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Pro-forma &

Normalisation Equations

MINISTRY OF POWER
GOVERNMENT OF INDIA

Bureau of Energy Efficiency

(i)

Bureau of Energy Efficiency, Government of India, March 2015


All rights reserved. No part of this document may be reproduced in any form or by any means
without prior permission of Bureau of Energy Efficiency, Government of India.

Published by
Bureau of Energy Efficiency
Ministry of Power,
Government of India
4th Floor, Sewa Bhawan
R K Puram
New Delhi -110 066
Developed specifically for Designated Consumers notified under Perform Achieve and Trade
(PAT) Program for National Mission for Energy Efficiency (NMEEE)

Disclaimer
This document has been developed after an extensive and in consultation with a number of
experts and stakeholders of the scheme. BEE disclaim any liability for any kind of loss whatsoever,
whether special, indirect, consequential, or compensatory, directly or indirectly resulting from the
publication, or reliance on this document.
Conceptualized by Media NMEEE
Processed and Printed in India by Viba Press Pvt. Ltd.,
C-66/3, Okhla Industrial Area, Phase-II, New Delhi-110020
Tel. : 011-41611300 / 301 l Email : vibappl@hotmail.com

(ii)

Supporting Proforma for Form 1

Contents
Executive Summary

Abstract

Supporting Pro-forma for Form I and Normalisation Process

The Book

A. Form 1

Sector Spezcific Pro-forma for Form I

Supporting Pro-forma Sa1: Aluminium Sector (Refinery & Smelter)

Supporting Pro-forma Sa2: Aluminium Sector (Aluminium Cold Sheet)

Supporting Pro-forma Sb: Cement

111

Supporting Pro-forma Sc: Chlor Alkali

149

79

Supporting Pro-forma Sd: Fertilizer

197

Supporting Pro-forma Se1: Steel (Integrated Steel Plant)

213

Supporting Pro-forma Se2: Steel (Sponge Iron)

379

Supporting Pro-forma Sf: Pulp and Paper

437

Supporting Pro-forma Sg1: Textile (Composite)

527

Supporting Pro-forma Sg2: Textile (Fiber)

584

Supporting Pro-forma Sg3: Textile (Spinning)

633

Supporting Pro-forma Sg4: Textile (Processing)

683

Supporting Pro-forma Sh: Thermal Power Plant

731

B. Normalisation Equations

755

Sa1 Aluminium: Refinery and Smelter

756

1. Fuel Quality in CPP and Co-gen

756

2. Low PLF Compensation in CPP

758

3. Smelter Capacity Utilisation

759

4. Bauxite Quality

760

5. Carbon Anode production

762

6. Product Mix

763

7. Power Mix

773

Bureau of Energy Efficiency

(iii)

8. Normalisation Others

774

9. Gate to Gate Specific Energy Consumption

779

10. Normalised Gate to Gate Specific Energy Consumption

781

Sa2 Aluminium: Aluminium Cold Sheet

783

1. Product Mix (Equivalent Product)

783

2. Import Product Normalisation

788

3. Normalisation Others

790

4. Gate to Gate Specific Energy Consumption

793

Sb Cement Sector

795

1. Capacity Utilisation:

795

2. Product Mix and Intermediary Product

797

3. Power Mix

799

4. Coal Quality for CPP

800

5. Petcoke Utilisation in Kiln

801

6. Low PLF compensation in CPP

802

7. Normalisation Others

803

8. Gate to Gate Specific Energy Consumption

807

Sc Chlor-Alkali

809

1. Power Mix

809

2. Coal Quality for CPP and Cogen

811

3. Hydrogen Mix

813

4. Low PLF compensation in CPP

814

5. Normalisation Others

815

6. Gate to Gate Specific Energy Consumption

818

Sd Fertilizer

820

1. Low capacity utilization

820

2. Cold startup of the plant after forced shut down

821

3. Use of Naphtha

823

4. Catalyst reduction

823

5. Deterioration in quality of coal

824

(iv)

Supporting Proforma for Form 1

6. Additional provisions

825

7. GtG Specific Energy Consumption

825

Se1: Iron & Steel (Integrated Steel Plant)

826

1. Raw Material Quality

826

2. Coke Mix

831

3. Power Mix

832

4. Process Route Change

834

5. Product Mix

835

6. Start/Stop due to external Factor

841

7. Normalisation Others

844

8. Gate to Gate Specific Energy Consumption

857

Se2: Iron & Steel (Sponge Iron)

859

1. Start/Stop

859

2. Product Equivalent

861

3. Intermediary Product

873

3. Power Mix

878

5. Fuel Quality in CPP and Cogen.

879

6. Scrap Use

881

7. Normalization Others

881

8. Gate to Gate Specific Energy Consumption

885

Sf Pulp & Paper

896

1. Equivalent Product

896

2. Intermediary Product

905

3. Fuel Quality of Coal in CPP & Co-Gen

908

4. Power Mix

910

5. Normalisation Others

912

6. Gate to Gate Specific Energy Consumption

916


Bureau of Energy Efficiency

(v)

Sg Textile

1. Import & Export of Intermediary Products (Applicable in Composite,

918

Fiber & Spinning Sub-Group)

919

2. Value added product (Applicable in Spinning, Processing &

Composite Sub-Group)

924

3. Normalization for Product Mix (Applicable for All sub-Groups)

925

4. Power Mix Normalization (Applicable in all Sub-Groups)

930

5. Normalization of Yarn Products and Open End Products

931

6. Specific Energy Consumption of Spinning Sub Group

932

7. Finished Fabric of Composite sub group

932

8. Specific Energy Consumption calculation of Composite Sub Group

933

9. Normalization in Weaving Production

933

10. Normalization in Knitting Process

933

11. Normalization Factor for Plant Load Factor of Captive Power Plant

933

12. Normalization on Fuel Quality of Coal in CPP & Co-Gen

934

13. Normalization for Start & Stop

936

14. Other Normalizations Factors:

937

Sh Thermal Power Plant

941

Thermal Power Plant Normalised Net Operating Heat Rate

942

1. Formula for Target Setting

942

1.1 Formula for target setting for Coal based Thermal Power Plant

942

1.1.1 Design Net Heat Rate

942

1.1.2 Operating Net Heat Rate

942

1.1.3 Heat Hate Reduction Target

943

1.1.4 Coal based thermal Power Plant Station Target Net Operating Heat

Rate without Normalization

943

1.2 Formula for target setting Gas based Thermal Power Plant

944

1.2.1 Design Parameters

944

1.2.2 Operating parameters

944

(vi)

Supporting Proforma for Form 1

1.2.3 Heat Hate Reduction Target

945

1.2.4 Target Station Net Operating Heat Rate without Normalization for AY

945

2. Formulae for Normalization

945

2.1 Common Calculations for Normalization

945

2.2 Normalizations for Coal Based Thermal Power Plant

949

2.2.1 Coal Quality Normalization

949

2.2.2 PLF Normalization for Coal / Gas/ Diesel based Thermal Power

952

2.2.3 APC Normalization for Coal / Gas/ Diesel based Thermal Power

955

2.2.4 Other Normalization

961

2.2.5 Sation Net Operating Heat Rate with Narmalizations

963

2.3 Normalizations for Gas Based Thermal Power Plant

963

2.3.1 Gas Fuel Mix Normalization

963

2.3.2 Gas OC cycle Normalization

964

2.3.3 Gas Quality Normalization

965

2.3.4 PLF Normalization for Coal / Gas / Diesel based Thermal Power

966

2.3.5 APC Normalization for Coal / Gas / Diesel based

Thermal Power Sation

966

2.3.6 Other Normation

966

2.3.7 Station Net Operating Heat Rate with Normalizations

966

3. Summary

966

3.1 Coal Based Thermal Power Plant

966

3.2 Gas based Thermal Power Plant

967

3.3 Diesel Nased Thermal Power Plant

967

Bureau of Energy Efficiency

(vii)

Supporting Proforma for Form 1

Executive Summary
The document PAT Pro-forma and Normalization Equations is a compilation of Sector specific
Pro-forma and normalization equations applicable to 8 notified sectors.

Pro-forma
These Pro-forma facilitates capturing of data and information related to energy consumption
and production and external factors considered for normalizing the target reduction of Specific
Energy Consumption of a particular Designated Consumer.
These Pro-forma are developed with an objective of assimilating additional information or data
which was not being captured in earlier notified generic FORM-1 which was common to all above
sectors.
In order to address the sector/sub-sector characteristics, development of a comprehensive
reporting format was essential to develop sector/subsector specific Pro-forma based on parameters
such as process, product, input material etc.
To cover the complete details of sector/subsector specific parameters, 13 nos. of Pro-forma
have been designed for 8 sectors. This would facilitate 478 Designated Consumers to assess their
specific energy consumption which are notified under Perform Achieve and Trade (PAT) scheme
of National Mission of Enhanced Energy Efficiency (NMEEE.

Normalisation Equations
Normalization is a process of rationalization of the energy and production data of a plant of
Designated Consumers to take into account the impact of quantifiable external variables such as
natural disaster or rioting or social unrest, or major change in the Government policy including
environmental standards or impact of market such as shortage of raw material including its quality
or sales, or any other factor beyond the control of the Designated consumers on the value of energy
and production so as to ensure that the Designated Consumers is not placed in a position of
advantage or disadvantage when compared to baseline scenario
To account for the impact of external factors beyond the control of Designated consumers ,
normalization factors and their equations are developed and integrated with the Pro-forma.
These normalization equations help in assessment of normalized energy performance of a
Designated consumers.
These Pro-forma and normalization equations have been developed in consultations with
sectoral technical committees, industrial associations, Designated Consumers, research and
development organizations/institutions and other key stakeholders.

Bureau of Energy Efficiency

Abstract
The Perform, Achieve and Trade (PAT) scheme
is a market based mechanism under the National
Mission for Enhanced Energy Efficiency
(NMEEE) to make energy efficiency more cost
effective through certification of energy savings
that could be traded. PAT is designed particularly
for energy-intensive large industries and facilities
in 8 energy intensive industrial sectors, including
thermal power stations. PAT is a mechanism that
flows from the Energy Conservation Act, 2001
(amended in 2010).

on special trading platforms to be created in the


two power exchanges. The scheme also allows
units which have earned ESCerts to bank them
for the next cycle of PAT. The number of ESCerts
would depend upon the quantum of energy
saved in the particular year.

Indian
industry
needs
to
undertake
modernisation of old plants and install energy
efficient technologies, which will help lower
the energy intensity. Technological revamp
and retrofit projects need to be undertaken in
a number of industries. Many industrial units
have already taken conscious and concerted
Eight energy intensive sectors thermal power measures to lower their specific energy
plants, iron and steel, cement, fertilisers, consumption in order to be competitive while
aluminium, textiles, pulp and paper and chlor- maintaining profitability given the rising fuel
alkali have been included during the first cycle and feedstock prices.
of PAT, i.e. from 2012-13 to 2014-15. There are
478 designated consumers (DC) in the 8 sectors Industries, including power plants, have
and they account for about 165 million Tonne great responsibility to perform and achieve
oil equivalent (mtoe) of energy consumption the targets through implementation of best
annually. This implies a saving of 3.4 mtoe from available technologies with better operation
7 of the 8 energy intensive industries (DCs) and and maintenance. At the same time capacity
utilisation,
product
mix,
power
mix,
3.2 mtoe from the thermal power sector alone.
intermediary products, plant load factor, fuel
The savings in the first 3 years of the scheme availability and its quality, scheduling or
are estimated at 6.686 million Tonne of oil backing down, new project activities, legal
equivalent of energy, without compromising factors,among other aspects, are also being
on the industrial output. This will significantly looked at for normalisation and a level playing
enhance global competitiveness of industry field. The exercise ensures uniformity in the
while simultaneously reducing Indias overall baseline as well as the assessment year, so that
a designated consumer is not accorded undue
greenhouse gas (GHG) emissions.
advantage or disadvantage in the assessment
Further, the scheme incentivises units to of its performance in the target year 2014-15 as
achieve energy efficiency higher than their compared to the baseline year.
specific energy consumption (SEC) targets. The
scheme rewards industries that achieve better Direct comparison of an SEC value in the
performance with Energy Saving Certificates assessment year with its corresponding
(ESCerts) and allows them to trade the SEC in the baseline year allows for a simple
certificates with other designated consumers measurement of improvement in energy
who have overshot their SEC target. Since failing performance. This direct, or un-normalised,
to achieve the target would attract penalty for method reflects the results from all activities
non-compliance, these units would like to buy that occurred during the assessment period
these certificates to comply with their reduction and includes the contributions from all relevant
targets. The ESCerts so issued will be tradable variables present.
2

Supporting Proforma for Form 1

At times however, the plant may have the need


to determine the performance change resulting
from specific selected activities and conditions
as distinct from the effect of certain variables
and thus calls for normalisation. In real terms
this will equate the variables of the baseline year
in the assessment year.

framework also requires stout contribution and


assistance from various sector specific technical
and sub-technical committees on formulation of
appropriate normalisation factors within these
8 sectors.

