ESSAR POWER GUJARAT LTD (EPGL), Dist : Dev Bhumi Dwarka, Gujarat - - PDF document

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ESSAR POWER GUJARAT LTD (EPGL), Dist : Dev Bhumi Dwarka, Gujarat - - PDF document

May 11, 2023 272 likes •457 views

Welcome to the CII 17 th National Award for ISO 50001 :2011 - 2016 Excellence in ISO 9001:2008 - 2014 Energy Management - 2016 ISO 14001:2004 - 2014 ISO 18001:2007 - 2014 ESSAR POWER GUJARAT LTD (EPGL), Dist : Dev Bhumi Dwarka, Gujarat

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Welcome to the CII 17th National Award for Excellence in Energy Management - 2016

ESSAR POWER GUJARAT LTD (EPGL),

Dist : Dev Bhumi Dwarka, Gujarat 1200 MW ( 2 X 600 MW ) THERMAL POWER PLANT ISO 9001:2008 - 2014 ISO 14001:2004 - 2014 ISO 18001:2007 - 2014 ISO 50001 :2011 - 2016

INDEX

  • 1. Company Profile - A Walk Through.
  • 2. Young Entrant in Thermal Power Sector
  • 3. Process Flow of EPGL Plant
  • 4. Continual Reduction in SEC in last 4 yrs.
  • 5. Our GOAL- SEC Near to Global Benchmark
  • 6. EPGL Road Map Towards Excellence in Energy Mgmt. System
  • 7. a) Energy Savings Projects : 2012-15

b) Energy Savings Projects :2015-16

  • 8. Innovations in ENCON Projects in 2015-16
  • 9. Efficient Utilization of Renewable Energy
  • 10. a) Environmental Projects for Carbon Emission reduction.

b) Productive Utilization of Waste

  • 11. ENCON Projects from ISO 9001 & EMS 14001
  • 12. Replication of ENCON BEST Practices
  • 13. EPGL Journey towards Excellence
  • 14. ENCON Projects -- Next 3 Years
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  • 1. COMPANY PROFILE :

ESSAR POWER GUJARAT LTD.

Location Salaya, Dev Bhumi Dwarka District, Gujarat Capacity 1200 MW (2 x 600 MW) Fuel Imported Thermal Coal Technology / Equipment

  • Sub-Critical Technology
  • BTG Package- HEI , China
  • BOP- Reputed Vendors ( ABB/Areva/SPIG )

Power Off-take

  • 1000 MW - Long term PPA with GUVNL
  • Balance 118 MW - Merchant Power

Water Requirement

  • Presently 64 MLD River water
  • Future-Sea Water - 9375 m3/hr

Power Evacuation

  • Evacuation at 400 KV – STU Network
  • 2. YOUNG ENTRANT IN THERMAL POWER

Essar Power Gujarat Ltd

UNIT-1 COD : 01st April 2012 UNIT-2 COD : 15th June 2012

New Entrant …. Just 4 Years

PLANT OVERVIEW

Boiler Area

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  • 3. PROCESS FLOW DIAGRAM

71% 69% 80% 73%

7.15% 6.60% 5.83% 6.06%

1000 2000 3000 4000 5000 6000 7000 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% FY 2012-13 FY 2013-14 FY 2014-15 FY 2015-16 Plant Loading Factor (%) Auxiliary Consumption (%) Generation (MU)

GHR 2339

  • 4. CONTINUAL REDUCTION IN SEC IN LAST 4 YRS.

OPERATIONAL PERFORMANCE

YOY Improvement

  • Good and Consistent O&M practices

GHR 2451

GHR 2333

4093 MU 5387 MU 6609 MU 5229 MU

GHR 2421

GHR - 2423 GHR - 2385 GHR - 2339 GHR - 2315

AT Normative Loading

6.85% 6.3% 5.83% 5.76%

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  • 5. OUR GOAL:

SEC NEAR TO GLOBAL BENCHMARK

  • HEAT RATE ( Kcal / Kwh )
  • Specific Oil Consumption ( ml / kwh)
  • DM WATER MAKE UP ( % )
  • AUX POWER ( % )

CERC NORM 5.75 %

O&M 2012-13 2013-14 2014-15 2015-16

Norm 12.1 13.3 14.4 15.3 Actual 11.2 10.8 11.3 13.4 CERC NORM 15.3 Rs Lac / MW

FY 2012-13 FY 2013-14 FY 2014-15 FY 2015-16

2451 2421 2339 2333 CERC NORM 2375 Kcal /kwh

2012-13 2013-14 2014-15 2015-16

ML/ kwh 1.8 0.32 0.23 0.28 KL /Start 189 102 67 54 CERC NORM 0.5 ML / kwh

2012-13 2013-14 2014-15 2015-16 Aux Cons.

