1

KARNATAKA POWER CORPORATION LTD

WELCOME TO PRESENTATION ON DG PLANT , YELAHANKA,

BANGALORE-64

2

INTRODUCTION The 120 MW Diesel Engine Power Station was set

up by the Karnataka Electricity Board in Yelahanka Bangalore-64 ,during 1992-93.

The Plant was functioning under erstwhile Vishweswaraya Vidyuth Nigama Ltd (VVNL).

VVNL is amalgamated with KPCL on 27th Dec, 2006 hence DG Plant is now under the administrative control of KPCL.

The DG Plant Yelahanka houses six DG sets of 21.32 MW (Installed capacity) each.

3

Low Sulphur Heavy Stock (LSHS) with <1% Sulphur is used as primary fuel. HSD oil is used for initial startup and for low loads operation as secondary fuel.

LSHS is supplied by IOCL from the infrastructure put up in DG Plant land on lease under long term agreement. HSD is supplied from IOCL Devangunthi terminals by road.

4

Salient Features of DG Plant,Yelahanka

Area of Land : 102 acresProject cost : Rs. 265 croresInstalled Capacity : 6 x 21.32 MW=127.92MWYear of Commission : 1992-1993Engine Manufacturer/Supplier : M/s. SEMT Pielstick, France. (Now renamed as MAN Diesel SAS) Type of Plant Operation : On base Load at 18 MW /UNIT (6x18MW)As per recommendation of OEM supplier due to ISO conditions

COMMISSIONING DATES

Unit-6 31.03.1993

Unit-5 14.05.1993

Unit-4 27.07.1993

Unit-3 19.10.1993

Unit-2 26.11.1993

Unit-1 31.01.1994

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Details of systems

Mechanical systems : Diesel Engine Type : PC 4.2B V 570 , 4 stroke single acting. Number of cylinders: 18 in Vee of 450 Continuous rating: 1650 HP(1215 Kw), Rotation speed: 428 RPMBore -570mmStroke: 660mmSwept volume: 168.4 dM3 Thermal Efficiency: 46.7%

6

7

Diesel engines

Main Piston Speed 9.4 m/s Mean Effective pressure 20.2 Bar at 100% load Compression Ratio 13.3:1 Max pressure 14.5 MPa Exhaust Gas Flow 137421Kg/hr Overload acceptance 10% for one hr in Every 12 hrs

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SYSTEMS INSTALLED FOR DG SETS

▶ AIR INTAKE SYSTEM ▶ COMPRESSED AIR SYSTEM ▶ FUEL SYSTEM ▶ EXHAUST SYSTEM ▶ LUBE OIL SYSTEM ▶ JACKET WATER COOLING SYSTEM ▶ INJECTOR COOLING WATER SYSTEM ▶ STEAM SYSTEM ▶ PLANT WATER SYSTEM

9

UNIT AUXILIARIES

TURBOCHARGERS LUBE OIL SEPARATORS THERMOSTATIC VALVES RADIATORS REGULATION VALVES AIR REGULATION VALVES STEAM DRUM CONDENSATE DRUM CONDENSATE RECOVERY TANK OIL BATH AIR FILTERS OIL FILTERS

10

FUEL HANDLING SYSTEM

▶ LSHS is received by IOCL,from Gujarat Refineries Limited (GRL), through railways. Each railway rakes contain about 70 Wagons of capacity 20 Tons each.

▶ LSHS is unloaded and stored in IOCL depot in 2 Nos. of Storage tanks of 5000KL capacity each and supplied to DG Plant through pipe line.

▶ The transferred quantity, for the billing purpose will be reckoned from this tank through dip level method and weight basis taken jointly by the IOCL and KPCL representatives.

▶ LSHS is taken for plant operation through 365KL and 1065KL tanks of KPCL Store by means of 25HP capacity pumps, as and when required by DG Plant.

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FUEL HANDLING SYSTEM

▶365KL or 1065KL tanks are electrically heat traced and temperature maintained at 580 C and fuel transferred to station tanks viz.,settling tanks 200KLx2 and service tanks 100KLx2.

