A small write up on working experience at SLPP (Surat

Lignite Power Project), GIPCL.

Before describing about my working experience at SLPP, GIPCL,

let me give some information about GIPCL and further for SLPP.
The details are as mentioned below:

About GIPCL and SLPP, GIPCL:

GIPCL (Gujarat Industries Power Company Ltd.) was formed in the

era of 90s, in lieu of supply of continues quality power to major
and most important industries like GACL, IPCL, Petrofils, GSFC
and such other few in Nandesari Industrial area at Vadodara,
Gujarat. All the above mentioned industries are very important for
state and the nation. All these industries are having 24*7 working
units and power interruption of even few minutes affects the
production in very bad way due to chocking of plants and many
such problems.

Before setting up of GIPCLs Vadodara units (Gas and Gas+Naptha

based), the power supply scenario to the above industries was not
at all satisfactory and lot of production loss/ plant shutdowns etc.
was a common phenomena. The managements were struggling
to resolve the problem and then the Gujarat government with the
help of GEB (Gujarat Electricity Board) came up with an idea to
set up a power unit in the industrial area at Nandesari to cater
power especially to all these important industries. The stakes
were from GEB, GACL, GSFC , Petrofils (Now with IDBI and LIC)
and public participation through stocks/shares.

The idea went well and GIPCLs Vadodara units are supplying the
quality power to surrounding major industries in a very
satisfactory manner.

After this success, after four years of observations for the plant
performance, the then MD of GIPCL thought for going for another
power projects in Gujarat with some different fuel. The thought
was supported by trail exploration for Lignite (bio Coal) in the
areas of Mangrol Taluka in Surat district. Here Lignite reserves
were found deposited in ample quantity and also it was estimated
that the quantity was sufficient to run total 500 MW capacity
power plants for 30 to 35 years.

Though Lignite is having comparatively low calorific value and

more ash & Sulphur contains, being the most available fuel
resource in the state, it was decided to go for it. This was also
done in lieu of reducing dependency on other states or Coal
Corporation of India for Coal. The then MD of GIPCL took the
challenge and adopted the considerably new and still not very
proven technology for India i.e. CFBC boilers.For saving of fuel as
well as for getting the optimum burning efficiency, CFBC
(Circulating Fluidized Bed Combustion) technology was
considered in other countries as best one and it was also adopted
for Surat Lignite Power Project (SLPP). Project got commenced by
GIPCL in 1996 from Green field stage. The highest capacity of
CFBC boilers in India was selected and each units capacity was
selected as 125 MW. Total station capacity was decided (For 1 st
phase) as 2*125 MWs.

The main plant (BTG) was supplied by M/s BHEL with help of
technical knowhow from LLB (Lurgi, Landhoff, Babcock).

B) Major technological changes in CFBC units comparing to

Sub- Critical/Conventional Boiler units:

Conventional boiler are having coal or lignite firing with this fuel
in pulverized or powdered form whereas the CFBC technology
requires Lignite in -20 mm2 size so mills are not required and
sized Lignite crushed by Primary and secondary crushers is
directly fed.

Further, flew carrying fly ash and unburned particles of Lignite is

routed through Cyclones and due to this, unburned heavy
particles of Lignite are re- collected (Or otherwise which would
have gone to air from chimney) and again send to boiler. This
process considerably increases fuel burning efficiency and there is
considerable saving in fuel. Initial costing slightly increases as for
heat exchange from flew gas, FBHE (Fluidised Bed Heat
Exchangers are added in convective path, Cyclone also ads to the
cost and also the FBHE Blowers adds to the cost. But due to fuel
burning efficiency and other advantages (e.g. Mills are not
required so entire milling floor is abolished and some boier
parameter sare also improved in the steam generating process
etc.).

About my tenure and work exposure in SLPP:

Prior to joining SLPP, GIPCL, I was serving for M/s Gujarat

Electricity Board at 400 kV Asoj Construction S/Dn. In GEB
services, I was very fortunate to have guidance from few best
technical Gurus as well as working exposure at every voltage
level for lines, switchyards and transformers and reactors etc..