Supporting Pro-forma
Normalisation Process

The substantial workouts carried out to


formulate normalisation factors is a unique
example in the world. In no other country has
the normalisation methodology been adopted in
such a broad range, with micro level data input,
for comparing the baseline with the reporting
year to assess the tangible outcome of energy
saving from the measures adopted in the 3 years
of the cycle.

for

Form

and

The Bureau of Energy Efficiency (BEE) has taken


up the issue of normalisation and constituted
a technical committee to formulate factors
that affect a plants energy performance in the
assessment year. To facilitate normalisation,
a data entry format needs to be developed to
capture the parameters used for calculating the
factors for different variables and change with
respect to the baseline year in assessment year.
The massive exercise was carried out for all
the 8 sectors under PAT with an inclusive and
rational approach besides developing 13 sector
and sub-sector specific data entry supporting
Pro-forma for Form I in 8 PAT sectors. The
relevant Pro-forma comprises all the energy
and production parameters required for the
valuation of different factors.
The approach was made very simple and
comprehensible utilising the mathematical
tools with statistical analysis for the actual
energy performance of the plant while keeping
the design and operating parameters in the
calculation of normalisation factors. A logical
methodology was followed to arrive at the
situation onthe ground level keeping various
plant operating conditions in consideration.
PAT requires a conducive operational and
implementation framework. This makes
necessarythe involvement of various industrial
bodiesto facilitate interactions between the
industry and the government, the participating
designated consumer units to provide an
insight into their processes and access to their
vital annual energy performance database. The
Bureau of Energy Efficiency

The Book

BEE has been instrumental in setting the pace


of the PAT scheme by incorporating all the
necessary measures in bringing the variables
on one platform. To make these outcomes more
visible and available to all, consolidation of
all the Pro-forma and normalisation equation
is required; this will support a smooth
monitoring and verification process. BEE has
been disseminating the information among DC
energy managers, certified energy auditors,
and empanelled accredited energy auditors in
a consultative and transparent manner from a
single platform.
By introducing the sector specific pro-forma and
Normalisation factors, the pace of the scheme
is all set to accelerate further for its timely
implementation.
The empanelled accredited energy audit
agencies will have a much bigger task to follow,
when the practical aspects of these factors
are looked into. Monitoring and verification,
due after March 2015, will require technical
expertise and exposure to field processes. A
pool of experts and accredited energy auditors
will be conducting actual data verification and
comparing data of the assessment year with that
of the baseline year.
3

A.

Form 1

(2) The details of data furnished in Form 1shall


be drawn from the sector-specific pro-forma
(1) Every designated consumer shall furnish in applicable to a designated consumer, and duly
electronic form as well as in hard copy to the filled in relevant sector specific pro-forma shall
be annexued to Form 1.
state designated agency, a report on the status
of energy consumption for the financial year
Sector specific pro-forma means the
ending on the 31st March of every calendar year supporting pro-forma for the sector specified in
on or before 30th June of the said calendar year, section F of Form I applicable to a designated
in Form 1
consumer.
Form-1
Details of information regarding total energy consumed and specific
energy consumption per unit of production
(See Rule 3)
A.

General Details

Description

Name of the Unit

i) Year of Establishment
ii) Registration No (As provided by BEE)

Sector and Sub-Sector in which the Designated


Consumer falls

4. (i)

Complete address of DCs unit location


(including Chief Executives name &
designation) with mobile, telephone, fax nos.
& e-mail.

(ii)

Registered Office address with telephone, fax


nos. & e-mail

(iii)

Energy Managers name, designation, EM/EA


Registration No., address, mobile, telephone,
fax nos. & e-mail

Sector

Sub-Sector

B. Production details
5

Manufacturing Industries specified as Designated Consumers

Sr.
No.

Products

Unit
(1)

(i)

Product 1

Tonne

(ii)

Product 2

Tonne

(iii)

Product 3

Tonne

(iv)

Product (Please add extra rows in case of Tonne


additional products)

(v)

Total Equivalent Product

Previous Year Current Year


(20__- 20__)
(20__- 20__)
(2)

(3)

Tonne
Supporting Proforma for Form 1

Energy Consumption Details of Manufacturing Industries specified as Designated Consumers


(1)

6. (i)

Total Electricity Purchased from Grid/Other Million kWh


Source

(ii)

Total Electricity Generated

Million kWh

(iii)

Total Electricity Exported

Million kWh

(iv)

Total Electrical Energy Consumption

Million kWh

(v)

Total Solid Fuel Consumption

Million kcal

(vi)

Total Liquid Fuel Consumption

Million kcal

(vii)

Total Gaseous Fuel Consumption

Million kcal

(viii)

Total Thermal Energy Consumption

Million kcal

(ix)

Total Energy
Electrical)

(x)

Total Normalized Energy


(Thermal + Electrical)

Specific Energy Consumption Details

7. (i)

Specific Energy
Normalization)

(ii)

Specific Energy Consumption (Normalized)

Power Plants specified as Designated Consumer

8. (i)

Total Capacity

MW

(ii)

Unit Configuration

No. of units with


their capacity

(iii)

Annual Gross Generation

MU

(iv)

Annual Plant Load Factor (PLF)

(v)

Station Gross Design Heat Rate

kcal/kWh

(vi)

Station Gross Operative Heat Rate

kcal/kWh

(vii)

Auxiliary Power Consumption

(viii)

Operative Net Heat Rate

kcal/kWh

(ix)

Operative Net Heat Rate (Normalized)

kcal/kWh

Sector- specific details

S.
No
a.

Consumption

(Thermal

+ TOE

Consumption

(Without TOE/Tonne
TOE/Tonne

Sub-Sector

Supporting Pro-froma for


Form 1 in which the details
to be furnished

Refinery/Smelter

Sa1

Cold Rolling
Sheet

Sa2

b.

Cement

Cement

Sb

c.

Chlor-Alkali

Chlor-Alkali

Sc

d.

Fertilizer

Fertilizer

Sd

Bureau of Energy Efficiency

(3)

Consumption TOE

Name of the Sector

Aluminium

(2)

e.

Iron and Steel

Integrated Steel

Se1

Sponge Iron

Se2

f.

Pulp and Paper

Pulp and Paper

Sf

g.

Textile

Composite

Sg1

Fiber

Sg2

Spinning

Sg3

Processing

Sg4

h.

Thermal Power Plant

Thermal
Plant

Power

Sh

I/We undertake that information supplied in the the Form 1 and pro-forma is accurate to the best of my
knowledge and the data furnished in From 1 has been adhered to the data given in the concerned proforma.
Signature: Signature:
Name of Energy Manager:

Registration Number:
Authorised signatory and seal
Name :
Designation :
Name of the Designated Consumer :
Address :
Seal
Date

Sector Specific Pro-forma for Form 1


The supporting pro-froma is made with the purpose of capturing correct data for Production and Energy as
well as Normalization while maintaining the data format for ease of entry. The Profroma, so filled up is also
being used to calculate the Notional Energy for Normalization to be deducted or added in separate sheets
Once complete data are filled inthe Pro-forma, the SEC after Normalization of plant automatically comes
out in the summary sheet enabling the DC to see the status of GtG SEC of the plant
The following sector-specific Pro-forma, as specified in section F of the said Form 1, shall be used, namely:-

Supporting Proforma for Form 1

Bureau of Energy Efficiency

5
a

1
2
3
4

Name of the Unit


Sub Sector
Major Product
i) Year of Establishment
ii) Registration No (As provided by BEE)
Plant Contact Details & Address
City/Town/Village
District
State
Telephone
Plants Chief Executive Name
Designation
Telephone
Mobile
Registered Office
Companys Chief Executive Name
Designation
Address
City/Town/Village
District
State
Telephone
Energy Manager Details
Name
Designation
EA/EM Registration No.
Telephone
Mobile
Pin
Fax

P.O.

Fax

Pin
Fax

Subsector

E-mail Id

Fax

Whether EA or EM

E-mail Id

Form-Sa1 (General Information)


Sector - Aluminium Sector

Supporting Pro-forma Sa1: Aluminium Sector (Refinery & Smelter)

Supporting Proforma for Form 1

iii

ii

Production Capacity
Annual Capacity Tonne
(Molten Aluminium)
Production Capacity - Annual Capacity Tonne
Cast House
Total Molten
Annual
Tonne
Aluminum Production

Tonne

Tonne

Tonne

Tonne

[A1(iii) / A1(i)]
X 100
[A1(iv) / A1(ii)]
X 100

Annual

Annual

Annual

Annual

Unit

Smelter Process

Production and
capacity utilization
details
Refinery Process
Production Capacity
(Hydrate Alumina)
Production Capacity
(Calcined Alumina)
Total Hydrate
Alumina Production
Total Calcined
Alumina Production
Capacity Utilization
(Hydrate Alumina)
Capacity Utilization
(Calcined Alumina)

Basis / Formulae

A2

vi

iv

iii

ii

A1
i

Sector: Aluminium Sector


Name of the Unit
Sub Sector
Major Product
S. No
Particulars
Year 1

Year 2

Year 3 /
Previous
Year

Baseline
Year [BY]
(Average
of Year 1
to Year 3)

Sector Specific Form-Sa1 (Details of Production and Energy Consumption)

Year 4 /
Current /
Assessment /
Target Year

Source
of data

Bureau of Energy Efficiency

Hydrate Alumina

Total Hydrated
Alumina sold to
Market (Export)
Total Hydrated
Alumina purchased
from Market for
Calcined Alumina
(Import)
Opening stock of
Hydrated alumina
Closing stock of
Hydrated alumina
Thermal SEC of
Hydrated Alumina
Electrical SEC of
Hydrated Alumina
Running Hrs

A3.1

vii

vi

iv

iii

ii

Digestion Process
Parameter
Type of Digestion
Technology

Process wise
production and
performance detail
Refinery Process

A3

vi

Total Production- Cast


House
Capacity Utilization
(Molten Aluminum)
Capacity Utilization
(Cast House)

iv

Annual

Annual

Annual

Annual

Annual

Annual

Annual

Annual

[A2(iii) / A2(i)]
X 100
[A2(iv) / A2(ii)]
X 100

Annual

Single/
Double

Hrs

Mkcal/
Tonne
kWh/Tonne

Tonne

Tonne

Tonne

Tonne

Tonne

10

Supporting Proforma for Form 1

xv
xvi
xvii

xiv

x
xi
xii
xiii

ix

viii

vii

vi

iv

iii

ii

Specific Power
Consumption for
Digestion
Temperature of Low
Temperature Digestion
Units
Pressure of Low
Temperature Digestion
Units
Temperature of High
Temperature Digestion
Units
Pressure of High
Temperature Digestion
Units
LP Steam Temperature
LP steam Pressure
LP Steam Enthalpy
LP Steam
Consumption
MP Steam
Temperature
MP steam Pressure
MP Steam Enthalpy
MP Steam
Consumption
Annual
Annual
Annual

Annual

Annual
Annual
Annual
Annual

Annual

Annual

Annual

Annual

Annual

Number of Digestion
Annual
Units
Production Capacity of Annual
Digestion Units
Specific Steam
Annual
Consumption for
Digestion

kg/cm2
kcal/kg
Tonne

C
o

C
kg/cm2
kcal/kg
Tonne

kg/cm2

kg/cm2

Tonne of
Steam/
Tonne of
Hydrate
Alumina
kWh/Tonne

Tonne

No.

Bureau of Energy Efficiency

11

Specific Power
Consumption for
Evaporation
Weighted average of
Enthalpy

Calcined Alumina
Opening stock of
Calcined alumina
cintegrated process
Closing stock of
Calcined alumina
cintegrated process
Type of Calciner
Technology
Calcination
Temperature
Specific Power
Consumption for
calciner
Specific Thermal
Consumption for
calciner
Running Hrs

xxiii

c
i

vii

vi

iv

iii

ii

xxiv

xxii

HP Steam Temperature
HP steam Pressure
HP Steam Enthalpy
HP Steam
Consumption
Specific Steam
Consumption for
Evaporation

xviii
xix
xx
xxi

C
kg/cm2
kcal/kg
Tonne

Annual

Annual

Annual

Annual

Hrs

kcal/T

kWh/T

Technology

Tonne

Annual
Annual

Tonne

Annual

Tonne of
Steam/
Tonne of
Hydrate
Alumina
Annual
kWh/Tonne
of hydrate
Alumina
Annual weighted kcal/kg
with steam
consumption

Annual

Annual
Annual
Annual

12

Supporting Proforma for Form 1

Special Hydrate
(Course)
Installed Capacity
Actual Production
Thermal SEC

Electrical SEC

Special Hydrate
(Micro Fined)

Installed Capacity
Actual Production
Thermal SEC

Electrical SEC

Special Hydrate
(Milled)