▶ As per the requirement of plant, the fuel after reaching sufficient viscosity and cleanliness (Centrifuging on line in fuel treatment plant) pumped to Fuel header in the plant.

12

LUBE OIL SYSTEM

LUBE OIL SYSTEM: The lube oil SAE 40 grade is supplied by M/s

IOCL and M/s HPCL by road from tank trucks, of 16 to 20KL capacity and stored into tanks of 50KL capacity (2 nos.) The oil is then transferred to each Unit tanks of 40 KL Capacity .

The lube oil is centrifuged before circulation in Engine.

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EFFLUENT TREATMENT PLANT(ETP)

The fuel/oil spillovers received from the following are reclaimed through ETP

a) Drip tanks (2nos.) from the engines and separators.

b) Sample fuel valve of the engines.c) From excess return from Service tank.

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ELECTRICAL SYSTEMS

1.ALTERNATOR Apparent power :23690 KVA, Voltage-11Kv,current,1243 amp, Frequency-50Hz,Insulation:classF, Rotor -14 poles,2.OUT DOOR YARD-11/66KV 3.INSTRUMENTATION & PROTECTION SYSTEM.

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ALTERNATOR: Manufacturer M/s GEC Alsthom, France.

Excitation System Brush less excitation with rotating diodes mounted on Rotor Shaft.

Voltage Regulator Thyristors type suited for parallel operation with the grid.

▶ STATOR ELECTRICAL- CHARACTERISTICS: Apparent Power 23690 KVA Rated Power 21321 KW Voltage 11000 V Current 1243 A Power Factor 0.9 Frequency 50 Hz Air Gap 15 mm No. of terminals 6 No. of Phases 3

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Pulsing short circuit Torque at 50 Hz 2612.5 knmOn constant direction 213.8 knmMagnetic pull for 1mm Eccentricity 67 KNResistance in colds state 0.0215 Ohm

▶ MAGNETIC CIRCUIT- CHARACTERISTICS:Outer Diameter 3350 mmBore Diameter 2790 mmTotal Length 850 mmNo. of slots 189No. of cooling vents 16

▶ STATOR WINDING CHARACTERISTICS:Insulation Class FTemperature increase Class FNo. of Conductors per slot 20Winding pitch 0 to 11Type of Winding Y-connection

 

17

ROTOR MECHANICAL CHARACTERISTICSNo. of Poles 14

Rotation Speed 428 rpm

Over Speed 514 rpm

No. of Fans 2No. of Blades per fan 36

Internal Air Flow rate 21.8 m3 / sec

Air Gap 15 mm

Poles Outer Diameter 2760 mm

Total Length 910 mm

Total weight including Exciter rotor 41420 Kg

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EXCITER RK 110-20:

Its installation inside the Generator ensures a very small volume of space and allows to have full benefit of an efficient cooling.

▶ The advantages of ‘Rotating diodes inverter generator excitation system’ are.

•Elimination of Rings and Brushes, •Elimination of Brush Dust •Low excitation power.

    

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OUTDOOR YARD▶ The Outdoor Yard consists of 7 Nos of 25 MVA, 11/66

KV transformers one each per DG set and one Standby.

▶ The Voltage generated in the alternator at 11KV is stepped up by 25 MVA transformer to 66KV and fed into the 66KV double bus.

▶ From the bus the power is evacuated through 6 transmission lines of 66KV viz Peenya-1 &2, WAP 1&2, DBP 1&2.

▶ 1No of 6.3 MVA &1 no of 8MVA station auxiliary transformers to step down the voltage from 66KV to 11KV and 2 Nos of 2.5MVA, 11/0.4 KV station auxiliary Transformers to further step down the voltage to 400V.

▶ Each unit is provided with 1MVA capacity 11/0.4KV unit auxiliary transformer to feed power supply to the unit auxiliaries.