7.1 6.6 5.8 6.0

Loading

71% 69% 80% 73% CONTINUAL IMPROVEMENT & EXCELLENCE

Gross Heat Rate ( GHR ) Specific Oil Consumption Annual O&M Cost ( Rs in Lac / MW ) Aux Consumption ( % )

0.77 0.94 0.82 1.26 1.23 0.99 0.91 1.06 0.99 0.70 0.68 0.63 552 424 669 416 431 592 464 62 515 615 552 451 100 200 300 400 500 600 700 800 0.60 0.80 1.00 1.20 1.40 1.60 1.80 2.00 2.20 2.40 MU % Specific DM consumption (%) Generation (MU) Top Few Power Stations

DM WATER CONSUMPTION TREND

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  • 6. EPGL ROAD MAP TOWARDS

EXCELLENCE IN ENERGY MANAGEMENT

Designated Consumer (PAT-2) Baseline Net Heat Rate Consumption 2014-15 Target Net Heat rate 2018-19 Actual Net Heat Rate FY 2016-17 ( YTD till July ‘16) STATION (Kcal/Kwh) (Kcal/Kwh) (Kcal/Kwh) ESSAR POWER GUJARAT LIMITED 2512 2506 2497

INGRAINED IN CULTURE : EVERY KCAL COUNTS - MEASURED DAILY

  • CHALLENGING SELF – ENCON OBJECTIVE IN IMS
  • ALIGNED TO TECHNOLOGICAL DEVELOPMENT
  • BENCHMARKING WITH BEST IN INDUSTRY
  • ZERO TOLERANCE TO INEFFICIENT EQUIPMENTS

ESSAR POWER GUJARAT LTD - ENERGY POLICY

Opportunities Register Sr. N O. Date of Identificat ion Plant/ Unit Area/ Activity Identifi ed Energy Use Opportunity Implementabl e (Yea/No) A B C D *Priority No. (Greater the number = higher the priority) Priority Number Calculation Energy Wastage*/ Energy Loss If Yes, Describe benefit Target Date Acti

  • n

Plan ref no. Completion date/Status 1 Oct-15 EPGL Turbine Heat (Kcal/k wh) Improvement in turbine performance Yes 4 3 3 3 108 Energy Loss Major annual

  • verhauling of

Unit-2 Turbine Apr-16 3 To start from 25 Feb 2016 and to complete in 50 Days 2 May-15 EPGL Vaccum improve ment by Cooling Tower modifica tion Heat (Kcal/k wh) Improvement in condenser vaccum and heat rate Yes 4 2 3 3 72 Energy Loss 1) Increase in

  • No. of fan

blades 2) Increasing height of recovery cone 3) Nozzle replacement with new design 4) Structure strengthening Oct-16 1 12.5 % completion 3 Dec-15 EPGL Conden sate extractio n pumps Electric al power Reduction in Energy use Yes 4 2 3 3 72 Energy Loss 1) Installation of VFD in CEPs for reduction in energy use Feb-17 2 Technical Discussion under progress 4 Dec-15 EPGL Seal Air Fan Electric al power Reduction of Electrical energy Yes 3 2 3 3 54 Energy Loss Installation of VFD in seal air fans Aug- 16 8 Technical Discussion under progress 5 Aug-15 EPGL LED Lighting Electric al power Reduction in Light consumption Yes 2 2 2 3 24 Energy Loss Under ImplementationJun-16 4 Under Implementati

  • n

6 Feb-16 EPGL AHP Electric al power Reduction in Energy use Decision after feasibility study Energy Loss Feasibility study under progress Feasibility study under progress 7 Sep-15 EPGL Non conventi

  • nal

energy usage for heating

  • f

condens ate Heat (Kcal/k wh) Reduction plant heat rate Decision after feasibility study Energy Loss Feasibility study under progress 5 Party visted

  • site. Offer

awaited 8 Sep-15 EPGL Solar Street Lights Electric al power Use of Solar Energy for street lights Decision after feasibility study Energy Loss Feasibility study under progress 6 Party visted

  • site. Offer

awaited

  • Doc. No: EPGL/EnMS/F/025
  • Rev. Date:

20-02-2016

  • Rev. No: 01
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SLIDE 6

6 OUR BELIEF … ENERGY CONSERVATION. A TEAM EFFORT ……. Target Evaluate Options Analyze and Apply Monitor and Maintain

E N E R G Y C O N

E

T

A M

ENCON --- Driven across Levels 21 Energy Auditors / Managers

ENGR MD COO MGR HOD

ENERGY MANAGEMENT SYSTEM & REPORTING

Continuously Collating HMBD with Actual Data For Timely Intervention AUTOMATED DAILY EFFY. REPORT

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7 7 A. Summary- Energy Savings ( MU / Annum ) FY 2012-15

  • S. No

Energy Conservation Projects Cost Incurred (Rs in Lacs) Energy Saving MU/Annum 1 Coal Mill Utilization None 3.50 2 Plant Air compressor None 2.41 3 Coal conveying system None 0.13 4 Ash Handling system None 1.28 5 DM Hot well pump None 0.1 6 Compressor cooling system None 0.35 7 Lighting Load Optimization None 0.06 A TOTAL SAVINGS ( MU ) 7.83 Energy Saving M Kcal/Annum 1 HP Exhaust Valve modification None 52872 2 Turbine Operation Philosophy None 99135 3 Start Up Oil reduction None 19088 B TOTAL SAVINGS ( MKCAL ) 171095

A+B :Total Savings (Rs in Lacs)

1648

7 B. Summary- Energy Savings ( MU / Annum ) FY 2015-16

Sr. No ENCON Projects

Cost Incurred (INR Lacs) Energy Saving /Annum Total savings (INR Lacs) 1 Pre- Ponment of Turbine Capital Overhaul 340 115500 Mkcal 850 2 Condenser Vacuum Improvement – Up gradation of Cooling tower 200 24000 Mkcal 200 3 Boiler DM make up reduction. Nil 72160 Mkcal 600 4 Specific oil reduction during Boiler startup. Nil 432 KL ( 9 X 48 KL) 150 5 Optimization of SEC - AHP None 1.06 MU 21.2 6 Optimization of SEC - CHP None 0.105 MU 2.1 7 Optimization of SEC - Chlorination System. None 0.13 MU 2.5 8 LED Lighting installation 11.5 0.10 MU 2.0

Total Savings (INR Lacs)

1827.8

ENERGY SAVING CALCULATED AT NORMATIVE LOAD AND OVER BASELINE OF 2012-13

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  • 8. Innovations in ENCON Projects in 2015-16.

Innovation-1: Pre-ponement of Unit 2 Capital Overhaul

Overview -

  • Preponing Turbine capital overhaul for heat

rate improvement.

  • Details-
  • Turbine COH without OEM support
  • Shutdown executed in 37 days against

schedule of 55 days

  • Improvement of GHR by 35 Kcal/kwh
  • Steam path audit –

Third Party Expert

  • Major jobs executed are :
  • Optimised Steam flow path clearances
  • Use of Fresh seals with intact profile
  • Rectification of identified problems
  • Rotor cleaning
  • Routine Maintenance.

Total Energy Savings = 1,15,500 MKcal / Annum Innovation-1: Pre-ponement of Capital Overhaul

19.1 5.6 9.3 9.1 7.8 6.3 57.1 2.1 1.9 3.5 4.7 4.2 3.4 19.8 17.0 3.7 5.8 4.4 3.5 2.8 37.2

HPT IPT LPT-1 (T) LPT-1 (G) LPT-2 (T) LPT-2 (G) TOTAL

Heat Loss Recovery – Casing wise

OPENING CLOSING

3.7 14.5 11.8 26.6 0.2 56.8 2.8 5.0 1.0 11.1 0.0 19.9 1.0 9.4 10.8 15.5 0.2 36.9

INTERSTAGE PACKING TIP SPILL STRIPS SHAFT END PACKINGS SURFACE ROUGHNESS COVER DEPOSITS TOTAL

Heat Loss Recovery – Category wise OPENING CLOSING

202 5 1990

1960 1970 1980 1990 2000 2010 2020 2030 2040 2050

SUBSTANTIAL HEAT RATE IMPROVEMENT

Turbine Heat Rate before COH Turbine Heat Rate after COH

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SLIDE 9

9 Innovation-2 : Condensor Vacuum improvement by up gradation of Cooling tower

Overview-

  • Modification of cooling tower to achieve

reduction of cooling water temperature by 1.5 Deg. for improvement of condenser vacuum

  • Details of Innovation-
  • Increasing
  • Fan blades from 8 to 10
  • Height of Fan stack for preventing of

hot air recirculation.