After 10 years of such beautiful work exposure, I came across one

advertisement in news papers for requirements at newly started
SLPP project of GIPCL. Initially I though that as a transmission
engineer, why and how I should apply for a power station project
but I just applied and it worked. I joined SLPP in 1996 itself
(During Green field stage of the project).

Initially I found it very difficult to match with the abbreviations of

long form like AHS. LHP or CHP etc.. Also it was difficult for me to
understand the main areas of project and the electrical needs as I
was not aware of the power plant working philosophy. Bu due to
family like working culture and support from site head (Shri D V
Iyer), within few weeks, I got familiar with many of the areas of
this power project.

The team was very small and of only about 35 executives. This
team was looking after the following areas:
 1. Main Plant
2. BOP
3. Lignite Mines
4. Intake pump house which was 12 Kms away from plant and
situated at village named Bodhan on the river banks of Tapi
River.

The working areas being taken care or being assisted by the

engineers from all disciplines are:

1. LAQ
2. Statutory clearances.
3. Dealing with related government authorities for clearances
and permissions.
4. Resource management study and resource management
5. Review and check the engineering done by Tata Consultancy
Engineers, Bangalore.
6. Preparation of tenders for various packages (The different
areas were awarded with different packages and only BTG
was a single largest package).
7. Floating bids via Limited open or Global tenders as per the
estimated costing.
8. Bid evaluations including checking prequalification criteria of
received bids/vendors quoting the bids, Techno-commercial
meets and bringing all bids technically and commercially at
par. Further, final price negotiations etc..
9. Even maintaining BGs (Bank Guarantees) for EMD, PBG or
SD.
10. Execution supervision of contracts.
11. Commissioning activities.
12. Maintenance of the project after commissioning (Plant
stage).
13. Codifications of equipments and spares, preparing
maintenance planning (Using SAP and PERT modules),budget
preparation after estimating the annual requirement for
contractual man power, spares and consumables.
14. Finalizing AMCs and ARCs etc..
As almost all the areas were covered, every engineer became a
true project engineer. Also, due to continues interaction between
engineers of all the discipline, every engineer got basic know how
of Electrical, Mechanical, Civil, C&I and water chemistry (DM
Plant) etc.. Over and above these assignments, I got an additional
opportunity to complete the half done work of 200 kV D/c
Zagadia-SLPP (Mangrol) line.

Experience in working/interacting with consultants and vendors:

In all the working culture was maintained like as if we were

working in a friendly and family like atmosphere and so engineers
and executives from all the departments were free to interact with
any department for technical study or cooperation in combined
tasks. This sort of a practice made all the engineers to become
project execution and management engineers instead of only
becoming Electrical, Mechanical or Civil engineers.

The main consultant i.e. TCE and main vendor i.e. BHEL were also
very cooperative and the project work was going in all in smooth
manner. However, somewhat delay took place due mainly due to
delays in drawing and data approvals by consultants and also due
to delayed material deliveries by vendors. But such things are
common in such big projects and can be overcome to possible
extent by extra efforts and the same was done by our team.

Unit 1 was delayed for only around 4 to 5 months and unit 2 was
subsequently delayed for another four monhts. Being a
considerably new technology for India and that is too with highest
capacity of units with this technology in India, the stabilization
took a bit longer period than conventional technology power
plants.

But after stabilization, the units worked to excellent efficiency and

with PLF of more than 85%. The main problem being faced by
these units is boiler tube leakages and route cause of this
problem is not the technology part but the inherent properties in
Lignite like Sulphor and mainly Gypsum. Sulphor brings corrosion
effect to boiler wall tubes and Gypsum cuts the tubes under high
pressure and temperature.

To overcome this problem partially, the boiler water walls (Three

to Four Meters height above refractory) are applied with special
metal spray during every years annual overhauling. Excluding
such problem, the units are running at nearing 100% PLF with
almost unity power factor.

This is all about my working experience at SLPP, GIPCL. The

readers of this small article can freely contact me on my mail ID:
milindmdeodhar@rediffmail.com or my cell phone No.: 099791
69085.