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CVT CVT CVT

2.5MVA11KV/415V 11KV/415V

2.5MVA

CBCB

6.3MVA66KV/11KV 66KV/11KV

8MVA

0.2S-EM

0.2S-EM 0.2S-EM 0.2S-EM0.2S-EM0.2S-EM0.2S-EM

UAT UAT UAT UATUAT

MCBs MCBs MCBs MCBs

AuxiliariesTo Common

1.0 EM1.0 EM1.0 EM1.0 EM1.0 EM1.0 EM1.0 EM1.0 EM1.0 EM1.0 EM1.0 EM

1.0 EM

0.2 TM0.2 TM0.2 TM0.2 TM0.2 TM0.2 TM

0.2S-EM

29B29A

NCT

NCT NCT NCT NCT NCT NCT NCT

DRG-Z

TBAT

MCBs

SNCBSNCB

GT5

SNCB

GT6

SNCB

29E 29E29E 29E

29E

SPARE

VVNL, YELAHANKA, BANGALORE-64

LA LA LA LA LA LA

LA LA

LALALALALALA

CB

CB CB

CB

66kV BUS-A

66kV BUS-B

29A

29A

29A

29A

29A

29A

29A

29A

29A

29A

LA

29C 29C 29C 29C 29C

29BBUS-A

BUS-B

29B 29B 29B

29B 29B

29B 29B

29B 29B 29B

29L 29L 29L 29L 29L

TO

29T 29T 29T 29T 29T 29T

29C 29C 29C 29C 29C 29C

To CommonAuxiliaries

ALT4

AXCB

ALT5

TBAT

GT4

GTCB

ALT1

GT1

ALT2 ALT3

GT2 GT3

SNCB

AXCB

SNCB

COLONYFEEDER

COMMON AUXILIARIES

DBP-2DBP-1PNY-2PNY-1WAP-2WAP-1

29E 29L

C.TLCB LCB

C.T

LCB

C.TLCBC.T

LCBC.T

LCBC.T

TC-1

TA-1

PT-1 PT-2

TA -2

C.T

29B 29A 29B 29A

GTCB GTCB

GTCBC.TC.T

B/C

C.TC.TC.TC.TC.TC.T

GTCBGTCBGTCB

29C

29A66kV BUS-A

29A

PT-1

29B

29C

UAT

MCBs

ALT6

AXCBAXCBAXCBAXCB

TBAT TBAT TBAT TBAT

PT-2

TC-2

SINGLE LINE DIAGRAM OF SWITCHYARD[ODY] AT 120MW DIESEL POWER PLANTINDEX

GT7

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PRESENT STATUS OF DG PLANT

Plant status : All Units are available for Generation.

: Generation will be as per Load Despatch

direction.

Status of Maintenance : 60000 Hrs. major maintenance

Works have been completed on 3 Units.

Plan of Action proposed:

2008-09 a) 6000 Hrs. maintenance works on unit-1,3 & 5.

b) Procurement of spares for 6000 hrs Scheduled maintenance works of unit 1 and 3 under progress.

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SEMT Guidelines for Scheduled Maintenance Works

a) Major maintenance works to be carried-out at: 12000 Hrs. 24000 Hrs.

36000 Hrs. 48000 Hrs. & 60000 Hrs and so on.

b) Minor maintenance works to be carried-out at 6000 Hrs. 18000 Hrs. 30000 Hrs.

42000 Hrs. 54000 Hrs. and so on.

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SL. NO. COMPULSORY REPLACEMENT OF PARTS EVERY 6 000 HRS.

EVERY 12, 000 HRS.

EVERY 24, 000 HRS.

1. EXHAUST SEALING RINGS NO YES YES

2. ROCKER ARM SHAFTS & BUSHES NO NO YES

3. BIG END BEARING SHELL NO YES YES

4. BIG END TIE BOLTS & NUTS NO NO YES

5. PISTON RINGS NO YES YES

6. LINER ‘O’Rings NO NO YES

7. GASKETS OF INSPECTION DOOR & SAFETY VALVES

NO YES YES

8. LIP SEAL OF SHAFT OIL SEAL NO NO YES

9. EXTERNAL BEARING SHELL NO NO YES

10. REPLACE AUTOMISERS YES YES YES

11. INSPECT THE ROTATING DEVICES, CRANK CASE, BEARINGS

YES YES YES

12. INSPECTION OF TIMING GEARS, FILTERS, AIR VALVES

YES YES YES

13. INSPECTION OF GOVERNOR YES YES YES

14. REPLACEMENT OF STATIC ‘O’ RINGS YES YES YES

NOTE: REPLACEMENT OF MAJOR PARTS LIKE EXHAUST VALVES, INLET VALVES, CYLINDER HEADS, LINERS ETC., DEPEND ON THE MEASUREMENTS& CLEARANCES TAKENOUT AFTER DISMANTLING