Installed Capacity
Actual Production

i
ii
iii

iv

i
ii
iii

iv

i
ii

xi

ix

Calcined Alumina
Exported (Integrated
Process)
Calcined Alumina
Imported (Integrated
Process)
Specific Thermal
Energy Consumption
of Calcined Alumina
(upto)
Specific Electrical
Energy Consumption
of Calcined Alumina
(upto)

viii

Annual
Annual

Annual

Annual
Annual
Annual

Annual

Annual
Annual
Annual

Annual

Annual

Annual

Annual

Tonne
Tonne

Tonne
Tonne
Mkcal/
Tonne
kWh/Tonne

Tonne
Tonne
Mkcal/
Tonne
kWh/Tonne

kWh/Tonne

Mkcal/
Tonne

Tonne

Tonne

Bureau of Energy Efficiency

13

Electrical SEC

Special Alumina
(Course)
Installed Capacity
Actual Production
Thermal SEC

Electrical SEC

Special Alumina
(Micro Fined)
Installed Capacity
Actual Production
Thermal SEC

Electrical SEC

Special Alumina
(Milled)
Installed Capacity
Actual Production
Thermal SEC

Electrical SEC

Carbon Black
Production
Installed Capacity
Actual Production
Thermal SEC

iv

i
ii
iii

iv

i
ii
iii

iv

i
ii
iii

iv

i
ii
iii

Thermal SEC

iii

Annual
Annual
Annual

Annual

Annual
Annual
Annual

Annual

Annual
Annual
Annual

Annual

Annual
Annual
Annual

Annual

Annual

Tonne
Tonne
Mkcal/
Tonne

Tonne
Tonne
Mkcal/
Tonne
kWh/Tonne

Tonne
Tonne
Mkcal/
Tonne
kWh/Tonne

Tonne
Tonne
Mkcal/
Tonne
kWh/Tonne

Mcal/
Tonne
kWh/Tonne

14

Supporting Proforma for Form 1

Electrical SEC

Zeolite Production
Installed Capacity
Actual Production
Thermal SEC

Electrical SEC

Other Production
Product name
Installed Capacity
Actual Production
Thermal SEC

Electrical SEC

i
ii
iii

iv

l
i
ii
iii

iv

m
i
ii
iii
iv

Major Product
(Calciner/Major
product) section start/
stop
Equivalent Major
Production during
Cold Start

Carbon Paste
Production
Installed Capacity
Actual Production
Thermal SEC

Electrical SEC

iv

Annual

Annual

Annual
Annual
Annual

Annual

Annual
Annual
Annual

Annual

Annual
Annual
Annual

Annual

Tonne

Name
Tonne
Tonne
Mkcal/
Tonne
kWh/Tonne

Tonne
Tonne
Mkcal/
Tonne
kWh/Tonne

Tonne
Tonne
Mkcal/
Tonne
kWh/Tonne

kWh/Tonne

Bureau of Energy Efficiency

15

Calciner Operating
Electrical SEC (Up to
section product)

Calciner Running Hrs


Calciner Hot to Cold
stop due to external
factor
Calciner Hot to Cold
stop due to external
factor
Calciner Hot to Cold
stop due to external
factor (Electrical
Energy Consumption)
Calciner Cold to Hot
start due to external
factors
Calciner Cold to Hot
start due to external
factors
Calciner Cold to
Hot start due to
external factors taking
production into
account (Electrical
Energy Consumption)
Calciner Cold to
Hot start due to
external factors taking
production into
account (Thermal
Energy Consumption)

iii

iv
v

xi

ix

viii

vii

vi

Calciner Operating
Thermal SEC (Up to
section product)

ii

Nos

Annual

Annual

Annual

Million kcal

Lakh kWh

Nos

Hrs

Annual
Annual

Lakh kWh

Annual

Annual
Annual

Annual

kcal/kg
equivalent
Major
product
kWh/t
equivalent
Major
product
Hrs
Hrs

Annual

16

Supporting Proforma for Form 1

Smelter Process
Molten Aluminum
Production
Thermal SEC up to
molten Aluminium

Electrical SEC up to
molten Aluminium

Total Calcined
Alumina Consumed
Running Hrs

Smelter Process
Operating Parameters
Line 1
Rated Capacity
Total Molten
Aluminium
Production
Smelting Technology
No of Operating
Pots (NOP) [based
on operating pots
weighted with the
time]
No of Pots/Potline
(NOPP)
Dead pot voltage
(DPV)

A3.2
a

ii

iii

vi

iii
iv

b.1
i
ii

iv

Calciner Cold to Hot


start due to internal
factors

xii

Annual

Annual

Annual
Annual

Annual
Annual

Annual

Annual

Annual

Annual

Annual

Volts

No.

Technology
No.

Tonne
Tonne

Hrs

kcal/Tonne
Molten
Aluminium
kWh/Tonne
Molten
Aluminium
Tonne

Nos

Bureau of Energy Efficiency

17

Line 2
Rated Capacity
Total Molten
Aluminium
Production
Smelting Technology

b.2
i
ii

iii

Annual

Annual
Annual

Annual

Carbon Consumption
Factor

xv

xiv

xvi

Annual
Annual
Annual

Annual

Annual

Annual

Design DC Specific
Annual
Power Consumption
of pots
Annual
Actual DC Specific
Power Consumption
of pots
Alumina Consumption Annual
Factor

Design Pot Voltage


(DnPV)
Design Bus Bar
Voltage Drop (DnBV)
Design Current
Efficiency of Pots (CE)
DC Current Design
DC Current Actual
Anode Effect

xiii

x
xi
xii

ix

viii

vii

Technology

Tonne
Tonne

Tonne of
Alumina/
Tonne of
Molten
Aluminum
Tonne of
Carbon/
Tonne of
Molten
Aluminum

kWh/Tonne

Kilo Amp
Kilo Amp
No./Pot/
Cell/day
kWh/Tonne

Fraction

Volts

Volts

18

Supporting Proforma for Form 1


Annual

Carbon Consumption
Factor

xv

xiv

xvi

Annual
Annual
Annual

Annual

Annual

Annual

Annual

Annual

Annual

Design DC Specific
Annual
Power Consumption
of pots
Actual DC Specific
Annual
Power Consumption
of pots
Alumina Consumption Annual
Factor

No of Operating
Pots (NOP) [based
on operating pots
weighted with the
time]
No of Pots/Potline
(NOPP)
Dead pot voltage
(DPV)
Design Pot Voltage
(DnPV)
Design Bus Bar
Voltage Drop (DnBV)
Design Current
Efficiency of Pots (CE)
DC Current Design
DC Current Actual
Anode Effect

xiii

x
xi
xii

ix

viii

vii

vi

iv

Tonne of
Alumina/
Tonne of
Molten
Aluminum
Tonne of
Carbon/
Tonne of
Molten
Aluminum

kWh/Tonne

Kilo Amp
Kilo Amp
No./Pot/
Cell/day
kWh/Tonne

Fraction

Volts

Volts

Volts

No.

No.

Bureau of Energy Efficiency

19

xv

xiv

xiii

x
xi
xii

ix

viii

vii

vi

iii
iv

b.3
i
ii

Annual
Annual
Annual

Annual

Annual

Annual

Annual

Annual

Annual
Annual

Annual
Annual

Design DC Specific
Annual
Power Consumption
of pots
Actual DC Specific
Annual
Power Consumption
of pots
Alumina Consumption Annual
Factor

Line 3
Rated Capacity
Total Molten
Aluminium
Production
Smelting Technology
No of Operating
Pots (NOP) [based
on operating pots
weighted with the
time]
No of Pots/Potline
(NOPP)
Dead pot voltage
(DPV)
Design Pot Voltage
(DnPV)
Design Bus Bar
Voltage Drop (DnBV)
Design Current
Efficiency of Pots (CE)
DC Current Design
DC Current Actual
Anode Effect

Tonne of
Alumina/
Tonne of
Molten
Aluminum

kWh/Tonne

Kilo Amp
Kilo Amp
No./Pot/
Cell/day
kWh/Tonne

Fraction

Volts

Volts

Volts

No.

Technology
No.

Tonne
Tonne

20

Supporting Proforma for Form 1

xiv

xiii

x
xi
xii

ix

viii

vii

vi

Design DC Specific
Power Consumption
of pots
Actual DC Specific
Power Consumption
of pots

Line 4
Rated Capacity
Total Molten
Aluminium
Production
Smelting Technology
No of Operating
Pots (NOP) [based
on operating pots
weighted with the
time]
No of Pots/Potline
(NOPP)
Dead pot voltage
(DPV)
Design Pot Voltage
(DnPV)
Design Bus Bar
Voltage Drop (DnBV)
Design Current
Efficiency of Pots (CE)
DC Current Design
DC Current Actual
Anode Effect

b.4
i
ii

iii
iv

Carbon Consumption
Factor

xvi

Annual

Annual

Annual
Annual
Annual

Annual

Annual

Annual

Annual

Annual

Annual
Annual

Annual
Annual

Annual

kWh/Tonne

Kilo Amp
Kilo Amp
No./Pot/
Cell/day
kWh/Tonne

Fraction

Volts

Volts

Volts

No.

Technology
No.

Tonne
Tonne

Tonne of
Carbon/
Tonne of
Molten
Aluminum

Bureau of Energy Efficiency

21

Line 5
Rated Capacity
Total Molten
Aluminium
Production
Smelting Technology
No of Operating
Pots (NOP) [based
on operating pots
weighted with the
time]
No of Pots/Potline
(NOPP)
Dead pot voltage
(DPV)
Design Pot Voltage
(DnPV)
Design Bus Bar
Voltage Drop (DnBV)
Design Current
Efficiency of Pots (CE)
DC Current Design
DC Current Actual
Anode Effect

b.5
i
ii

x
xi
xii

ix

viii

vii

vi

iii
iv

Carbon Consumption
Factor

xvi

Annual
Annual
Annual

Annual

Annual

Annual

Annual

Annual

Annual
Annual

Annual
Annual

Annual

Alumina Consumption Annual


Factor

xv

Kilo Amp
Kilo Amp
No./Pot/
Cell/day

Fraction

Volts

Volts

Volts

No.

Technology
No.

Tonne
Tonne

Tonne of
Alumina/
Tonne of
Molten
Aluminum
Tonne of
Carbon/
Tonne of
Molten
Aluminum

22

Supporting Proforma for Form 1

Line 6
Rated Capacity
Total Molten
Aluminium
Production
Smelting Technology
No of Operating
Pots (NOP) [based
on operating pots
weighted with the
time]
No of Pots/Potline
(NOPP)
Dead pot voltage
(DPV)
Design Pot Voltage
(DnPV)
Design Bus Bar
Voltage Drop (DnBV)

b.6
i
ii

viii

vii

vi

iii
iv

Annual

Annual

Annual

Annual

Annual
Annual

Annual
Annual

Annual

Carbon Consumption
Factor

xvi

xv

xiv

Design DC Specific
Annual
Power Consumption
of pots
Actual DC Specific
Annual
Power Consumption
of pots
Alumina Consumption Annual
Factor

xiii

Volts

Volts

Volts

No.

Technology
No.

Tonne
Tonne

Tonne of
Alumina/
Tonne of
Molten
Aluminum
Tonne of
Carbon/
Tonne of
Molten
Aluminum

kWh/Tonne

kWh/Tonne

Bureau of Energy Efficiency

23

Line 7
Rated Capacity
Total Molten
Aluminium
Production
Smelting Technology
No of Operating
Pots (NOP) [based
on operating pots
weighted with the
time]
No of Pots/Potline
(NOPP)

b.7
i
ii

iii
iv

Annual

Annual
Annual

Annual
Annual

Annual

Carbon Consumption
Factor

xv

xiv

xvi

Annual
Annual
Annual

Annual

Design DC Specific
Annual
Power Consumption
of pots
Actual DC Specific
Annual
Power Consumption
of pots
Alumina Consumption Annual
Factor

Design Current
Efficiency of Pots (CE)
DC Current Design
DC Current Actual
Anode Effect

xiii

x
xi
xii

ix

No.

Technology
No.

Tonne
Tonne

Tonne of
Alumina/
Tonne of
Molten
Aluminum
Tonne of
Carbon/
Tonne of
Molten
Aluminum

kWh/Tonne

Kilo Amp
Kilo Amp
No./Pot/
Cell/day
kWh/Tonne

Fraction

24

Supporting Proforma for Form 1

iii

b.8
i
ii

Line 8
Rated Capacity
Total Molten
Aluminium
Production
Smelting Technology
Annual

Annual
Annual

Annual

Carbon Consumption
Factor

xv

xiv

xvi

Annual
Annual
Annual

Annual

Annual

Annual

Annual

Annual
Design DC Specific
Power Consumption
of pots
Annual
Actual DC Specific
Power Consumption
of pots
Alumina Consumption Annual
Factor

Dead pot voltage


(DPV)
Design Pot Voltage
(DnPV)
Design Bus Bar
Voltage Drop (DnBV)
Design Current
Efficiency of Pots (CE)
DC Current Design
DC Current Actual
Anode Effect

xiii

x
xi
xii

ix

viii

vii

vi

Technology

Tonne
Tonne

Tonne of
Alumina/
Tonne of
Molten
Aluminum
Tonne of
Carbon/
Tonne of
Molten
Aluminum

kWh/Tonne

Kilo Amp
Kilo Amp
No./Pot/
Cell/day
kWh/Tonne

Fraction

Volts

Volts

Volts

Bureau of Energy Efficiency

25

Annual

Carbon Consumption
Factor

xv

xiv

xvi

Annual
Annual
Annual

Annual

Annual

Annual

Annual

Annual

Annual

Design DC Specific
Annual
Power Consumption
of pots
Actual DC Specific
Annual
Power Consumption
of pots
Alumina Consumption Annual
Factor

No of Operating
Pots (NOP) [based
on operating pots
weighted with the
time]
No of Pots/Potline
(NOPP)
Dead pot voltage
(DPV)
Design Pot Voltage
(DnPV)
Design Bus Bar
Voltage Drop (DnBV)
Design Current
Efficiency of Pots (CE)
DC Current Design
DC Current Actual
Anode Effect

xiii

x
xi
xii

ix

viii

vii

vi

iv

Tonne of
Alumina/
Tonne of
Molten
Aluminum
Tonne of
Carbon/
Tonne of
Molten
Aluminum

kWh/Tonne

Kilo Amp
Kilo Amp
No./Pot/
Cell/day
kWh/Tonne

Fraction

Volts

Volts

Volts

No.