  • Spray nozzle with Modified design.
  • Structure strengthening

Total Energy Savings = 24,000 MKcal / Annum Innovation-3 : Boiler DM water Make up reduction

  • Overview-
  • Reduction in DM make up from 3.0% to 1.0%

in last 3 years.

  • Make up further reduced to current value of

0.63 % in 2016-17

  • Details of Innovation-
  • Adoption of ultra pure DM water regime

and rigorous monitoring of consumption.

  • Boiler blowdown optimization

Total Energy Savings = 72,160 MKcal / Annum

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10 Innovation-4 : Specific oil reduction during startup. Overview -

  • The

boiler cold startup procedure was studied in detail and scope was identified to reduce the boiler startup time by-

  • Details

Result Oil reduction

Pre-heating of Feed water Start up time reduced by @ 25 Mins 5 KL / Start Introducing coal in Furnace ~180 deg C Cold Startup Oil Consumption reduced by 26 KL. 26 KL / Start Oil Gun Nozzle Modification Leads to reduction in Oil Firing time before start

  • f Coal Firing.

5 KL / Start Better O&M Practice 12 KL / Start

48 KL /Start

Innovation-4 : Pre-heating of Feed water during startup and reduction of Boiler startup time

Amongst Top Few CEA monitored stations

1.84 0.32 0.23 0.28 0.00 0.20 0.40 0.60 0.80 1.00 1.20 1.40 1.60 1.80 2.00 FY 2012-13 FY 2013-14 FY 2014-15 FY 2015-16 Cold Start-9 Cold Start-9 Cold Start-5

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11 Innovation 5 : Optimization of SEC in Ash Conveying System

Overview -

  • Due Diligence done for ash conveying system

and scope identified for reduction in power consumption by increasing pressure.

  • Details-
  • Optimised jet pump running time
  • Ash conveyed at increased air pressure from

1.92 Kg/cm2 to 2.3 Kg/cm2

  • Result
  • Compressor running hours reduced
  • SEC reduced from 13.6 Kwh/T to 9.8 Kwh/T
  • Evacuation time reduced: 8 hrs to 6 hrs per day

Total Energy savings – 1.06 MU / Annum

  • Overview -
  • Reduction in power consumption in coal

handling system

  • Details-
  • Reduced the idle belt running.
  • Sequential and synchronized operation of

coal belts.

  • Increased Coal Reclaiming.
  • Increased coal conveyor loading from 800

TPH to 1100 TPH .

Innovation-6 : Optimization of SEC in Coal Conveying system

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  • Total savings-

Before Power Consumption for the Period of October 2014 - March 2015 Coal Reclaimed

  • 1.11 Million MT

Power Consumed

  • 2045 MWH

Power consumed /Ton - 1.84 Kwh/Ton After Power Consumption for the Period of April 2015 - Mar 2016 Coal Reclaimed

  • 2.01 Million MT

Power Consumed

  • 3597 MWH

Power Consumed / Ton

  • 1.79 Kwh/Ton

Power Saved (in 12 months) - 100 500 Kwh

Innovation-6 : Optimization of SEC in Coal Conveying system Total Energy savings – 0.10 MU / Annum Innovation 7: Optimization of SEC in Chlorination system

  • Overview-
  • Optimization of CW chlorination

booster pump operation

  • Details -
  • Using CW discharge header for

maintaining FRC of 0.2 to 0.3 with a flow

  • f 20 Kg / Hr to 30 Kg/Hr.
  • As per current scenario water chemistry

parameters being maintained by CW header Pressure resulting into stoppage

  • f HP chlorination booster pump.

Total Energy savings – 0.13 MU / Annum

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SLIDE 13

13 Innovation 8- Lighting Load Optimization- LED

Overview -

  • Plant lighting load optimization by LED

lamps

  • Details-
  • 200 Nos. of lights in BTG area replaced

with LED lamps last year . Additional 600 Lights to be replaced in the current year.

  • Maintaining the lighting lux level above

100 Lux which is industrial safety standard.

Total Energy savings (Existing) – 0.10 MU / Annum

  • 9. Efficient Utilization of Renewable Energy

Installed Turbo –driven Fans in the O&M Building and Power House in place of Ventilation fans.

Total Savings : 70 kwh

Capex Planned for installing Solar heaters in our Power Castle Colony near to Plant.