SEMT GUIDELINES FOR SCHEDULE MAINTENANCE WORKS

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Type of Maintenance

WorksUnit-1 Unit-2 Unit-3 Unit-4 Unit-5 Unit-6

Average Cost of

Maintenance

12,000 Hrs. 175.77 48.48 48.97 331.25 68.12 17.64 115

24,000 Hrs. 469.47 337.38 299.73 290.67 331.83 330.19 343

36,000 Hrs. 154.65 159.45 190.28 139.19 222.68 124.65 165

48,000 Hrs. 254.36 292.04 260.83 315.67 - 265.00 283

54,000 Hrs. - 31.89 32.99 - - 23.61 30

60,000 Hrs. - 230.00 244.00 - - 230.00 235.00

Cost of Major Maintenance Works Carried-out at DG PlantAmount in Rs. lakhs

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YEAR TYPE OF MAINTENANCE UNITS

1996-97 12000 hrs 2,3,5 & 6

1997-98 12000 hrs 1 & 4

1998-99 24000 hrs 2, 3 & 6

1999-0024000 hrs 1, 4 & 5

30000 hrs 2 & 6

2000-0130000 hrs 4 & 5

36000 hrs 3, 4 & 6

2001-0236000 hrs 1, 2 & 5

42000 hrs 3, 4 & 6

2002-03

42000 hrs 1, 2 & 5

48000 hrs 2, 3 & 6

54000 hrs 3

2003-04 48000 hrs 4

54000 hrs 2 & 6

2004-0548000 hrs 5

54000 hrs 2,3 & 6

60000 hrs 3

2005-06 60,000 hrs. 2 & 6

2006-07 Nil nil

YEARS IN WHICH SCHEDULED MAINTENANCE CARRIED-OUT

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FUEL SPECIFIC FUEL CONSUMPTION /

gms/Kwh

Lube Oil CONSUMPTION

grms/hourAt 100% load 191.9 22730 At 75% load 189.9 17820At 50% load 196.2 14850At 25% load 219.2 ---

The Specific Fuel Consumption past in is 10 years , varied from 196.23 gms to 216.46 gms/Kwh for base load operation. The lube oil consumption also varied from 1.6grams/kwh to 1.9grams/kwh against the performance test result of 1.4grams/hr(22.490Kg/Hr) at base load .

SCHEDULE OF GUARANTEES

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DIESEL ENGINES

▶ The 6 Diesel Engines each 21.32 MW capacity along with the auxiliary equipments were supplied by M/s SEMT Pielstick, France.

▶ These Diesel Engines are medium speed type running at 428 RPM directly coupled (without flywheel) to the alternator and are designed to operate on multifuels viz. heavy fuel oil, LSHS and FO .Thermal efficiency of Diesel Engine is 46.7%.

▶ Each Diesel Engine has got 18 cylinders and each cylinder has got 2 inlet valves, 2 exhaust valves and one fuel injector with fuel pump.

▶ Each Diesel Engine is equipped with 2 turbo-chargers and a waste heat recovery boiler.

▶ The Turbo Charger (TC) supplies air required for ignition at a pressure of 2.5 to 3 bar

▶ The TC comprises mainly a compressor coupled to a turbine driven by engine exhaust gas .

For starting, and for running at low loads upto 35% of rated capacity, the engines require HSD as secondary fuel.

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Waste Heat Recovery Boiler

The Exhaust gas at 410°C heats the water in Waste recovery boiler to a temperature of 135°C and the steam produced is used for heat tracing LSHS lines to reach Engines at appropriate viscosity(13.5 to 16.5 Cst)

The exhaust gas escapes to atmosphere at a height of 45 Mtr Stack (Restricted due to Aviation Controls) The Stack releases are monitored as per the norms of Pollution

Control Board in considerations of the dew points. SOx & NOx levels of the exhaust contents. Proper Aviation lights are provided at top of Stacks.

