 15.135 4.86 148 PAC MT 4 49 Lime Kg 200 - 200

10 Q Sand MT c 7.0+ F 4.0 MTc 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 - 80013 WBA - -14 SAC Lit 750 - 75015 NaCl Kg 105 - - 105


Chemical Consumption For the month of August 2015

S.No.


Unit

Previous Balance

Total Received

Total Consumed

Opening Balance

1 NaOH Kg 1090 4400 3955 15352 HCl MT 38.79 84.91 81.975 41.7253 NH4OH Lit 60 100 140 204 TSP Kg 50 600 550 1005 HH Kg 110 100 106 SBP Kg 550 500 507 NFA MT 140 21.56 7.915 27.6458 PAC MT 10 6.5 3.59 Lime Kg 2 - 200

10 Q Sand MT c 1.750+ F 4.250 MTc 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 MTC .2 + F 1.1 MT

12 SBA Lit 800 - 80013 WBA - -14 SAC Lit 750 - 75015 NaCl Kg 105 - - 105


Chemical Consumption For the month of September 2015

S.No.


Unit

Previous Balance

Total Received

Total Consumed

Opening Balance

1 NaOH Kg 1535 8000 3670 8652 HCl MT 41.725 84.67 31.135 45.263 NH4OH Lit 20 100 100 204 TSP Kg 100 600 600 1005 HH Kg 10 200 105 1056 SBP Kg 50 1000 750 3007 NFA MT 27.645 2.645 258 PAC MT 3.5 10 7.5 69 Lime Kg 200 - 200

10 Q Sand MT 0.75+2.65 0.75+2.65

11 A/C MT 0.2+1.1C .2 + F 1.1 MT

12 SBA Lit 800 850 750 90013 WBA - -14 SAC Lit 750 1250 1750 25015 NaCl Kg 105 - - 105


Chemical Consumption For the month of October 2015

S.No.


Unit

Previous Balance

Total Received

Total Consumed

Opening Balance

1 NaOH Kg 865 6000 5080 17852 HCl MT 45.26 35.445 36.5 44.2053 NH4OH Lit 20 500 385 1354 TSP Kg 100 600 550 1505 HH Kg 105 400 315 1906 SBP Kg 300 1000 925 3757 NFA MT 25 30.045 3.045 528 PAC MT 6 5.5 0.59 Lime Kg 500 200 300

10 Q Sand MT 0.75+2.65 0.75+2.65

11 A/C MT 0.2+1.1C .2 + F 1.1 MT

12 SBA Lit 900 90013 WBA - -14 SAC Lit 250 25015 NaCl Kg 105 - 105


Chemical Consumption For the month of November 2015

S.No.


Unit

Previous Balance

Total Received

Total Consumed

Opening Balance

1 NaOH Kg 1785 3000 3650 11852 HCl MT 44.205 32.32 31.8 44.2053 NH4OH Lit 135 100 155 804 TSP Kg 150 500 550 1005 HH Kg 190 200 150 2406 SBP Kg 375 1000 775 6007 NFA MT 52 7.5 44.58 PAC MT 6 5.5 0.59 Lime Kg 300 300

10 Q Sand MT 0.75+2.65 0.75+2.65

11 A/C MT 0.2+1.1C .2 + F 1.1 MT

12 SBA Lit 900 90013 WBA - -14 SAC Lit 200 20015 NaCl Kg -


Chemical Consumption For the month of December 2015

S.No.


Unit

Previous Balance

Total Received

Total Consumed

Opening Balance

1 NaOH Kg 1135 1200 620 17152 HCl MT 44.725 34.85 41.243 NH4OH Lit 80 30 504 TSP Kg 100 50 505 HH Kg 240 20 2206 SBP Kg 600 300 3007 NFA MT 44.5 10.64 3.14 528 PAC MT 5.5 5.59 Lime Kg 300 100 200

10 Q Sand MT 0.75+2.65 0.75+2.65

11 A/C MT 0.2+1.1C .2 + F 1.1 MT

12 SBA Lit 900 50 85013 WBA - -14 SAC Lit 200 50 15015 NaCl Kg -


Chemical Consumption For the month of January 2016

S.No.


Unit

Previous Balance

Total Received

Total Consumed

Opening Balance

1 NaOH Kg 1715 600 640 16752 HCl MT 41.24 6.5 34.743 NH4OH Lit 50 150 130 704 TSP Kg 50 505 HH Kg 220 200 100 3206 SBP Kg 800 1000 550 7507 NFA MT 52 5 478 PAC MT 5.5 5.59 Lime Kg 200 100 100

10 Q Sand MT 0.75+2.65 0.75+2.65

11 A/C MT 0.2+1.1C .2 + F 1.1 MT



Chemical Consumption For the month of February 2016

S.No.


Unit

Previous Balance

Total Received

Total Consumed

Opening Balance

1 NaOH Kg 1675 520 11552 HCl MT 34.79 4.2 30.543 NH4OH Lit 70 704 TSP Kg 50 505 HH Kg 320 3206 SBP Kg 750 500 2507 NFA MT 47 5.5 41.58 PAC MT 5.5 5.59 Lime Kg 100 50 50

10 Q Sand MT 0.75+2.6 0.75+2.6

11 A/C MT 0.2+1.1C .2 + F 1.1 MT


DM Water Preparation NilDM Water Consumed 315 MT

Chemical Consumption For the month of March 2016

S.No.


Unit

Previous Balance

Total Received

Total Consumed

Opening Balance

1 NaOH Kg 1155 3000 3490 3652 HCl MT 30.54 32.195 28.725 34.013 NH4OH Lit 70 100 100+50 204 TSP Kg 50 400 250 2005 HH Kg 320 130 1906 SBP Kg 250 1000 950 1907 NFA MT 41.5 11.5 308 PAC MT 5.5 5.59 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+1.1C .2 + F 1.1 MT



ptps chemical consumption report

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