Energy Efficiency Management Date, Venue, etc ..( Arial, Font size - - PDF document

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Energy Efficiency Management Date, Venue, etc ..( Arial, Font size - - PDF document

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Presentation Title ( Arial, Font size 28 ) Energy Efficiency Management Date, Venue, etc ..( Arial, Font size 18 ) TATA POWER Trombay Unit#8 17 th National Energy Efficient Management Award 2016 22nd 24th August 2016, CII- Hyderabad

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Presentation Title ( Arial, Font size 28 )

Date, Venue, etc..( Arial, Font size 18 )

Energy Efficiency Management – TATA POWER Trombay Unit#8

17th National Energy Efficient Management Award 2016 22nd – 24th August 2016, CII- Hyderabad

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  • LCI drives ( V / F control) for 6.6 KV motors

415 V VFD used for 6.6 KV auxiliary Pipe Conveyors with VFD’s for coal transportation Energy efficient coating (Coro coating) & Fluid couplings for pumps Impeller trimming in HT pumps CFD analysis & its implementation for flue gas ducting Combustion optimization Compressed Air pressure controller, Light Pipes, Turbo ventilators, Micro wind & Hybrid Units In-house developed Energy management system for monitoring using PI

Key Energy Management Initiatives AT Trombay

Technology Adopters in Energy Management Technology Adopters in Energy Management

Recommended ISO 50001 Certification

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Trombay: Present Generation Capacity Trombay: Present Generation Capacity

Unit Year Capacity (MW) Fuel Used Unit 5 1984 500 Coal, Oil & Gas Unit 6 1990 500 Oil & Gas Unit 7 (CCPP) 1993-94 120+60 = 180 Gas Unit 8 2009 250 Coal

Established in 1956 Total Generation Capacity : 1430 MW

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Recovered from major catastrophe

Specific Energy Consumption of Last three Years Specific Energy Consumption of Last three Years

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HEAT RATE UoM DTPS Dahanu Tata Power Trombay Unit 8

Best Performance (FY12) Best Performance (FY14) Actual Heat Rate Kcal/kwh 2282 2259.6 Deviation in Heat rate Kcal/kwh

  • 22

Auxiliary Power Consumption UoM DTPS (Dahanu) Tata Power Trombay Unit 8

Best Performance (FY11) Best Performance (FY16)

Actual Auxiliary Consumption % 7.38 6.2 Deviation in Auxiliary Consumption %

  • 1.18

Benchmarking Parameters ( 250 MW UNIT 8) Benchmarking Parameters ( 250 MW UNIT 8)

Information Sourced from CII Award PPT, MERC tariff order

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Energy Saving projects implemented in FY 14

Total Annual Savings Rs Million

  • Invest. Made

Rs Million

Civil Lighting Saving project by transparent roof tops in three cell collectors 0.1 0.30 Additional O2 Transmitters on both sides of RAPH 1.3 0.5 Installation of COC Power supply switch for to ON/OFF COC in running Feeder condition & replacement of Failed Shear pin in running Feeder 0.6 0.01 Combustion Optimisation 9.2 2 Replacement of Compound Lights with LED lights 1.4 0.5 Cut-in & cut-out set point revised for Station air compressor saved auxiliary power consumption 0.1 NIL

Total

12.7 3.31

Energy Saving Projects : FY 14 Energy Saving Projects : FY 14

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Energy Saving projects implemented in FY 15 & 16

Total Annual Savings Rs Million

  • Invest. Made

Rs Million

Stopping of one CW pump due to sub cooling (22 million saving in FY15) 17.8 Nil Replacement of BFP cartridge 1.08 1.4 Replacing Roof tops of stores with transparent roofs 0.3 0.93 Provision of ON/OFF Push button at various switchgear & unmanned location 0.37 0.11 Combustion optimisation 0.5 0.01

Total

20.05 2.45

Energy Saving Projects : FY 15 & FY 16 Energy Saving Projects : FY 15 & FY 16 …Message Box ( Arial, Font size 18 Bold)

Energy Saving projects

Estimated Annual Savings (Rs Million) Estimated Investment (Rs Million)

Arresting Air infiltration in Flue gas path 2.51 2 Combustion optimisation 0.6 Nil Boiler Skin plate insulation improvement 0.1 0.84 Optimisation of Compressed air pressure 0.06 Improving Coal conveying system Efficiency using Six Sigma 4 2

Total

7.27 4.84

Energy Saving Projects Planned In Next Three Years Energy Saving Projects Planned In Next Three Years

Installation of measurement and monitoring system for of AC & Lighting load (strengthening of monitoring systems) ISO 50001 project

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KPI impacted Savings (Rs. Million) Investment (Rs. Million) ROI (%) Auxiliary Consumption 1.7 Method of KPI impact measurement Auxiliary power consumption of CW Pump NA Syndicated

Key enablers:

  • Higher Auxiliary power

consumption

  • Higher Turbine cycle Heat

Rate Idea description : Heat rate & Aux power Saving from condensate system Before: . Unit was operated at higher vacuum with 4 CW Pumps running. After : Unit operated at rated Vacuum with 3 CW Pump

Stopping of one CW pump due to sub cooling Stopping of one CW pump due to sub cooling

Trigger : Sub Cooling in the Condenser

Condensate Hot well Temperature Design Temperature : 45 Deg C , Actual Temperature : 40 Deg C

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45 40 42

  • 0.915
  • 0.927
  • 0.919
  • 0.95
  • 0.95
  • 0.94
  • 0.94
  • 0.93
  • 0.93
  • 0.92
  • 0.92
  • 0.91
  • 0.91
  • 0.90
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4 9 14 19 24 29 34 39 44 49 Design FY 15 FY 16 Condenser Vacuum Condensate Temperature (Deg C)