No.

26

Supporting Proforma for Form 1

xv

xiv

xiii

x
xi
xii

ix

viii

vii

vi

iii
iv

b.9
i
ii

Annual
Annual
Annual

Annual

Annual

Annual

Annual

Annual

Annual
Annual

Annual
Annual

Design DC Specific
Annual
Power Consumption
of pots
Actual DC Specific
Annual
Power Consumption
of pots
Alumina Consumption Annual
Factor

Line 9
Rated Capacity
Total Molten
Aluminium
Production
Smelting Technology
No of Operating
Pots (NOP) [based
on operating pots
weighted with the
time]
No of Pots/Potline
(NOPP)
Dead pot voltage
(DPV)
Design Pot Voltage
(DnPV)
Design Bus Bar
Voltage Drop (DnBV)
Design Current
Efficiency of Pots (CE)
DC Current Design
DC Current Actual
Anode Effect

Tonne of
Alumina/
Tonne of
Molten
Aluminum

kWh/Tonne

Kilo Amp
Kilo Amp
No./Pot/
Cell/day
kWh/Tonne

Fraction

Volts

Volts

Volts

No.

Technology
No.

Tonne
Tonne

Bureau of Energy Efficiency

27

Line 10
Rated Capacity
Total Molten
Aluminium
Production
Smelting Technology
No of Operating
Pots (NOP) [based
on operating pots
weighted with the
time]
No of Pots/Potline
(NOPP)
Dead pot voltage
(DPV)
Design Pot Voltage
(DnPV)
Design Bus Bar
Voltage Drop (DnBV)
Design Current
Efficiency of Pots (CE)
DC Current Design
DC Current Actual
Anode Effect

Design DC Specific
Power Consumption
of pots
Actual DC Specific
Power Consumption
of pots

b.10
i
ii

xiii

xiv

x
xi
xii

ix

viii

vii

vi

iii
iv

Carbon Consumption
Factor

xvi

Annual

Annual

Annual
Annual
Annual

Annual

Annual

Annual

Annual

Annual

Annual
Annual

Annual
Annual

Annual

kWh/Tonne

Kilo Amp
Kilo Amp
No./Pot/
Cell/day
kWh/Tonne

Fraction

Volts

Volts

Volts

No.

Technology
No.

Tonne
Tonne

Tonne of
Carbon/
Tonne of
Molten
Aluminum

28

Supporting Proforma for Form 1

Line 11
Rated Capacity
Total Molten
Aluminium
Production
Smelting Technology
No of Operating
Pots (NOP) [based
on operating pots
weighted with the
time]
No of Pots/Potline
(NOPP)
Dead pot voltage
(DPV)
Design Pot Voltage
(DnPV)
Design Bus Bar
Voltage Drop (DnBV)
Design Current
Efficiency of Pots (CE)
DC Current Design
DC Current Actual
Anode Effect

b.11
i
ii

x
xi
xii

ix

viii

vii

vi

iii
iv

Carbon Consumption
Factor

xvi

Annual
Annual
Annual

Annual

Annual

Annual

Annual

Annual

Annual
Annual

Annual
Annual

Annual

Alumina Consumption Annual


Factor

xv

Kilo Amp
Kilo Amp
No./Pot/
Cell/day

Fraction

Volts

Volts

Volts

No.

Technology
No.

Tonne
Tonne

Tonne of
Alumina/
Tonne of
Molten
Aluminum
Tonne of
Carbon/
Tonne of
Molten
Aluminum

Bureau of Energy Efficiency

29

Carbon Anodes
Production
Installed Capacity
Actual Carbon Anode
Production
Capacity Utilization
Electrical SEC upto
Carbon Anode
Production

Opening Stock of
Carbon Anode
Closing Stock of
Carbon Anode
Imported Anode

vi

viii

vii

Thermal SEC upto


Carbon Anode
Production

(v)

(iii)
(iv)

(i)
(ii)

Annual

Annual

Annual

Annual

Annual

Annual
Annual

Annual

Carbon Consumption
Factor

xvi

xv

xiv

Design DC Specific
Annual
Power Consumption
of pots
Actual DC Specific
Annual
Power Consumption
of pots
Alumina Consumption Annual
Factor

xiii

Tonne

Tonne

%
kWh/Tonne
of Carbon
Anode
Production
kcal/Tonne
of Carbon
Anode
production
Tonne

Tonne
Tonne

Tonne of
Alumina/
Tonne of
Molten
Aluminum
Tonne of
Carbon/
Tonne of
Molten
Aluminum

kWh/Tonne

kWh/Tonne

30

Supporting Proforma for Form 1

Ingot
Capacity
Production
Thermal SEC of Ingots
Electrical SEC of Ingots

Bars
Capacity
Production
Thermal SEC of Bars
Electrical SEC of Bars

Primary Foundry
Alloys
Capacity
Production
Thermal SEC of Alloys
Electrical SEC of
Alloys

d.1
(i)
(ii)
(iii)
(iv)

d.2
(i)
(ii)
(iii)
(iv)

d.3
(i)
(ii)
(iii)
(iv)

d.4

d.5
(i)

Wire Rod
Capacity

Cast House
Production
Billets
Capacity
Production
Thermal SEC of Billets
Electrical SEC of Billtes

(i)
(ii)
(iii)
(iv)

Exported Anode

ix

Annual

Annual
Annual
Annual
Annual

Annual
Annual
Annual
Annual

Annual
Annual
Annual
Annual

Annual
Annual
Annual
Annual

Annual

Tonne

Tonne
Tonne
kcal/Tonne
kWh/Tonne

Tonne
Tonne
kcal/Tonne
kWh/Tonne

Tonne
Tonne
kcal/Tonne
kWh/Tonne

Tonne
Tonne
kcal/Tonne
kWh/Tonne

Tonne

Bureau of Energy Efficiency

31

Strips
Capacity
Production
Thermal SEC of Strips
Electrical SEC of Strips

Others , if Any
Product name
Capacity
Production
Thermal SEC
Electrical SEC

Scrap
Scrap Purchased
Scrap Generated
Scrap Used in Cast
House
Scrap %

Boiler Details
For Steam Generation
Boiler 1
Type
Rated Capacity
Total Steam
Generation

d.6
(i)
(ii)
(iii)
(iv)

d.7
(i)
(ii)
(iii)
(iv)
(v)

d.8
(i)
(ii)
(iii)

e
e1
e1.1
(i)
(ii)
(iii)

(iv)

(iv)

Production
Thermal SEC of Wire
Rod
Electrical SEC of Wire
Rod

(ii)
(iii)

Tonne
Tonne
Tonne

Name
Tonne
Tonne
kcal/Tonne
kWh/Tonne

Tonne
Tonne
kcal/Tonne
kWh/Tonne

kWh/Tonne

Tonne
kcal/Tonne

Annual
Annual

TPH
Tonne

For Steam Generation (Process Boiler)

Annual

Annual
Annual
Annual

Annual
Annual
Annual
Annual
Annual

Annual
Annual
Annual
Annual

Annual

Annual
Annual

32

Supporting Proforma for Form 1

(xxi)

(xviii)
(xix)
(xx)

(xvii)

(xvi)

(xiv)
(xv)

(xii)
(xiii)

(x)
(xi)

(viii)
(ix)

(iv)
(v)
(vi)
(vii)

Percentage of Coal
Energy Used in steam
Generation

Running Hrs
Coal Consumption
GCV of Coal
Type of Fuel - 2 Name :
Consumption
GCV of any Fuel -2
Type of Fuel - 3 Name :
Consumption
GCV of any Fuel -3
Type of Fuel - 4 Name :
Consumption
GCV of any Fuel -4
Feed water
Temperature
Operating Efficiency
SH Steam outlet
Pressure (Operating)
SH Steam outlet
Temperature
(Operating)
SH Steam Enthalpy
(Operating)
Design Efficiency
Operating Capacity
Specific Energy
Consumption
(iii)/(iv)
[(v)x(vi)+(vii)
x(viii)+(ix)
x(x)+(xi)x(xii)]/
(iii)
[(v)x(vi)]/
[(v)x(vi)+(vii)
x(viii)+(ix)
x(x)+(xi)x(xii)]

Annual Average

Annual Average

Annual Average
Annual Average

Annual Average
Annual

Annual Average
Annual

Annual Average
Annual

Annual
Annual
Annual Average
Annual

%
TPH
kcal/kg of
Steam

kcal/kg

%
kg/cm2

kcal/kg
C

kcal/kg
Tonne

kcal/kg
Tonne

Hrs
Tonne
kcal/kg
Tonne

Bureau of Energy Efficiency

33

(xviii)
(xix)
(xx)

(xvii)

(xvi)

(xiv)
(xv)

(xii)
(xiii)

(x)
(xi)

(viii)
(ix)

(iv)
(v)
(vi)
(vii)

e1.2
(i)
(ii)
(iii)

Boiler 2
Type
Rated Capacity
Total Steam
Generation
Running Hrs
Coal Consumption
GCV of Coal
Type of Fuel - 2 Name :
Consumption
GCV of any Fuel -2
Type of Fuel - 3 Name :
Consumption
GCV of any Fuel -3
Type of Fuel - 4 Name :
Consumption
GCV of any Fuel -4
Feed water
Temperature
Operating Efficiency
SH Steam outlet
Pressure (Operating)
SH Steam outlet
Temperature
(Operating)
SH Steam Enthalpy
(Operating)
Design Efficiency
Operating Capacity
Specific Energy
Consumption
(iii)/(iv)
[(v)x(vi)+(vii)
x(viii)+(ix)
x(x)+(xi)x(xii)]/
(iii)

Annual Average

Annual Average

Annual Average
Annual Average

Annual Average
Annual

Annual Average
Annual

Annual Average
Annual

Annual
Annual
Annual Average
Annual

Annual

%
TPH
kcal/kg of
Steam

kcal/kg

%
kg/cm2

kcal/kg
C

kcal/kg
Tonne

kcal/kg
Tonne

Hrs
Tonne
kcal/kg
Tonne

TPH
Tonne

For Steam Generation (Process Boiler)

34

Supporting Proforma for Form 1

Boiler 3
Type
Rated Capacity
Total Steam
Generation
Running Hrs
Coal Consumption
GCV of Coal
Type of Fuel - 2 Name :
Consumption
GCV of any Fuel -2
Type of Fuel - 3 Name :
Consumption
GCV of any Fuel -3
Type of Fuel - 4 Name :
Consumption
GCV of any Fuel -4
Feed water
Temperature
Operating Efficiency
SH Steam outlet
Pressure (Operating)
SH Steam outlet
Temperature
(Operating)
SH Steam Enthalpy
(Operating)
Design Efficiency
Operating Capacity

e1.3
(i)
(ii)
(iii)

(xviii)
(xix)

(xvii)

(xvi)

(xiv)
(xv)

(xii)
(xiii)

(x)
(xi)

(viii)
(ix)

(iv)
(v)
(vi)
(vii)

Percentage of Coal
Energy Used in steam
Generation

(xxi)
%

(iii)/(iv)

Annual Average

Annual Average

Annual Average
Annual Average

Annual Average
Annual

Annual Average
Annual

Annual Average
Annual

Annual
Annual
Annual Average
Annual

Annual

%
TPH

kcal/kg

%
kg/cm2

Tonne

Tonne

Tonne

Hrs
Tonne

TPH
Tonne

For Steam Generation (Process Boiler)

[(v)x(vi)]/
[(v)x(vi)+(vii)
x(viii)+(ix)
x(x)+(xi)x(xii)]

Bureau of Energy Efficiency

35

Percentage of Coal
Energy Used in steam
Generation

Boiler 4
Type
Rated Capacity
Total Steam
Generation
Running Hrs
Coal Consumption
GCV of Coal
Type of Fuel - 2 Name :
Consumption
GCV of any Fuel -2
Type of Fuel - 3 Name :
Consumption
GCV of any Fuel -3
Type of Fuel - 4 Name :
Consumption
GCV of any Fuel -4
Feed water
Temperature
Operating Efficiency
SH Steam outlet
Pressure (Operating)
SH Steam outlet
Temperature
(Operating)

(xxi)

e.1.4
(i)
(ii)
(iii)

(xvi)

(xiv)
(xv)

(xii)
(xiii)

(x)
(xi)

(viii)
(ix)

(iv)
(v)
(vi)
(vii)

