MONITORING REPORT

Monitoring Period
02/04/2007 to 31/05/2008
(Both days included)

Version: 06
Date: 25/01/2009

Rice Husk based power project at Satia Paper Mills Limited (SPML), Punjab,
India.
UNFCCC Reference No.- 0955

Project Site:

Village- Rupana, District- Muktsar, State-Punjab

Satia Paper Mills Limited

Table of contents
Current Status of the Project.............................................................................................................3
Monitoring Period ...........................................................................................................................4
Parameters monitored.......................................................................................................................5
Recorded observations for monitored parameters ............................................................................8
Emission reduction .........................................................................................................................10
Details of Down Time at the plant .................................................................................................12
Measures to ensure the Results / uncertainty analysis....................................................................13
Roles & Responsibilities ...............................................................................................................13
Training Procedure ........................................................................................................................13

Current Status of the Project

Satia Paper Mills Limited (SPML) is a leading integrated paper manufacturing unit in Punjab
with daily production in the range 130-150 Tons per day (TPD) of paper. The paper
manufacturing process requires thermal and electrical energy for various processes of
manufacturing unit. In order to meet the power requirements of the paper unit, SPML proposed a
rice husk based power project.
This project was successfully commissioned by Satia Paper Mills Limited (SPML), Punjab and
has been operational since July 2003.
The major equipments deployed in the project activity are as follows:

Turbine details
Description

Fully condensing

Make

Siemens

Power (MW)

Boiler details
Prior to the project activity two rice husk boilers (capacity 15 TPH and 27 TPH respectively)
were operational to meet the total steam requirements (23 TPH) of the process. The boiler with
installed capacity of 27 TPH was running on lower capacity in pre project scenario. After
installation of turbine, 27 TPH boilers runs on full capacity and generates 19 TPH of extra high
pressure steam which is used to run the project turbine. The electricity produced from project
turbine shall displace equivalent amount of electricity supply from the grid which would have
otherwise happened in absence of the project activity.
The configuration details of the boilers are as follow:
Description

Parameter

Steam generating capacity (tons per hour)

15

Steam pressure (kg/cm )

14.06

Steam temperature (0 C)

200

Description

Parameter

Steam generating capacity (tons per hour)

27

Steam pressure (kg/cm2)

32.9

Steam temperature ( C)

400 10

Monitoring Period
The Monitoring Period is chosen from 02/04/2007 to 31/05/2008 (both days included).

Parameters monitored
The following parameters have been monitored:
Data / Parameter:

Total Electricity generated

Data unit:

kWh

Description:

Total electricity generated by the project activity

Data reported in :

Plant log books

Instrument used for

measurement:
Description of
measurement
methods and
procedures to be
applied:
QA/QC procedures
to be applied:

Electronic energy meter

Energy meter at the plant location record the total electricity generated
which is then reported in the plant log books on every 8 hours shift &
daily basis.

Accuracy class

In order to ensure the highest levels of accuracy in the monitoring

procedures, the instrument used for the monitoring is calibrated annually.
As measure of quality assurance, efficient compilation and easy
accessibility of the data logged for the monitored parameter, the observed
readings are reported in the excel sheet as well. PSEB meter is installed
for cross verification
1.0

Data / Parameter:

Auxiliary Consumption

Data unit:

kWh

Description:

Electricity consumption in the plant

Data reported in :

Plant log books

Instrument used for

measurement:
Description of
measurement
methods and
procedures to be
applied:
QA/QC procedures
to be applied:

Electronic energy meters

Energy meters at different auxiliary locations shall measure the energy
consumed in auxiliaries which is then reported in the plant log books on
every 8 hours shift & daily basis.

In order to ensure the highest levels of accuracy in the monitoring

procedures, the instruments used for the monitoring are calibrated

Accuracy class

annually.
As measure of quality assurance, efficient compilation and easy
accessibility of the data logged for the monitored parameter, the observed
readings are reported in the excel sheet as well.
1.0

Data / Parameter:

Power supplied to the plant

Data unit:

kWh

Description:

Net power supply to plant

Data reported in :

Plant log books

Description of
measurement
methods and
procedures to be
applied:
QA/QC procedures
to be applied:

The net power supplied to plant is calculated by taking the difference of

the gross power generated and the auxiliary power consumption in the
plant.

Data / Parameter:

Rice husk Quantity

Data unit:

Tones

Description:

Quantity of rice husk used

Data reported in :

Plant log books

Instrument used for

measurement:
Description of
measurement
methods and
procedures to be
applied:
QA/QC procedures
to be applied:

Weighto meter

In order to avoid any discrepancies in the reporting of the monitoring

parameters the calculated readings would be directly reported in the excel
sheets.

The rice husk quantity consumed is measured by the weighto meter

installed at the plant site.

In order to ensure the highest levels of accuracy in the monitoring

procedures, the instrument used for the monitoring is calibrated annually.
As measure of quality assurance, efficient compilation and easy
accessibility of the data logged for the monitored parameter, the observed
readings are reported in the excel sheet as well.

Data / Parameter:

Calorific Value

Data unit:

kCal/kg

Description:

NCV of rice husk

Data reported in :

Test Reports

Description of
measurement
methods and
procedures to be
applied:
QA/QC procedures
to be applied:

The net calorific value of the rice husk samples sent by SPML is tested by
the third party agency.

As measure of quality assurance, efficient compilation and easy

accessibility of the data, the records for the net calorific value is
maintained in the excel sheets as well.