Condensate Temperature

Final Outcome & Benefits Final Outcome & Benefits

  • Improvement in Heat rate due to

reduction in sub cooling

  • Reduction in Auxiliary consumption :

5.9 Mus / Annum Sub cooling Reduction Investment : Nil FY 16 Annual Savings : 17.8 Million Rs

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Significance:

Accurately measure O2, CO2, CO at goose-neck Measure furnace exit temperature Detects unbalanced heat transfer and flame propagation

Innovative Project : High Velocity Traverse Test Holder Innovative Project : High Velocity Traverse Test Holder

Trigger Risk of the Probe getting bend due to CW failure resulting n Unit outage High Temperature Probe

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Before After

What makes it Innovative

Its in-house Design & fabrication of HVT probe holder with pulley arrangement Utilisation of Scrap for fabrication of above probe holder.

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  • FY 14

Q1 FY 14 Q3 FY 15 Q3 FY 15 Q4 FY 16 Q1 FY 16 Q2 FY 16 Q3 FY 16 Q4 FY 17 Q1

  • Benefits & Costing

Benefits & Costing

  • 0.1 Lakhs

Investment

  • 5 Lakhs

Annual Savings

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Before After

Care For Environment- Renewable & Energy Conservation Project Care For Environment- Renewable & Energy Conservation Project

Replacement of OLD AC sheet with new transparent sheet along with turbo ventilators in Materials Department

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…Message Box ( Arial, Font size 18 Bold) Care For Environment- Renewable & Energy Conservation Project Care For Environment- Renewable & Energy Conservation Project

Use of polycarbonate transparent sheets – for Natural lighting inside bunker gallery

Lux intensity Reqd Before After Non Monsoon Monsoon Non Monsoon Monsoon 50-100 108 82 240 207

Benefits Illumination with natural Sunlight Improvement in LUX levels Saving in Auxiliary Consumption

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70 Solar lights ( MV-3 model- 11 W) have been installed in dark areas of communities

  • f Trombay to address safety of women

Installation of Solar Lights in the Neighbouring Community

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Pipe Conveyors with VFD ensure transfer of coal without any spillage. Captive Jetty with Screw Unloader to unload coal without any spillage.

Care For Environment- Fuel Handling (Eliminating Fugitive emission) Care For Environment- Fuel Handling (Eliminating Fugitive emission)

…Message Box ( Arial, Font size 18 Bold) Care For Environment : Waste Management (Development of greenbelt Using Bottom Ash) Care For Environment : Waste Management (Development of greenbelt Using Bottom Ash)

Base formation using bottom ash Covering base level with red soil Planting green carpet grass for landscaping

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…Message Box ( Arial, Font size 18 Bold) Care For Environment- Waste Management Care For Environment- Waste Management

Alternative to Brick masonry Silt/ash filled in bottle Bricks are replaced with these bottle Road side kerbing work with ash/silt filled plastic bottle

INNOVATIVE & UNIQUE PROJECT Use of silt/Ash for non structural construction work –by filling Ash/Silt in to plastic bottles

Plasto Silt Plasto Silt …Message Box ( Arial, Font size 18 Bold)

0.19 0.10 0.08 0.05 0.04 0.10 0.05 0.00 0.05 0.10 0.15 0.20 0.25 FY10 FY11 FY12 FY13 FY14 FY15 FY16 M3/MWH Recovered from major catastrophe

Reduction in Unit 8 Specific Make Up Water Consumption Reduction in Unit 8 Specific Make Up Water Consumption Care For Environment- Resource Conservation (Water) Care For Environment- Resource Conservation (Water)

Further Analysis being done using Six Sigma “Specific Water Consumption for Trombay Site for FY16: 0.216 M3/MWH

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  • Care For Community & Customers

Energy conservation & Awareness Programme Care For Community & Customers Energy conservation & Awareness Programme

Energy conservation campaign For Schools, Colleges, Employees & Contractors

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  • Sr. No.

Source of En-con Idea Source of Idea Generation Year of Idea Origination Extent of Manpower Involved Progress of Implementation

1 HVT holder Brainstorming 2015-16 02 engineer and 02 workmen Successfully Implemented 2 Stopping of CW pump due to sub cooling Discussions with OEM 2014-15 05 engineer including group heads & HOD’s Successfully Implemented 3 Replacing Roof tops of stores with transparent roofs Energy Audit Recommendation 2014-15 2 Engineers and 10 Workmen along with contractors Successfully Implemented 4 Combustion Optimisation Energy Audit Recommendation 2013-14 08 Engineers and 20 workmen Successfully Implemented 5 Cut-in & cut-out set point revised for Station air compressor. Discussions with OEM 2013-14 04 engineer and 04 workmen Successfully Implemented in FY13 6 CFD analysis Unit 8 flue gas path. #SANKALP (Core Group) 2012-13 05 Engineers Successfully Implemented 7 Debris Filter Modification #SANKALP (Core Group) 2012-13 04 Engineers and 8 workmen Successfully Implemented

Source of Idea Generation & Involvement of All Source of Idea Generation & Involvement of All

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  • Monitoring : Unit 8 PI Dash Board

Monitoring : Unit 8 PI Dash Board …Message Box ( Arial, Font size 18 Bold) Online Monitoring : Unit 8 Auxiliary Power (M & A) Online Monitoring : Unit 8 Auxiliary Power (M & A)

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Website: www.tatapower.com Email ID: aabhat@tatapower.com

vijay.kottalgi@tatapower.com pratiksha.naik@tatapower.com