Specific Energy
Consumption

(xx)

kcal/kg of
Steam

Annual Average

Annual Average
Annual Average

Annual Average
Annual

Annual Average
Annual

Annual Average
Annual

Annual
Annual
Annual Average
Annual

Annual

%
kg/cm2

kcal/kg
C

kcal/kg
Tonne

kcal/kg
Tonne

Hrs
Tonne
kcal/kg
Tonne

TPH
Tonne

For Steam Generation (Process Boiler)

[(v)x(vi)+(vii)
x(viii)+(ix)
x(x)+(xi)x(xii)]/
(iii)
[(v)x(vi)]/
[(v)x(vi)+(vii)
x(viii)+(ix)
x(x)+(xi)x(xii)]

36

Supporting Proforma for Form 1

Boiler 5
Type
Rated Capacity
Total Steam
Generation
Running Hrs
Coal Consumption
GCV of Coal
Type of Fuel - 2 Name :
Consumption
GCV of any Fuel -2
Type of Fuel - 3 Name :
Consumption
GCV of any Fuel -3
Type of Fuel - 4 Name :
Consumption
GCV of any Fuel -4
Feed water
Temperature
Operating Efficiency

e1.5
(i)
(ii)
(iii)

(xiv)

(xii)
(xiii)

(x)
(xi)

(viii)
(ix)

(iv)
(v)
(vi)
(vii)

Percentage of Coal
Energy Used in steam
Generation

SH Steam Enthalpy
(Operating)
Design Efficiency
Operating Capacity
Specific Energy
Consumption

(xxi)

(xviii)
(xix)
(xx)

(xvii)

%
TPH
kcal/kg of
Steam

kcal/kg

Annual Average

Annual Average
Annual

Annual Average
Annual

Annual Average
Annual

Annual
Annual
Annual Average
Annual

Annual

kcal/kg
C

kcal/kg
Tonne

kcal/kg
Tonne

Hrs
Tonne
kcal/kg
Tonne

TPH
Tonne

For Steam Generation (Process Boiler)

(iii)/(iv)
[(v)x(vi)+(vii)
x(viii)+(ix)
x(x)+(xi)x(xii)]/
(iii)
[(v)x(vi)]/
[(v)x(vi)+(vii)
x(viii)+(ix)
x(x)+(xi)x(xii)]

Annual Average

Bureau of Energy Efficiency

37

Total Steam
Generation (Process
Boiler)

Total Operating
Efficiency of Boiler
(Process Boiler)
Total Operating
Capacity of Boilers
(Process Boiler)

Weighted Specific
Energy Consumption
(Process Boiler)
Weighted Percentage
of Coal Energy Used
in steam Generation
(Process Boiler)

e1.6

e1.7

e1.9

e1.10

e1.8

Percentage of Coal
Energy Used in steam
Generation

SH Steam outlet
Pressure (Operating)
SH Steam outlet
Temperature
(Operating)
SH Steam Enthalpy
(Operating)
Design Efficiency
Operating Capacity
Specific Energy
Consumption

(xxi)

(xviii)
(xix)
(xx)

(xvii)

(xvi)

(xv)

(iii)/(iv)
[(v)x(vi)+(vii)
x(viii)+(ix)
x(x)+(xi)x(xii)]/
(iii)
[(v)x(vi)]/
[(v)x(vi)+(vii)
x(viii)+(ix)
x(x)+(xi)x(xii)]
e.1.1(iii) +
e.1.2(iii) +
e.1.3(iii) +
e.1.4(iii) +
e.1.5.(iii)
Weighted
average of all 5
boilers
e.1.1(xix) +
e.1.2(xix) +
e.1.3(xix) +
e.1.4(xix) +
e.1.5.(xix)
Weighted
average of all 5
boilers
Weighted
average of all 5
boilers

Annual Average

Annual Average

Annual Average

kcal/kg of
Steam

TPH

Tonnes

%
TPH
kcal/kg of
Steam

kcal/kg

kg/cm2

38

Supporting Proforma for Form 1

(xviii)
(xix)
(xx)

(xvii)

(xvi)

(xiv)
(xv)

(xii)
(xiii)

(x)
(xi)

(viii)
(ix)

(iv)
(v)
(vi)
(vii)

(iii)/(iv)
[(v)x(vi)+(vii)
x(viii)+(ix)
x(x)+(xi)x(xii)]/
(iii)

Annual Average

Annual Average

Annual Average
Annual Average

Annual Average
Annual

Annual Average
Annual

Annual Average
Annual

Annual
Annual
Annual Average
Annual

Annual

Type
Rated Capacity
Total Steam
Generation
Running Hrs
Coal Consumption
GCV of Coal
Type of Fuel - 2 Name :
Consumption
GCV of any Fuel -2
Type of Fuel - 3 Name :
Consumption
GCV of any Fuel -3
Type of Fuel - 4 Name :
Consumption
GCV of any Fuel -4
Feed water
Temperature
Operating Efficiency
SH Steam outlet
Pressure (Operating)
SH Steam outlet
Temperature
(Operating)
SH Steam Enthalpy
(Operating)
Design Efficiency
Operating Capacity
Specific Energy
Consumption

(i)
(ii)
(iii)

%
TPH
kcal/kg of
Steam

kcal/kg

%
kg/cm2

kcal/kg
C

kcal/kg
Tonne

kcal/kg
Tonne

Hrs
Tonne
kcal/kg
Tonne

TPH
Tonne

Co-Gen Boiler used for Power generation


Boiler 6
Co-Gen

e2
e2.1

Bureau of Energy Efficiency

39

Boiler 7
Type
Rated Capacity
Total Steam
Generation
Running Hrs
Coal Consumption
GCV of Coal
Type of Fuel - 2 Name :
Consumption
GCV of any Fuel -2
Type of Fuel - 3 Name :
Consumption
GCV of any Fuel -3
Type of Fuel - 4 Name :
Consumption
GCV of any Fuel -4
Feed water
Temperature
Operating Efficiency
SH Steam outlet
Pressure (Operating)
SH Steam outlet
Temperature
(Operating)
SH Steam Enthalpy
(Operating)
Design Efficiency
Operating Capacity

e2.2
(i)
(ii)
(iii)

(xviii)
(xix)

(xvii)

(xvi)

(xiv)
(xv)

(xii)
(xiii)

(x)
(xi)

(viii)
(ix)

(iv)
(v)
(vi)
(vii)

Percentage of Coal
Energy Used in steam
Generation

(xxi)

(iii)/(iv)

Annual Average

Annual Average

Annual Average
Annual Average

Annual Average
Annual

Annual Average
Annual

Annual Average
Annual

Annual
Annual
Annual Average
Annual

Annual

Co-Gen

[(v)x(vi)]/
[(v)x(vi)+(vii)
x(viii)+(ix)
x(x)+(xi)x(xii)]

%
TPH

kcal/kg

%
kg/cm2

kcal/kg
C

kcal/kg
Tonne

kcal/kg
Tonne

Hrs
Tonne
kcal/kg
Tonne

TPH
Tonne

40

Supporting Proforma for Form 1

Percentage of Coal
Energy Used in steam
Generation

Boiler 8
Type
Rated Capacity
Total Steam
Generation
Running Hrs
Coal Consumption
GCV of Coal
Type of Fuel - 2 Name :
Consumption
GCV of any Fuel -2
Type of Fuel - 3 Name :
Consumption
GCV of any Fuel -3
Type of Fuel - 4 Name :
Consumption
GCV of any Fuel -4
Feed water
Temperature
Operating Efficiency
SH Steam outlet
Pressure (Operating)
SH Steam outlet
Temperature
(Operating)

(xxi)

e2.3
(i)
(ii)
(iii)

(xvi)

(xiv)
(xv)

(xii)
(xiii)

(x)
(xi)

(viii)
(ix)

(iv)
(v)
(vi)
(vii)

Specific Energy
Consumption

(xx)

Annual Average

Annual Average
Annual Average

Annual Average
Annual

Annual Average
Annual

Annual Average
Annual

Annual
Annual
Annual Average
Annual

Annual

Co-Gen

[(v)x(vi)+(vii)
x(viii)+(ix)
x(x)+(xi)x(xii)]/
(iii)
[(v)x(vi)]/
[(v)x(vi)+(vii)
x(viii)+(ix)
x(x)+(xi)x(xii)]

%
kg/cm2

kcal/kg
C

kcal/kg
Tonne

kcal/kg
Tonne

Hrs
Tonne
kcal/kg
Tonne

TPH
Tonne

kcal/kg of
Steam

Bureau of Energy Efficiency

41

Boiler 9
Type
Rated Capacity
Total Steam
Generation
Running Hrs
Coal Consumption
GCV of Coal
Type of Fuel - 2 Name :
Consumption
GCV of any Fuel -2
Type of Fuel - 3 Name :
Consumption
GCV of any Fuel -3
Type of Fuel - 4 Name :
Consumption
GCV of any Fuel -4
Feed water
Temperature
Operating Efficiency
SH Steam outlet
Pressure (Operating)

e2.4
(i)
(ii)
(iii)

(xiv)
(xv)

(xii)
(xiii)

(x)
(xi)

(viii)
(ix)

(iv)
(v)
(vi)
(vii)

Percentage of Coal
Energy Used in steam
Generation

SH Steam Enthalpy
(Operating)
Design Efficiency
Operating Capacity
Specific Energy
Consumption

(xxi)

(xviii)
(xix)
(xx)

(xvii)

Annual Average
Annual Average

Annual Average
Annual

Annual Average
Annual

Annual Average
Annual

Annual
Annual
Annual Average
Annual

Annual

(iii)/(iv)
[(v)x(vi)+(vii)
x(viii)+(ix)
x(x)+(xi)x(xii)]/
(iii)
[(v)x(vi)]/
[(v)x(vi)+(vii)
x(viii)+(ix)
x(x)+(xi)x(xii)]
Co-Gen

Annual Average

%
kg/cm2

kcal/kg
C

kcal/kg
Tonne

kcal/kg
Tonne

Hrs
Tonne
kcal/kg
Tonne

TPH
Tonne

%
TPH
kcal/kg of
Steam

kcal/kg

42

Supporting Proforma for Form 1

Boiler 10
Type
Rated Capacity
Total Steam
Generation
Running Hrs
Coal Consumption
GCV of Coal
Type of Fuel - 2 Name :
Consumption
GCV of any Fuel -2
Type of Fuel - 3 Name :
Consumption
GCV of any Fuel -3
Type of Fuel - 4 Name :
Consumption
GCV of any Fuel -4

e2.5
(i)
(ii)
(iii)

(xii)

(x)
(xi)

(viii)
(ix)

(iv)
(v)
(vi)
(vii)

Percentage of Coal
Energy Used in steam
Generation

SH Steam outlet
Temperature
(Operating)
SH Steam Enthalpy
(Operating)
Design Efficiency
Operating Capacity
Specific Energy
Consumption

(xxi)

(xviii)
(xix)
(xx)

(xvii)

(xvi)

Annual Average

Annual Average
Annual

Annual Average
Annual

Annual
Annual
Annual Average
Annual

Annual

Co-Gen

(iii)/(iv)
[(v)x(vi)+(vii)
x(viii)+(ix)
x(x)+(xi)x(xii)]/
(iii)
[(v)x(vi)]/[(v)
x(vi)+(vii)
x(viii)+(ix)
x(x)+(xi)x(xii)]

Annual Average

Annual Average

kcal/kg

kcal/kg
Tonne

kcal/kg
Tonne

Hrs
Tonne
kcal/kg
Tonne

TPH
Tonne

%
TPH
kcal/kg of
Steam

kcal/kg

Bureau of Energy Efficiency

43

Total Operating
Efficiency of Boiler
(Co-Gen Boiler)
Total Operating
Capacity of Boilers
(Co-Gen Boiler)

e3.2

e3.3

e.2.1(iii) +
Total Steam
Generation (Co-Gen e.2.2(iii) +
e.2.3(iii) +
Boiler)
e.2.4(iii) +
e.2.5.(iii)

e3.1

Weighted
average of all 5
boilers
e.2.1(xix) +
e.2.2(xix) +
e.2.3(xix) +
e.2.4(xix) +
e.2.5.(xix)

Weighted Average
Boiler 6-10

e3

TPH

Tonnes

%
TPH
kcal/kg of
Steam

kcal/kg

%
kg/cm2

(iii)/(iv)
[(v)x(vi)+(vii)
x(viii)+(ix)
x(x)+(xi)x(xii)]/
(iii)
[(v)x(vi)]/[(v)
%
x(vi)+(vii)
x(viii)+(ix)
x(x)+(xi)x(xii)]
For Steam
Generation Boiler

Annual Average

Annual Average

Annual Average
Annual Average

Annual

Percentage of Coal
Energy Used in steam
Generation

Feed water
Temperature
Operating Efficiency
SH Steam outlet
Pressure (Operating)
SH Steam outlet
Temperature
(Operating)
SH Steam Enthalpy
(Operating)
Design Efficiency
Operating Capacity
Specific Energy
Consumption

(xxi)

(xviii)
(xix)
(xx)

(xvii)

(xvi)

(xiv)
(xv)

(xiii)

44

Supporting Proforma for Form 1

(v)

(iv)

(iii)

(ii)

(i)