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Unit Total No of Running Hours

Previous Major maintenance

After Previous major

maintenance Unit – 1 57852 52117 5735Unit – 2 68679 66398 2681

Unit – 3 73211 66496 6715

Unit – 4 63356 61070 2286

Unit – 5 61598 57269 4329

Unit – 6 68156 65107 3049

NUMBER OF RUNNING HOURS AS ON 31.1.2008

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STARTING OF DG SETS(FROM COLD CONDITION)

Lube oil main pump to run about 15 Hrs to get Engine Lube oil temperature of 45°C.

Jacket Water pump to run for 15 Hrs to get Engine Jacket Water temperature of 40°C.

Two units to be run on HSD for about 24 Hrs to get steam pressure of 2.5 Bar and temperature of 120°C.

LSHS should attain 80°C by Steam tracing to Start Ring Pump.

160 KL of HSD Required for cold starting.

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Sl no.

LSHSgm/kwh

HSDgm/Kwh

WACV in KCal/Kg

Heat rate Kcal/Kg

No.of Units

PLF %

GenerationMU/Month

1 175 25 9805.0 2054.52 2 24 18.792 180 18 9787.3 2029.02 2 & 3 33 25.923 185 12 9771.7 2014.44 3 41 38.884 190 6 9755.9 1999.85 3 & 4 49 45.365 192 4 9750.6 1950.38 4 67 51.84 VC=FC

6 193 2.8 9747.4 1942.47 5 & 6 72.5 60.917 193 2.5 9746.6 1937.92 6 98 69.98

BREAK POINT OF FUEL CONSUMPTION (HSD AND LSHS)

(@Net Cal. Values of Std sample) (@Net Cal. Values of Std sample) (HSD:10260 & LSHS:9740 Kcal/Kg)(HSD:10260 & LSHS:9740 Kcal/Kg)

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POWER PURCHASE AGREEMENT-PPA

DRAFT PPA STIPULATES PAYMENT OF VARIABLE CHARGES LOWER OF THE FOLLOWING:

A. VARIABLE CHARGES CALCULATED AS PER THE FORMULA (Rs./KWH) a) VC (due to fuel) =1995 X Wtd.Av. Cost of fuel Wtd.Av.Cal.value (1-AC%)

b) VC (due to LO) =1.1 X LO Cost per gram (1-AC%)

B. Actual expenses made on fuel and Lube oils against accounts of a tariff calendar month.

Most of the times A < B and there is revenue loss to DG Plant

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PPA

Heat Rate :Station heat rate is stipulated by KERC is 1995 K Cal/KWH.based on the statistics of the plant during 2001-02,02-03

and LCV of the fuel. The heat rate now reached is more than 2050 K cal/KWH due to reasons:

a) Frequent Cold Starts consuming more secondary fuel ie.HSD & Auxiliary consumption.(More than 3.5%) with lower Cal. value of LSHS and viscosity.

b) Plant is operated in seasonal peaks from December to beginning of monsoon.

c) The life of the plant reaching 15 years influences the fuel consumption.

KERC should accept our appeal for Heat rate of 2050 Kcal/KWH & Aux Con. to extent of 4% of gross generation.

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M/s IOCL expressed their inability to supply more than 5TMT of LSHS owing to restricted availability of LSHS due to all refineries tending to become zero residual refinery(ZRR) due to increasing availability of LNG from other sourcesHence , requested us to accept LSFO with less than 2% sulphur

The IOCLs proposal for supply of LSFO with (< 2 % sulphur) has been apprised to KSPCB and SPPCC for necessary consent and concurrence for use in place of LSHS (<1 % sulphur).The consent and concurrence from KSPCB & SPPCC is awaited.

M/s IOCL were requested to explore the possibility for supply of LSFO(<1%sulphur). M/s IOCL offered to supply the LSFO (<1 % sulphur) by importing the same on high sea sales basis unloaded from the harbour and transported through tankers by road from Mangalore to Yelahanka for which KPCLs firm commitment was requested with price on back to back basis.