Biomass Availability:
An independent third party has conducted biomass assessment study for the period 01/12/2007 to
31/12/2008. The biomass assessment study clearly demonstrates that the quantity of available
biomass in the region (50 km radius), is 26.9% larger than the quantity of biomass (rice husk) that
is utilized including the project activity.
The biomass assessment report concludes that the surplus rice husk available in the command
area is 72622 MTPA when the requirement of biomass is around 269958 MTPA.

Recorded observations for monitored parameters

Month

Total
Electricity
Generated
(kWh)

Auxiliary
Consumption
(kWh) *

Power
Supplied to
the Plant
(kWh)

Rice Husk
Quantity
(Tonnes)

Net
Calorific
Value
(kCal/Kg)

Apr-07

1639783

128800

1510983

2507

3380

May-07

1095582

94300

1001282

2343

3480

Jun-07

2755022

154500

2600522

3859

3690

Jul-07

889263

63000

826263

2704

3680

Aug-07

1846531

95400

1751131

3082

3982

Sep-07

701731

37800

663931

2232

4070

Oct-07

3168168

144700

3023468

5106

4067

Nov-07

2964822

127600

2837222

4741

3770

Dec-07

2599422

118600

2480822

4560

3548

Jan-08

2880720

129900

2750820

5072

3660

Feb-08

2953491

124200

2829291

4725

3865

Mar-08

3165180

136800

3028380

5082

4079

Apr-08

2856308

129200

2727108

4765

4260

May-08

2630030

122000

2508030

4683

4290

Total

32146053

1606800

30539253

55461

Auxiliary Components
Auxiliary components for the project activity (Boiler No.4 and Turbo Generator) consist of CT
FAN & CWP-3 .CWP-2 (Stand by). The technical specifications for the auxiliary components are
follows:
CT FAN
Make

Paltech

Quantity

10 Nos

Capacity

12.5 HP

CWP-3
Make

KSB

Quantity

1 No.

Flow

900m3/hr

Head

35m

Motor

150 HP Crompton Make

CWP-2 (Stand by)

Make

KSB

Quantity

1 No.

Flow

900m3/hr

Head

35m

Motor

150 HP Crompton Make

Emission reduction
Baseline and project emissions are calculated as per the formulas mentioned in Section E of the
PDD. The same is given below:
Formulae used
The emission reduction is given by
Emission reduction = Baseline emissions Project emissions
Baseline emissions
BEY = EFY X EGY
BEY

baseline emission due to displacement of electricity during the year y (t CO2)

EGY

net quantity of electricity generated by the project activity during the year y (KWh)

EFY 1

CO2 baseline emission factor for the electricity displaced due to the project activity

in tons CO2/MWh (0.751 tCO2/MWh)

Project emissions
Since no fossil fuel used for the boiler operation, there is no project emission due to project
activity:
PEY = 0

The grid emission factor has been taken from the registered PDD.

http://cdm.unfccc.int/Projects/DB/TUEV-SUED1171633439.48/view

10

Emission reductions

Period

02/04/2007 -31/05/2008

Baseline

Net

Emission

Power

factor

produced

(tCO2/MWh)

(KWh)

(A)

(B)

0.751

30539253

11

Project
emissions
(t CO2)

Baseline
emissions
(t CO2 )
(C=
A*B)

22935

Emission
reductions
(t CO2)
(C-F)
22935

Details of Down Time at the plant

Major Outage Period2

Outage Period

Serial Number
Start from

Up To

(Days)

15/05/2007

25/05/2007

11

07/07/2007

24/07/2007

18

12/08/2007

14/08/2007

03

24/08/2007

31/08/2007

08

01/09/2007

22/09/2007

22

24/12/2007

26/12/2007

03

21/02/2008

21/02/2008

01

04/05/2008

05/05/2008

02
67

Total

The Downtime period is defined as the period during which the Turbine Generator (TG) was not in
operation / production was stopped due to scheduled preventive maintenance or brake down maintenance /
equipment failure / modification / equipment installation etc. or any of the reason.

12

Measures to ensure the Results / uncertainty analysis

In order to ensure the highest levels of accuracy the monitoring instruments are calibrated
regularly as per the manufacturers specifications. The gross power generated, auxiliary power
consumption and rice husk consumption are recorded in the plant log books which are reviewed,
verified and finally approved by the Director of the company. Also as a measure of quality
assurance in the data recording, the recorded parameters are reported in the excel format as well
which ensures the efficient compilation and easy accessibility of the data.
In order to avoid any kind of discrepancy in the monitoring process and to ensure quality and
error free monitoring process, regular internal audits are planned. The audit team comprise of the
in house technical experts and the senior officials.

13

Roles and responsibilities

SPML would be solely responsible for the monitoring activity. Organization structure responsible
for monitoring and reporting of parameters involved in CDM project activity is as presented in
the following flow chart.

Director

Director (Tech.)
Vice President (works)

Manager-Utilities

Monitoring Supervisormechanical

Monitoring Supervisor-electrical

14

Training Procedure
SPML would ensure the efficient working of the RICE HUSK BASED POWER PROJECT by
conducting training programmes. Aim of the procedure is to ensure training of SPML employees
associated with Project activity. The training will be on the following aspects of activity involved
in the Project operation, maintenance, monitoring of parameters, precautions, safety instructions
etc. These trainings will be meant to address the following key requirements related to the project
activity:
1. Corrective and preventive maintenance It would include the procedures for the general
inspection to be carried out, the maintenance required to ensure the uninterrupted
operation of the project plant.
2. Proper maintenance of the log books & reporting.
3. Calibration requirements of the monitoring equipments.
4. Monitoring of Fuel Efficiency
5. To take care of the other monitoring requirements of the CDM project activity.