B.1

e4

e3.6

e3.5

e3.4

Weighted Specific
Weighted
kcal/kg of
Energy Consumption
average of all 5
Steam
(Co-Gen Boiler)
boilers
Weighted Percentage
Weighted
%
of Coal Energy Used in average of all 5
steam Generation (Co- boilers
Gen Boiler)
Weighted Boiler
Weighted
%
Efficiency for Boilers
average of all 10
1-10
boilers
Note: DCs to provide separate Excel sheet in the Boiler format as specified above If no of boiler exceeds for additional nos
of boilers for Co-Gen/Steam
Electricity
Consumption
Electricity through
Grid / Other
(Including colony and
others)
Purchased Electricity
Annual
Lakh kWh
from grid (SEB)
Renewable Electricity
Annual
Lakh kWh
(Through Wheeling)
Electricity from CPP
Annual
Lakh kWh
located outside from
plant boundary
(Through Wheeling)
Renewable Purchase
Annual
%
obligation of plant
(RPO) (Solar & NonSolar)
Renewable Purchase
Annual
Lakh kWh
obligation of plant
(RPO) (Solar & NonSolar)

Bureau of Energy Efficiency

45

(xvi)

(xv)

(xiv)

(xiii)

(xii)

(x)
(xi)

(ix)

(viii)

(vii)

(vi)

Renewable Purchase
obligation of plant
(RPO) (Solar & NonSolar)
Renewable Energy
generator as approved
by MNRE
Quantum of
Renewable Energy
Certificates (REC)
obtained as a Renewal
Energy Generator
(Solar & Non-Solar)
Quantum of Energy
sold under preferential
tariff
Plant Connected Load
Contract Demand with
utility
Notified Baseline
Specific Energy
Consumption
Notified Target
Specific Energy
Consumption
Saving Target in TOE/
Tonne of product
as per PAT scheme
Notification
Equivalent Major
Product Output in
Tonnes as per PAT
scheme Notification
Total Electricity
Purchased from grid/
Other
B.1 (i) + B.1 (ii) +
B.1 (iii)

MWh

Annual

Lakh kWh

Tonnes

TOE/
Tonnes

TOE/
Tonnes

TOE/
Tonnes

kW
kVA

MWh

MW

MW

Annual

Annual

Annual

46

Supporting Proforma for Form 1

(i)
(ii)
(iii)

b.2.2

(viii)
(ix)

(vii)

(v)
(vi)

(iv)

B.2
b.2.1
(i)
(ii)
(iii)

(xviii)

(xvii)

B.1(xvii)x860/10

If(B.1(xvi)>b.5,
B.1(xvi)-b.5
otherwise 0)

Through Steam
turbine/ generator
(Please Fill
Attachment)
Grid Connected
Install Capacity
Gross Unit generation
Annual
Annual

Yes/No
MW
Lakh kWh

Yes/No
MW
Lakh kWh

Million kcal

Lakh kWh

Annual
Gross Unit
Generation
Annual Fuel
(FO/LDO/HSD/ Kilo Litre
Consumption
HSHS/LSHS)
Average density of fuel Annual
kg/lit
Auxiliary Power
Annual
%
Consumption
Designed Gross Heat
Annual
kcal/kWh
Rate of DG Set
Operating Heat Rate
Annual
kcal/kWh
Running Hrs
Annual
Hrs

Own Generation
Through DG sets
Grid Connected
Install Capacity
Annual generation

Total Electricity
Purchased from
grid/ Other with out
colony/construction
power etc.
Equivalent Thermal
Energy of Purchased
Electricity from Grid /
Other without colony/
construction power etc.

Bureau of Energy Efficiency

47

Through Gas turbine


Grid Connected
Install Capacity
Gross Unit generation
Plant Load Factor
(PLF)
Auxiliary Power
Consumption
Gross Design Heat
Rate
Running Hrs

Through Waste Heat


Recovery
WHR Capacity
Annual Generation
WHR Running Hrs

Through CoGeneration
(Extraction/Back
Pressure)
Grid Connected
Install Capacity
Annual Gross Unit
generation

b.2.3
(i)
(ii)
(iii)
(iv)

b.2.4

b.2.5

(i)
(ii)
(iii)

(i)
(ii)
(iii)

(vi)

(vi)

(v)

(vi)

(v)

Auxiliary Power
Consumption
Gross Design Heat
Rate
Operating Gross Heat
Rate

(iv)

Annual
Annual

Annual
Annual
Annual

Annual

Annual

Annual

Annual
Annual
Annual

Annual

Annual

Annual

Yes/No
MW
Lakh kWh

MW
Lakh kWh
Hrs

Hrs

kcal/ kWh

Yes/No
MW
Lakh kWh
%

kcal/ kWh

kcal/ kWh

48

Supporting Proforma for Form 1

Through CoGeneration (Extraction


Cum Condensing)
Grid Connected

(i)

(xxii)

(xxi)

b.2.6

Annual
Annual
Annual
Annual

Annual

Annual
Annual
Annual

Annual
Annual

Annual

Annual
Annual
Annual
Annual
[b2.5 (xiii) x b2.5
(xiv) +b2.5 (xviii)
x b2.5 (xix)]/1000
Thermal energy used
[b2.5 (vii) x b2.5
in Power
(x)]/1000 -b2.5
(xx)
% of thermal energy in b2.5(xx) x1000/
Process
[b2.5 (vii) x b2.5
(x)]

Auxiliary Power
Consumption
Design Heat Rate
Running Hrs
Input Steam
Input Steam Enthalpy
Input Steam Pressure
Input Steam
Temperature
Input Steam Flow
Steam Extraction 1
Steam Pressure
Steam Temperature
Steam Enthalpy
Mass Flow
Steam Extraction 2
Steam Pressure
Steam Temperature
Steam Enthalpy
Mass Flow
Thermal energy used
in process

(xv)
(xvii)
(xviii)
(xix)
(xx)

(xi)
(xii)
(xiii)
(xiv)

(x)

(vii)
(viii)
(ix)

(v)
(vi)

(iv)

Yes/No

Factor

Million kcal

kg/cm2
C
kcal/kg
Tonnes
Million kcal

kg/cm2
C
kcal/kg
Tonnes

Tonnes

kcal/kg
kg/cm2
C

kcal/ kWh
Hrs

Bureau of Energy Efficiency

49

(xxii)

(xxi)

(xv)
(xvii)
(xviii)
(xix)
(xx)

(xi)
(xii)
(xiii)
(xiv)

(x)

(vii)
(viii)
(ix)

(v)
(vi)

(iv)

(ii)
(iii)

Annual
Annual
Annual
Annual

Annual

Annual
Annual
Annual

Annual
Annual

Annual

Annual
Annual

Annual
Annual
Annual
Annual
[b2.6(xiii)
x b2.6(xiv)
+b2.6(xviii) x b2.6
(xix)]/1000
Thermal energy used
[b2.6 (vii) x b2.6
in Power
(x)]/1000 -b2.6
(xx)
% of thermal energy in b2.6(xx) x1000/
Process
[b2.6 (vii) x b2.6
(x)]

Install Capacity
Annual Gross Unit
generation
Auxiliary Power
Consumption
Design Heat Rate
Running Hrs
Input Steam
Input Steam Enthalpy
Input Steam Pressure
Input Steam
Temperature
Input Steam Flow
Steam Extraction 1
Steam Pressure
Steam Temperature
Steam Enthalpy
Mass Flow
Steam Extraction 2
Steam Pressure
Steam Temperature
Steam Enthalpy
Mass Flow
Thermal energy used
in process

Factor

Million kcal

kg/cm2
C
kcal/kg
Tonnes
Million kcal

kg/cm2
C
kcal/kg
Tonnes

Tonnes

kcal/kg
kg/cm2
C

kcal/ kWh
Hrs

MW
Lakh kWh

50

Supporting Proforma for Form 1

(iii)

(ii)

C.1
(i)

b.8

b.7

b.6

Solid Fuel
Consumption
Coal (Indian)
Landed Cost of fuel
(Last purchase)
Average Gross calorific
value (As Fired Basis)
Average Total
Moisture in coal (As
received Basis)

Electricity Supplied
to Grid/others
Electricity Supplied
to Colony/others
Electricity Supplied
to Grid/Colony/
others
Equivalent Thermal
Energy supplied to
grid/others
Total Electricity
Consumed in Process
& Auxiliaries

b.4

b.5

Total Own
Generation of
Electricity

Lakh kWh

B.4+[If B.5 >


B.1(xvi) then
(B.5-B.1(xvi))]
B.6*2717/10

Annual

Basic Cost +
Taxes + Freight
Annual

kcal/ kg

Rs/Tonne

if(b.5>B.1.(xvi) Lakh kWh


then (B.3-B.4)(B.5-B.1.(xvi)
otherwise
B.1.(xvii)-b.3-b.4

Million
kcal

Lakh kWh

Annual

B.2.1.(iii)+B.2.2.( Lakh kWh


iii)+B.2.3.(iii)+B.
2.4.(ii)+B.2.5(iii)
+B.2.6(iii)
Annual
Lakh kWh

Total % of thermal
[b2.5 (xx) +b.2.6
Factor
energy in Process from (xx)] / [{b.2.6
Co-Gen
(xxi) + b.2.5 (xxi)}
+ {b2.5 (xx) +
b.2.6 (xx)}]

b.3

(xxiii)

Bureau of Energy Efficiency

51

(vi)

(iv)
(v)

(iii)

(ii)

C.2
(i)

(xi)

(x)

(ix)

(viii)

(vii)

(vi)

(iv)
(v)

Pet coke/Carbon
Landed Cost of fuel
(Last purchase)
Average Gross calorific
value (As fired basis)
Average Total
Moisture in coal (As
received Basis)
Quantity purchased
Quantity used for
power generation
(CPP)
Quantity used for
power generation (CoGen)

Quantity purchased
Quantity used for
power generation in
CPP
Quantity used for
power generation (CoGen)
Quantity used for
process
Total Quantity
Consumed
Thermal Energy Used
in Power Generation
(CPP)
Thermal Energy Used
in Power Generation
(co-gen )
Thermal Energy Used
in Process

Annual

Annual
Annual

Annual

Basic Cost +
Taxes + Freight
Annual

(vii)x(ii)/1000

(vi)x(ii)/1000

(v)x(ii)/1000

(v)+(vi)+(vii)

Annual

Annual

Annual
Annual

Tonne

Tonne
Tonne

kcal/ kg

Rs/Tonne

Million kcal

Million kcal

Million kcal

Tonne

Tonne

Tonne

Tonne
Tonne

52

Supporting Proforma for Form 1

(ix)

(viii)

(vii)

(vi)

(iv)
(v)

(iii)

(ii)

C.3
(i)

(xi)

(x)

(ix)

(viii)

(vii)

Coal(Imported)
Landed Cost of fuel
(Last purchase)
Average Gross calorific
value (As fired Basis)
Average Total
Moisture in coal (As
received Basis)
Quantity purchased
Quantity used for
power generation
(CPP)
Quantity used for
power generation (CoGen)
Quantity used for
process
Total Quantity
Consumed
Thermal Energy Used
in Power Generation
(CPP)

Quantity used for


process
Total Quantity
Consumed
Thermal Energy Used
in Power Generation
(CPP)
Thermal Energy Used
in Power Generation
(co-gen )
Thermal Energy Used
in Process

(ii)x(v)/1000

(v)+(vi)+(vii)

Annual

Annual

Annual
Annual

Annual

Basic Cost +
Taxes + Freight

(ii)x(vii)/1000

(ii)x(vi)/1000

Million kcal

Tonne

Tonne

Tonne

Tonne
Tonne

kcal/ kg

Rs/Tonne

Million kcal

Million kcal

Million kcal

Tonne

(v)+(vi)+(vii)
(ii)x(v)/1000

Tonne

Annual

Bureau of Energy Efficiency

53

(xi)

(x)

(ix)

(viii)

(vii)

(vi)

(iv)
(v)

(iii)

(ii)

C.4
(i)

(xi)

(x)

Coal (lignite)
Landed Cost of fuel
(Last purchase)
Average Gross calorific
value (As fired Basis)
Average Total
Moisture in coal (As
received Basis)
Quantity purchased
Quantity used for
power generation
(CPP)
Quantity used for
power generation (CoGen)
Quantity used for
process
Total Quantity
Consumed
Thermal Energy Used
in Power Generation
(CPP)
Thermal Energy Used
in Power Generation
(co-gen )
Thermal Energy Used
in Process

Thermal Energy Used


in Power Generation
(co-gen )
Thermal Energy Used
in Process

(ii)x(vii)/1000

(ii)x(vi)/1000

(ii)x (v)/1000

(v)+(vi)+(vii)

Million kcal

Million kcal

Million kcal

Tonne

Tonne

Tonne

Annual
Annual

Tonne
Tonne

kcal/ kg

Rs/Tonne

Million kcal

Million kcal

Annual
Annual

Annual

Basic Cost +
Taxes + Freight
Annual

(ii)x(vii)/1000

(ii)x(vi)/1000

54

Supporting Proforma for Form 1

(i)

C.6

(xi)

(x)

(ix)

(viii)

(vii)

(vi)

(iv)
(v)

(iii)

(ii)

C.5
(i)