35

The infra structure for unloading LSHS at yelahanka terminal by IOCL is about one rake / day(1400MT).

To operate all the six units 11 to 12 rakes are to be unloaded per month . The turn around time taken by each rake for a long haul ( Koyali to Yelahanka) is 15 to 20 days per trip.

Only about 21 rakes are available in railway for transportation of LSHS . Hence M/s IOCL are facing difficulty in getting rakes for loading to DG plant , Yelahanka.

M/s IOCL were unable to get more than 3 to4 rakes from the railways. IOCL informed that railways are placing restriction at Koyali refinery for loading rakes to yelahanka and hence requested KPCL to address a letter to railways for releasing empty rakes for DG plant requirement of LSHS.

Accordingly a draft letter addressed to Member traffic railway ministry has been sent to HO for further transmission to Railway department.

36

M/s IOCL have taken action to supply LSHS , Ex Narimanam from their refinery at Narimanam through tankers by road due to non availability of railway facility at Narimanam. The existing infra structure at IOCL depot is sufficient to unload about 15 to 20 (200 MT) trucks per day.

In order to operate 5 units rake receipts with IOCL utility of tanks (1000 KL) have to be made use.

If other vendors are explored for supply of LSHS, maximum10 trucks can be directly unloaded to plant tanks. In this case only one unit can be run depending on truck unloading capacity and constraints due to available storage tank.

37

LSFO has not been used in DG Plant so far.

At present only one HFO ring pump circuit is available. Which may not be capable to handle two residual oils (LSHS & LSFO) simultaneously due to variation in fire points and pour points.

Pipe lines carrying the fuel may choke due to variations in viscosity.

The centrifuges require modifications to handle LSFO for separation of water and sludge content and also the annunciation panels and settings in the control room requires modification.

There is no separate storage facility for this fuel. If at all it requires to be used, the existing tanks and pipe lines are to be cleaned thoroughly for using LSFO.

To unload the fuel supplied by trucks additional crew is required and also it has to be done only during day light.

Only two units can be operated if both the fuels have to be used one after other depending upon its availability.

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ALTERNATE FUEL PROPOSAL Due to CNG becoming more available from new

sources , all refineries are switching over to CNG production and proceeding towards becoming ZRR( Zero residual refineries) i.e LSHS may become redundant shortly.

IOCL have intimated that Karnataka State is also expected to become complete user of CNG by 2011.

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Alternate fuel

HPCL have also opined the same .Hence LSFO(Low sulphur Furnace oil) with less sulphur content has been proposed for use in DG Plant yelahanka until switching over to gas.

As DG Plant units are designed to operate on multi fuels, proposal to use LSFO has been put up to KSPCB for issuing the consent. The HO has also been apprised about this issue.

40

Year

Gross units

generated in MUs

Aux. cons. in

MU

Aux. cons. in %

Net Units in

MUs

HSD in KL

F.O. in KL

LSHS in MT

L.O. in KL

Hours Run

%PLF 108 MW

92-93 0.012 0.003 25 0.009 36.97 -- -- 45.74 2 ---

93-94 148.46 9.055 6.1 139.41 36407.4 1149.63 716.735 668.1 15176.1 15.69

94-95 364.65 15.396 4.22 349.25 12288.9 61996.1 3901.67 823.3 25754.3 38.54

95-96 542.54 20.619 3.8 521.92 16664.8 6237.71 87703.4 911.3 31140.6 57.35

96-97 536.73 19.881 3.7 560.65 6585.0 4785.78 95868.7 896.9 29130.7 56.73

97-98 665.45 22.625 3.4 642.83 8406.75 -- 123898.3 1033.6 36798.1 70.34

98-99 625.01 22.079 3.53 602.93 8482.28 -- 117793.4 1013.5 36716 66.06

ENERGY GENERATED, FUEL CONSUMED FROM THE DATE OF COMMISSIONING TILL DATE AT DG PLANT (YEAR WISE GENERATION AT

DG PLANT YELAHANKA)

41

Year

Gross units

generated in

MUs

Aux. cons. in MU

Aux. cons. in %

Net Units

in MUs

HSD in KL

F.O. in KL

LSHS in MT

L.O. in KL

Hours Run

PLF % on 108 MW

99-00 707.49 21.32 3.01 686.17 3339.04 136130.1 1138 38547.9 74.78

00-01 658.40 19.51 2.96 632.50 2970.63 128219.3 1012.16 35530.5 69.59

01-02 768.73 22.75 2.96 738.52 2861.3 149129.9 1141.5 42637.2 81.25

02-03 706.82 21.82 3.09 685.01 2814.99 136712.6 1181.44 38878.6 74.71

03-04 397.91 13.90 3.49 384.01 3050.12 94419.12 726.33 22412.1 42.06

04-05 271.46 9.50 3.50 261.96 2224.26 52914.6 477.77 15674.35 28.69

05-06 96.69 3.38 3.50 91.57 825.82 18951.08 171.74 5367.2 10.22

06-07 139.55 4.89 3.50 134.65 1515.44 26848.36 167.387 8187.7 14.75

07-08* 96.44 3.41 3.54 93.01 642.48 18679.15 170.38 5465.4 10.19

ENERGY GENERATED, FUEL CONSUMED FROM THE DATE OF COMMISSIONING TILL DATE AT DG PLANT (YEAR WISE GENERATION

AT DG PLANT YELAHANKA)

42

SPECIFICATIONS LSHS HSD LUBE OIL

Sp gravity 0.91 0.83% -0.85 % @ 15 Deg cent

--

Ash content ( max) 0.10 % by weight 0.02 % by weight --

Pour point 72 deg C 12 deg –18deg C --

Kinematic viscosity CST

700 @ 500 C max 2.5-15.7 @ 38 deg C 13.5–15.3 @100

deg C

Sediment % by wt ( max)

0.25 0.10 --

Total sulphur content ( max)

0.75 % by wt 1.80 % --

Water content % by volume

1.00 0.25 (Max) --

Gross calorific value ( Kcal/Kg)

10000 10900 --

Net calorific value -- 10230 --

Viscosity index n.a. n.a 96

TBN (Total base number)

-- --- 29.5 –36.5

FUELOIL SPECIFICATIONS

43

TREND OF PRICE RISE OF FUEL OILS WITH TARIFF

YEAR

AVERAGE PRICE OF LSHS/Kg(in Rs.)

AVERAGE PRICE OF HSD/Ltr.(in Rs.)

AVERAGE PRICE OF

LO/Ltr.(in Rs.)

TREND

TARIFFLSHS HSD

2000-01 12.36 15.48 46.80 BASE BASE 2.6712001-02 10.83 17.16 53.14 -13% +10.8% 2.344

2002-03 13.49 17.14 56.74 +9% +10.7% 2.944

2003-04 13.53 21.11 51.47 +9% +37% 2.950 (PPA)

2004-05 15.05 25.99 52.72 +21% +68% 3.030

2005-06 20.34* 31.76 51.48 +64% +200% 4.9802006-07 24.76* 35.16 75.05 +200% +227% 5.640

2007-08 25.90* 41.98 92.40 +209% +271% 5.744

*EXICE DUTY AFFFECTED FROM SEPT’ 2005 ON LSHS

44

0

20

40

60

80

100

120

140

160

180

2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 2007-08

AVERAGE PRICE OF LO/Ltr. (in Rs.)

AVERAGE PRICE OF HSD/Ltr. (in Rs.)

AVERAGE PRICE OF LSHS/Kg (inRs.)