(vii)x(ii)/1000

Million kcal

Million kcal

Million kcal

(ii)x(v)/1000
(ii)x(vi)/1000

Tonne

Tonne

Tonne

Tonne
Tonne

kcal/ kg

Rs/Tonne

(v)+(vi)+(vii)

Annual

Annual

Annual
Annual

Annual

Basic Cost +
Taxes + Freight
Annual

Bio mass or Other


Thermal Energy Input through Biomass not to be taken into account
purchased Renewable
solid fuels (pl.
specify) bagasse, rice
husk, etc.
Landed Cost of fuel
Basic Cost +
Rs/Tonne
(Last purchase)
Taxes + Freight

Other Solid Fuels


Landed Cost of fuel
(Last purchase)
Average Gross calorific
value (As fired basis)
Average Total
Moisture in coal (As
received Basis)
Quantity purchased
Quantity used for
power generation
(CPP)
Quantity used for
power generation (CoGen)
Quantity used for
process
Total Quantity
Consumed
Thermal Energy Used
in Power Generation
(CPP)
Thermal Energy Used
in Power Generation
(co-gen )
Thermal Energy Used
in Process

Bureau of Energy Efficiency

55

(iv)

(iii)

(ii)

C.7
(i)

(xi)

(x)

(ix)

(viii)

(vii)

(vi)

(iv)
(v)

(iii)

(ii)

Million kcal

(ii)x(vi)/1000
Million kcal

Million kcal

(ii)x(v)/1000

(vii)x(ii)/1000

Tonne

Tonne

Tonne

Tonne
Tonne

(v)+(vi)+(vii)

Annual

Annual

Annual
Annual

Annual

kcal/ kg

Solid Waste (pl. specify and refer CPCB guidelines) rubber tyres chips, Municipal Solid waste etc.
Landed Cost of fuel
Basic Cost +
Rs/Tonne
(Last purchase)
Taxes + Freight
Average Gross calorific Annual
kcal/ kg
value as fired
Average Total
Annual
%
Moisture in coal (As
received Basis)
Quantity purchased
Annual
Tonne

Average Gross calorific


value as fired
Average Total
Moisture in coal (As
received Basis)
Quantity purchased
Quantity used for
power generation
(CPP)
Quantity used for
power generation (CoGen)
Quantity used for
process
Total Quantity
Consumed
Thermal Energy Used
in Power Generation
(CPP)
Thermal Energy Used
in Power Generation
(co-gen )
Thermal Energy Used
in Process

56

Supporting Proforma for Form 1

C.10

C.9

C.8

(xi)

(x)

(ix)

(viii)

(vii)

(vi)

(v)

Total Solid Energy


Used in Process

Thermal Energy Used


in Power Generation
(co-gen )

Quantity used for


power generation
(CPP)
Quantity used for
power generation (CoGen)
Quantity used for
process heating
Total Quantity
Consumed
Thermal Energy Used
in Power Generation
(CPP)
Thermal Energy Used
in Power Generation
(co-gen )
Thermal Energy Used
in Process
Thermal Energy Used
in Power Generation
(CPP)
Million kcal

Million kcal

Tonne

Tonne

Tonne

Tonne

Million
kcal
C.1(ix) + C.2(ix) + Million
C.3(ix) + C.4(ix) + kcal
C.5(ix) + C.6(ix) +
C.7(ix)
if, b.2.5 (i) or
Million
b.2.6 (i) is yes
kcal
then C.1(x) +
C.2(x) + C.3(x) +
C.4(x) + C.5(x) +
[C.6(x) x (1-b.2.6
(xxiii)] + [C.7(x)
x (1-b.2.6 (xxiii)]
otherwsie C.1(x)
+ C.2(x) + C.3(x)
+ C.4(x) + C.5(x)
C.1(xi) + C.2(xi) Million
+ C.3(xi) + C.4(xi) kcal
+ C.5(xi)

(vii)x(ii)/1000

(ii)x(vi)/1000

(ii)x(v)/1000

(v)+(vi)+(vii)

Annual

Annual

Annual

Bureau of Energy Efficiency

57

(xiii)

(xii)

(xi)

(x)

(ix)

(viii)

(vii)

(vi)

(ii)
(iii)
(iv)
(v)

D.1
(i)

Liquid Fuel
Consumption
Furnace Oil
Landed Cost of fuel
(Last purchase)
Gross calorific value
Quantity purchased
Average Density
Quantity used for
power generation (DG
Set)
Quantity used for
power generation
(CPP)
Quantity used for
power generation (CoGen)
Quantity used for
process
Total F. Oil
Consumption as fuel
Thermal Energy Used
in Power Generation
(DG Set)
Thermal Energy Used
in Power Generation
(CPP)
Thermal Energy Used
in Power Generation
(co-gen )
Thermal Energy Used
in Process
[((viii))x(ii)]
x(iv)/1000

[((vii))x(ii)]
x(iv)/1000

[((vi))x(ii)]
x(iv)/1000

((v) + (vi) + (vii)


+ (viii)) x (iv)
[((v))x(ii)]
x(iv)/1000

Million kcal

Million kcal

Million kcal

Million kcal

Tonne

kilolitre

kilolitre

Annual
Annual

kilolitre

kcal/ kg
kilolitre
kg/Litre
kilolitre

Rs/Tonne

Annual

Annual

Basic Cost +
Taxes + Freight
Annual
Annual

58

Supporting Proforma for Form 1

(i)

D.3

(xii)

(xi)

(x)

(ix)

(viii)

(vii)

(vi)

(v)

(ii)
(iii)
(iv)

(i)

D.2

High Sulphur Heavy


Stock (HSHS)
Landed Cost of fuel
(Last purchase)

Low Sulphur Heavy


Stock (LSHS)
Landed Cost of fuel
(Last purchase)
Gross calorific value
Quantity purchased
Quantity used for
power generation (DG
Set)
Quantity used for
power generation
(CPP)
Quantity used for
power generation (CoGen)
Quantity used for
process heating
Total LSHS
Consumption as fuel
Thermal Energy Used
in Power Generation
(DG Set)
Thermal Energy Used
in Power Generation
(CPP)
Thermal Energy Used
in Power Generation
(co-gen )
Thermal Energy Used
in Process
Tonne

Tonne

Tonne

kcal/ kg
Tonne
Tonne

Rs/Tonne

Basic Cost +
Taxes + Freight

[((vii))x(ii)]/1000

[((vi))x(ii)]/1000

[((v))x(ii)]/1000

[((iv))x(ii)]/1000

Rs/Tonne

Million kcal

Million kcal

Million kcal

Million kcal

(iv)+(v)+(vi)+(vii) Tonne

Annual

Annual

Annual

Basic Cost +
Taxes + Freight
Annual
Annual
Annual

Bureau of Energy Efficiency

59

(ii)
(iii)
(iv)

(i)

D.4

(xii)

(xi)

(x)

(ix)

(viii)

(vii)

(vi)

(v)

(ii)
(iii)
(iv)

High Speed Diesel


(HSD)
Landed Cost of fuel
(Last purchase)
Gross calorific value
Quantity purchased
Average Density

Gross calorific value


Quantity purchased
Quantity used for
power generation (DG
Set)
Quantity used for
power generation
(CPP)
Quantity used for
power generation (CoGen)
Quantity used for
process heating
Total HSHS
Consumption as fuel
Thermal Energy Used
in Power Generation
(DG Set)
Thermal Energy Used
in Power Generation
(CPP)
Thermal Energy Used
in Power Generation
(co-gen )
Thermal Energy Used
in Process
Tonne

Tonne

Tonne

kcal/ kg
Tonne
Tonne

Million kcal

[((vi))x(ii)]/1000

Annual
Annual

Basic Cost +
Taxes + Freight

kcal/ kg
kilolitre
kg/Litre

Rs/Tonne

Million kcal

Million kcal

[((v))x(ii)]/1000

[((vii))x(ii)]/1000

Million kcal

[((iv))x(ii)]/1000

(iv)+(v)+(vi)+(vii) Tonne

Annual

Annual

Annual

Annual
Annual
Annual

60

Supporting Proforma for Form 1

(ii)

(i)

D.5

(xiv)

(xiii)

(xii)

(xi)

(x)

(ix)

(viii)

(vii)

(vi)

(v)

Light Diesel Oil


(LDO)
Landed Cost of fuel
(Last purchase)
Gross calorific value

Thermal Energy Used


in Power Generation
(DG Set)
Thermal Energy Used
in Power Generation
(CPP)
Thermal Energy Used
in Power Generation
(Co-Gen)
Thermal Energy Used
in Process

Quantity used for


power generation (DG
Set)
Quantity used for
power generation
(CPP)
Quantity used for
power generation (CoGen)
Quantity used for
material handling /
Transportation (Raw
material handling,
Loco, etc.)
Quantity used for
process heating
Total HSD
Consumption as fuel

Basic Cost +
Taxes + Freight

[[((viii)+(ix))x(iv)
x(ii)/1000

[((vii))x(iv)]
x(ii)/1000

[((vi))x(iv)]
x(ii)/1000

[(v) + (vi) + (vii)


+ (viii) + (ix)] x
(iv)
[((v))x(iv)]
x(ii)/1000

Annual

Annual

Annual

Annual

Annual

kcal/ kg

Rs/Tonne

Million kcal

Million kcal

Million kcal

Million kcal

Tonne

kilolitre

kilolitre

kilolitre

kilolitre

kilolitre

Bureau of Energy Efficiency

61

(xiv)

(xiii)

(xii)

(xi)

(x)

(ix)

(viii)

(vii)

(vi)

(iii)
(iv)
(v)

Thermal Energy Used


in Power Generation
(DG Set)
Thermal Energy Used
in Power Generation
(CPP)
Thermal Energy Used
in Power Generation
(Co-Gen)
Thermal Energy Used
in Process

Quantity purchased
Average Density
Quantity used for
power generation (DG
Set)
Quantity used for
power generation
(CPP)
Quantity used for
power generation (CoGen)
Quantity used for
material handling /
Transportation (Raw
material handling,
Loco, etc.)
Quantity used for
process heating
Total LDO
Consumption as fuel

[((viii)+(ix))x(iv)
x(ii)/1000

[((vii))x(iv)]
x(ii)/1000

[((vi))x(iv)]
x(ii)/1000

[(v) + (vi) + (vii)


+ (viii) + (ix)] x
(iv)
[((v))x(iv)]
x(ii)/1000

Annual

Annual

Annual

Annual

Annual

Annual

Million kcal

Million kcal

Million kcal

Million kcal

Tonne

kilolitre

kilolitre

kilolitre

kilolitre

kilolitre
kg/Litre
kilolitre

62

Supporting Proforma for Form 1

(xiii)

(xii)

(xi)

(x)

(ix)

(viii)

(vii)

(vi)

(ii)
(iii)
(iv)
(v)

(i)

D.6

Liquid Waste (pl.


specify and refer
CPCB guidelines,
enclosed)
Landed Cost of fuel
(Last purchase)
Gross calorific value
Quantity purchased
Average Density
Quantity used for
power generation (DG
Set)
Quantity used for
power generation
(CPP)
Quantity used for
power generation (CoGen)
Quantity used for
process
Total Liquid waste
Consumption as fuel
Thermal Energy Used
in Power Generation
(DG Set)
Thermal Energy Used
in Power Generation
(CPP)
Thermal Energy Used
in Power Generation
(Co-Gen)
Thermal Energy Used
in Process
[((ix))x(iv)]
x(ii)/1000

[((vii))x(iv)]
x(ii)/1000

[((vi))x(iv)]
x(ii)/1000

[(v) + (vi) + (vii)


+ (viii)] x (iv)
[((v))x(iv)]
x(ii)/1000

Million kcal

Million kcal

Million kcal

Million kcal

Tonne

kilolitre

kilolitre

Annual
Annual

kilolitre

kcal/ kg
kilolitre
kg/Litre
kilolitre

Rs/Tonne

Annual

Annual

Annual

Basic Cost +
Taxes + Freight

Thermal Energy Input through Liquid waste, mentioned in CPCB guidelines, not to be taken
into account

Bureau of Energy Efficiency

63

Total Liquid Energy


Used in Power
Generation (Co-Gen)

Total Liquid Energy


Used in Process

Gaseous Fuel
Compressed Natural
Gas (CNG/NG/PNG/
LNG)
Landed Cost of fuel
(Last purchase)
Gross calorific value
Quantity purchased

D.9

D.10

E
E.1

(vi)

(v)

(iv)

(ii)
(iii)

Quantity used for


power generation
Quantity used for
transportation, if any
Quantity used for
process heating

Total Liquid Energy


Used in Power
Generation (CPP)

D.8

(i)

Total Liquid Energy


Used in Power
Generation (DG Set)

D.7

Annual

Annual

Annual

Annual

Basic Cost +
Taxes + Freight

D.1.(x) + D.2.(ix)
+ D.3.(ix) +
D.4.(xi) + D.5.(xi)
+ D.6.(x)
D.1.(xi) +
D.2.(x) + D.3.(x)
+ D.4.(xii) +
D.5.(xii) +
D.6.(xi)
D.1.(xii) +
D.2.(xi) + D.3.(xi)
+ D.4.(xiii) +
D.5.(xiii) +
[D.6.(xii) x
(1-b.2.6 (xxiii)]
D.1.(xiii) +
D.2.(xii) +
D.3.(xii) +
D.4.(xiv) +
D.5.(xiv)

kcal/SCM
Million
SCM
Million
SCM
Million
SCM
Million
SCM

Rs/SCM

Million
kcal

Million
kcal

Million
kcal

Million
kcal

64

Supporting Proforma for Form 1

F.5
F.5.1
F.5.1.1
(i)

E.4

E.3

(viii)

(vii)

(vi)

(v)

(ii)
(iii)
(iv)

(i)

E.2

(ix)

(viii)

(vii)

Steam Import/Export
Steam Import
LP Steam Import
Landed Cost of steam
(Last purchase)

Total Gaseous
Energy Used in
Power Generation
Total Gaseous
Energy Used in
Process

Liquefied Petroleum
Gas (LPG)
Landed Cost of fuel
(Last purchase)
Gross calorific value
Quantity purchased
Quantity used for
power generation
Quantity used for
process heating
Total LPG
Consumption as fuel
Thermal Energy Used
in Power Generation
Thermal Energy Used
in Process

Total CNG
Consumption as fuel
Thermal Energy Used
in Power Generation
Thermal Energy Used
in Process

Basic Cost +
Taxes + Freight

Rs/Tonne

Million
kcal

Million
kcal

E.1.(viii) +
E.2.(vii)
E.1.(ixi) +
E.2.(viii)

Million kcal

Million kcal

Million kg

Million kg

kcal/ kg
Million kg
Million kg

Rs/kg

Million kcal

Million
SCM
Million kcal

(v)x(ii)

(iv)x(ii)

(iv) + (v)

Annual

Annual
Annual

Basic Cost +
Taxes + Freight

((v)+(vi))x(i)

(iv)x(i)

(iv)+(v) + (vi)

Bureau of Energy Efficiency

65

F.5.2.2
(i)

(iv)
(v)
(vi)

(ii)
(iii)

F.5.2.1
(i)

F.5.1.3

(iv)
(v)
(vi)

(ii)
(iii)

F.5.1.2
(i)

(iv)
(v)
(vi)

(ii)
(iii)

HP Steam Export
Landed Cost of steam
(Last purchase)

LP Steam Energy
LP Steam Quantity
purchased
Average Temperature
Average Pressure
Thermal Energy
Imported for LP Steam
HP Steam Import
Landed Cost of steam
(Last purchase)
HP Steam Energy
HP Steam Quantity
purchased
Average Temperature
Average Pressure
Thermal Energy
Imported for HP Steam
Thermal Energy
Imported for LP & HP
Steam
LP Steam Export
Landed Cost of steam
(Last purchase)
LP Steam Enthalpy
LP Steam Quantity
purchased
Average Temperature
Average Pressure
Thermal Energy
Exported for LP Steam
Basic Cost +
Taxes + Freight

Annual
Annual
(ii)x(iii)/1000

Rs/Tonne

C
bar
Million kcal

kcal/kg
Tonnes

Rs/Tonne

Million kcal

K.8.1.1.(vi) +
K.8.1.2.(vi)

Basic Cost +
Taxes + Freight
Annual
Annual

C
bar
Million kcal

kcal/kg
Tonnes

Rs/Tonne

C
bar
Million kcal

kcal/kg
Tonnes

Annual
Annual
(ii)x(iii)/1000

Basic Cost +
Taxes + Freight
Annual
Annual

Annual
Annual
(ii)x(iii)/1000

Annual
Annual

66

Supporting Proforma for Form 1

Gross Heat Rate


Gross Heat Rate of DG
Set
Gross Heat Rate of
CPP (Steam Turbine)
Gross Heat Rate of
CPP (Gas Turbine)

H
H1

H3

H2

G3

G2

Total Thermal Energy


Total Thermal Energy
Used in Power
Generation
Total Thermal Energy
Used in Process
Total Thermal Energy
Input through all Fuels

HP Steam Enthalpy
HP Steam Quantity
purchased
Average Temperature
Average Pressure
Thermal Energy
Exported for HP Steam
Thermal Energy
Exported for LP and
HP Steam
Weighted Average
Boiler Efficiency
(Boiler 1-10)
Total Thermal Energy
Exported for Steam
Total Thermal Energy
for Steam (ImportExport)

G
G1

F.5.3

F.5.2.5

F.5.2.4

F.5.2.3

(iv)
(v)
(vi)

(ii)
(iii)

D.6 (x) x
10/B.2.1.(ii)
Heat rate with
Fuel
E.3/B.2.3.(iii)

G.1 + G.2 + F.5.3

C.8 + D.9 + E.4

C.8 + C.9 + D.7 +


D.8 + D.9 + E.3

(F.5.2.3/F.5.2.4)
x100
F.%.1.3-F.5.2.5

F.5.2.2.(vi) +
F.5.2.1.(vi)

Annual
Annual
(ii)x(iii)/1000

Annual
Annual

kcal/kWh

kcal/kWh

kcal/kWh

Million kcal

Million kcal

Million kcal

Million kcal

Million kcal

Million kcal

C
bar
Million kcal

kcal/kg
Tonnes

Bureau of Energy Efficiency

67

vii
viii
ix
x

vi

iv

ii
iii

J
i

i
ii
iii
iv

Bauxite Quality
Total Bauxite
Consumed
Type of Bauxite
Total Al2O3 /SiO2
Ratio
Bauxite Total Available
Alumina (TAA)
Bauxite Monohydrate
Alumina (MHA)
Bauxite Trihydrate
Alumina (THA)
Bauxite Silica
Bauxite Moisture
Overall Recovery
Wash Water
Annual
Annual
Annual
Annual

Annual

Annual

Annual

Annual
Annual

Annual

Annual
Annual
Annual
Annual

Coal Analysis in CoGen (As Fired Basis)


Gross Calorific Value
Ash
Hydrogen
Moisture

H6

H5

Gross Heat Rate of Co- Heat Rate with


Gen (Extraction cum
enthalpy
condensing)
Gross Heat Rate of
Heat Rate with
Co-Gen(Extraction/
enthalpy
Backpressure)
Weighted Heat Rate
Weighted
Heat Rate with
Generatiuon

H4

%
%
%
t/t

Type
Ratio

Tonne

kcal/kg
%
%
%

kcal/kWh

kcal/kWh

kcal/kWh

68

Supporting Proforma for Form 1

Biomass/ Alternate
Fuel availability (as
per Sr. No C.5/C.6/D.6)
Biomass replacement
Annual
with Fossil fuel
due to Biomass unavailability (used in
the process)
Alternate Solid Fuel
Annual
replacement with
Fossil fuel due to
Alternate Solid Fuel
un-availability (used in
the process)

K.2

(ii)

(i)

(ii)

(i)

Miscellaneous Data $
Additional Equipment
installation after
baseline year due
to Environmental
Concern
Additional Electrical
Annual
Energy Consumed
Additional Thermal
Annual
Energy Consumed

K
K.1

Annual
Annual
Annual
Annual
Annual

Steam Economy
Fe in Bauxite
Fe in Mud
Actual Steam Enthalpy
Boiler Efficiency

xi
xii
xiii
xiv
xv

Tonne

Tonne

Million kcal

Lakh kWh

t/t
%
%
kcal/kg
%

Bureau of Energy Efficiency

69

(iii)

(ii)

(i)

K.4

(ii)

(i)

K.3

(iii)

Alternate Liquid Fuel


replacement with
Fossil fuel due to
Alternate Liquid Fuel
un-availability (used in
the process)
Project Activities
(Construction Phase)
Electrical Energy
Consumed due to
commissioning of
Equipment
Thermal Energy
Consumed due to
commissioning of
Equipment
New Line/Unit
Commissioning
Electrical Energy
Consumed due to
commissioning of New
process Line/Unit
till it attains 70% of
Capacity Utilization
Thermal Energy
Consumed due to
commissioning of New
Process Line/Unit
till it attains 70% of
Capacity Utilization
Calcined Alumina
Production till new
line attains 70% of
Capacity utilization
(Refinery)
Annual

Annual

Annual

Annual

Annual

Annual

Tonne

Million kcal

Lakh kWh

Million kcal

Lakh kWh

Tonne

70

Supporting Proforma for Form 1

(x)

(ix)

(viii)

(vii)

(vi)

(v)

(iv)

Molten Aluminum
Production till new
line attains 70% of
Capacity utilization
(Smelter & Integrated)
Date of
Commissioning (70%
Capacity Utilization)
Electrical Energy
Consumed from
external source due
to commissioning of
New Line/Unit till it
attains 70% of Capacity
Utilization in Power
generation
Thermal Energy
Consumed due to
commissioning of
New Line/Unit till it
attains 70% of Capacity
Utilization in Power
generation
Net Electricity
Generation till new
line/unit attains 70%
Capacity Utilization
Steam Generation
From Co-Gen till new
line/Unit attains 70%
of Capacity Utilization
Date of
Commissioning (70%
Capacity Utilization)
Date

Annual

Annual

Annual

Annual

Date

Annual

Tonne

Lakh kWh

Million kcal

Lakh kWh

Tonne

Bureau of Energy Efficiency

71

Unforeseen
Circumstances
(i)
Electrical Energy to be Annual
Lakh kWh
Normalized
(ii)
Thermal Energy to be
Annual
Million
Normalized
kWh
$ Authentic documents in support of claim in Thermal and Electrical Energy is required
L
Documentation for
Normalization
(i)
Bauxite QualityYes/No
Document Available
for Normalization
(ii)
Smelter Capacity
Yes/No
Utilization-Document
Available for
Normalization
(iii)
Fuel Quality in CPP
Yes/No
& Co-Gen -Document
Available for
Normalization
(iv)
CPP PLF- Document
Yes/No
Available for
Normalization
Yes/No
(v)
Power Mix-Document
Available for
Normalization
(vi)
Product MixYes/No
Document Available
for Normalization
(vii)
Carbon Anode
Yes/No
Production- Document
Available for
Normalization
(viii)
Other Factors Yes/No
Document Available
for Normalization

K.5

72

Supporting Proforma for Form 1

Process Flow Diagram Yes/No


Attached

Annual

Million kcal
Million kcal
Million kcal
Million kcal
Million
kcal
Million
kcal
Lakh kWh

Million Rs

Annual

Annual
Annual
Annual
Annual
Annual

Million Rs

Annual

Electrical energy
Annual
Saving during the year

Energy Saving and


Investment
Investment made for
achieving target
Thermal Energy
Saving during the year
Solid Fuel
Coal
Lignite
Petro Coke
Biomass/Waste
Liquid Fuel (FO/HSD/
LDO/LSHS/HSHS)
Gaseous Fuel

(iii)

a
a.1
a.2
a.3
a.4
b

(ii)

(i)

Bureau of Energy Efficiency

73

Units

MW

Design
Capacity

Boiler
Efficiency

Unit
Heat
Rate *
kcal/
kWh
y=ax2bx+c

R2

kcal/kWh

Load Vs Source Remarks


Heat Rate of Data
or HBD
Curve
(at 100%
Load)
OEM Curve OR Cons - Cons - Cons - Turbine
HBD data curve tant 1 tant 2 tant 3 Heat Rate

Curve Equation
/ (R2)



*** Station Design Heat Rate = [(DGHR 1 x Capacity 1 + DGHR 2 x Capacity2 + -----------) / (Total Capacity of Station)]

** To be indicated only if OEM certified design or PG Test report is available and the same can be produced as documentary

proof, whenever required. If gas/liquid fuel is used, the Design/PG value for gas/liquid fuel may be given separately.

* Unit Heat Rate (kcal/kWh) = [Turbine Heat Rate (kcal/kWh) / Boiler Efficiency (%)]

Turbine
Heat
Rate
kcal/
kWh

As Provided by Original
Equipment Manufacturer
(OEM)

OEM Curve / HBD data

i
Unit-1
ii
Unit-2
iii. Unit-3
iv. Unit-4
v.
Unit-5
vi. Unit-6
vii. Unit-7
viii. Unit-8
ix. Unit-9
x. Unit-10
1.b Station Design Data Details ***

1.a

1.

Name of the Unit

Form- Sa1 Captive Power Plant Details

74

Supporting Proforma for Form 1

Unit-1
Unit-2
Unit-3
Unit-4
Unit-5
Unit-6
Unit-7
Unit-8
Unit-9
Unit-10
Station Operating Data Details ##
Station Auxiliary Power Consumption %

# Unit Heat Rate (kcal/kWh) = [Turbine Heat Rate (kcal/kWh) / Boiler Efficiency (%)]

## Station Operating Gross Heat Rate = [(OGHR 1 x Generation 1 + OGHR 2 x Generation 2 + -----------) /
(Total Generation of Station)]

Unit Gross
Heat Rate #
kcal/kWh

i
ii
iii.
iv.
v
vi
vii
viii
ix
x
2.b
2.c

Baseline Year (Average of Year 1 to Year 3)


Assessment/Current/Target Year
Unit Gross Operating Load ULF Gross
Operating Load ULF Gross
Generation
Heat Rate #
Generation
MW
%
Lakh Units
kcal/kWh
MW
%
Lakh Units

Units

2.a

2. Unit wise Operating Data Details


Source
of Data