TREND OF PRICE RISE OF FUEL OILS

45

KARNATAKA POWER CORPORTION LIMITED PARTICULARS OF GENERATION, FUEL COST, HEAT RATE, SFC & VARIABLE COST

2000-01 652.02 19.52 2.99 632.500 689 2970.630 128219.299 1012.160 9832.00 1952.00 68.92

2001-02 768.73 30.21 3.93 738.520 689 2861.300 149129.995 1141.480 9805.00 1933.00 81.25

2002-03 706.82 21.81 3.09 685.010 689 2814.990 136712.557 1181.440 9751.00 1919.00 74.71

2003-04 397.91 13.90 3.49 384.010 689 3050.120 94419.120 726.330 9778.18 1934.70 42.06

2004-05 271.46 9.50 3.50 261.961 689 2224.260 52914.601 477.770 9932.38 2007.50 28.69

2005-06 96.69 5.12 5.29 91.570 240 825.820 18951.080 171.740 9831.86 1963.50 10.22

2006-07 139.55 4.90 3.51 134.650 240 1515.436 26848.360 167.387 9862.83 1994.50 14.75

2007-08* 96.44 3.44 3.56 93.005 240 642.482 18679.145 170.380 9725.21 1999.33 10.19

* Generation up to October-2007 Tariff Month

NET GEN (in MU)

(SALE OF ENERGY)

TAR GETD.

GEN (in MU)

HSD CONSUMED

(in KL)

YEAR GROSS GEN

(in MU)

AUX. CONS.(in MU)

AUX. CONS. (in %)

LSHS CONSUMED

(in MT)

LUBE OIL CONS. (in KL)

% PLF on 108

MW

DG PLANT, YELAHANKA

As per KERC Norms the % Auxiliary Consumption is stipulated 3.5% of Gross Generation and Station Heat Rate is 1995 Kcal/Kwh

WTD. AVG CALORIFIC VALUE

(Kcal/Kg)

GROSS HEAT RATE

Kcal/Kwh

46

2.671

2.344

2.944

2.950

3.030

4.980

5.640

5.744

TOTAL VAR. COST

LSHS+ HSD

LO

2000-01 12366.03 459.930 15482.57 473.670 46797.94 12.46 52.17 190.41 1.47 2.61 0.059

2001-02 10831.61 491.230 17168.07 606.530 53135.40 10.82 59.73 220.60 1.66 2.28 0.068

2002-03 13498.07 502.700 17857.97 606.890 51368.67 13.63 56.74 202.51 1.71 2.88 0.064

2003-04 10807.98 635.840 20846.39 377.840 52020.43 13.64 51.81 253.82 1.83 2.89 0.060

2004-05 13497.50 604.080 27158.70 236.600 49521.74 14.27 56.34 210.48 1.76 2.97 0.060

2005-06 20344.28 262.490 31785.38 81.010 47170.14 23.38 48.42 215.98 1.78 4.92 0.060

2006-07 24764.08 531.370 35063.84 122.620 73255.39 26.44 78.45 210.65 1.20 5.55 0.090

2007-08* 25909.06 269.747 41985.15 157.414 92389.95 26.47 91.91 207.75 1.77 5.64 0.105

WTD. AVG

COST OF LUBE OIL (Rs/Kg)

SPECIFIC FUEL CONSUM- PTION

(gm/KWH)

VAR.COST

DUE TO FUEL

VAR.COST

DUE TO LUBE OIL

AV. PRICE OF LO / KL (in Rs.)

WTD. AVG

COST OF FUEL

(Rs/Kg)

AV. PRICE OF LSHS / MT (in

Rs.)

COST OF HSD

UTILISED (in Lakhs)

YEAR AV. PRICE OF HSD / KL (in Rs.)

COST OF LUBE OIL UTILISED (in Lakhs)

47

Requirement of fuel (LSHS) for operation of units on peak load of 18 MW

Fuel required per day (MT) / KL Fuel Cost In Lakhs

Remarks

MT KL

One unit 90 100 28.44

Two units 180 200 56.88

Three units 270 300 85.33

Four units 360 400 113.77

Five units 450 500 142.21

Six units 540 600 170.65

Monthly requirement for all units

16200 18000 511.95

The rate of fuel is taken as on 29-02-08 Rs.31602 per MT

48

Fuel receipts for last three years

Name of the fuel 2005-06 2006-07 2007-08

HSD 735.407 KL 1598.220 KL 1505.896 KL

LSHS 166617.28 MT 27675.56 MT 35739.43 MT

LUBE OIL 95.141 KL 193.439 KL 461.092 KL

49

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