Total Savings : 30 kwh

ESSAR POWER OWNS 1 MW Solar based Power plant

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SLIDE 14

14 10 A) Environmental Projects for Carbon Emission reduction Green Belt @ EPGL

By Energy Conservation, Last 3 Yrs ( 2012-15 ) CO2 saved:2,40,522 MT CO2 sequestered (MT)/Year Total CO2 sequestered (MT) till date

6972 45320

Total CO2 (MT) sequestered in Green Belt at EPGL

85000+

By Energy Conservation, Annual ( 2015-16 ) CO2 emissions saved : 94,607 MT

Efforts towards Environment Protection

EPGL has started experimenting plantation

  • f sturdy species of Date Palm around it’s

cooling tower which will withstand impact

  • f sea water.

Acoustic covering for TG Deck

Rain Water Harvesting Green Belt Development

Deaerator Vent silencer Injection - Ammonia in Flue Gas

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SLIDE 15

15 10 B) Productive Utilization of Waste

*100% Fly Ash Disposal : (Only five large power plants) ** a) 87% disposal to Cement manufacturing. b) 12% for back filling of low lying area. c) 1% for Fly ash brick& blocks manufacturers. * 84 ha Greenbelt developed * 100% reuse of STP / ETP water for various purpose, Last Two Year’s Sale Sale of Fly Ash : 4,49,000 MT - Rs 136 Lacs Sale of MS Scrap : 519 MT - Rs 145 Lacs Sale of Wood / Garbage : 149 MT - Rs 6 Lacs SWACHHTA ABHIYAN ** CEA Statistics 2013-14

CW BD

AHS System Makeup Construction activity for Plant & EBTSL area

Guard Pond (ETP)

  • Coal Handling system
  • Coal pile dust

suppression

  • Fire fighting
  • Service applications

Boiler Blowdown & DM Plant Waste water

Green Belt dev at plant, & Stockyard corridor Tanker fill arrangement to sprinkle on road

Productive Utilization of Waste: Zero Effluent Discharge

Cooling Tower (10 COC) EVAPORATION MAKE - UP

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  • 11. ENCON PROJECTS FROM ISO 9001 &

EMS 14001

MGMT System TARGET 2015-16 ACTUAL 2015-16 ENCON PROJECTS

ISO 9001 Aux Cons: 6.00 % (Loading 80%) Achieved: 5.76 % ( with equivalent 80% LF )

  • Annual Savings of 1330

MWH by various ENCON

  • Proj. mentioned above.

GHR Target : 2365 Kcal /kwh (Loading 80%) Achieved: 2315 kcal /kwh ( with equivalent 80% LF )

  • Annual Savings of 217802

MKCAL by Various ENCON

  • Proj. mentioned above

ISO 14001 Reduction in DM Water cons. to 1.5% Achieved : 1.2 %

  • DM Water Conservation

Audit

  • Stringent Water chemistry

Monitoring

  • 12. Replication of ENCON BEST Practices

implemented through EBTSL

ENCON PROJECTS IMPLEMENTED BY EBTSL Annual MU Saved Annual Savings In Rs in Lacs Yard Conveyor –1 and 3 running in slow speed as per Feed requirement . Approx. saving 24 unit / hour 0.10 2.1 SCR3 luff motor running in Star connection.

  • Approx. saving 10 unit / hour

0.02 0.4 SCR1 / SCR3 during stacking switching off Luff and Hagglund motor. Approx. saving - 115 unit / hour 0.41 8.4

0.53 10.9

EPGL ENCON Team visited EBTSL site and suggested various ENCON Measures.

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  • 13. EPGL Journey towards Excellence

18 Awards /Certificates in 4 Years. EPGL Journey Continues……….

EnMS ISO 50001:2011 CIO of the Year

2014AIMA award for training excellence

Young HR Champion

2014Greentech Gold Award in HR Practicies Excellence 2014Greentech Gold Award for Innovation in retantion strategies

Training Excellence CEA certification for EPLC

2015Lowest So2 Emissions from amongst the coal based power plants in India 2015Lowest Nox Emissions from amongst the coal based power plants in India

OHSAS 18001: 2007

2015Geentech Gold safety award 2015Greentech Gold Environment Award

ISO 14001:2004

2015Next 100 future CIO award 2015Digital Transformation of technology award (e-negotiations for Coal Procurement) 2015Data quest Award (e-negotiations for Coal Procurement)

ISO 9001:2008 Data quest Award Digital Transformation of technology Next 100 future CIO Environment Award Safety award Lowest Nox Emissions Lowest So2 Emissions

2015Quality Management Standard in terms of ISO 9001:2008 2015Environment Management System in terms of ISO 140001:2004

Innovation in retantion strategies

2015Occupational Health and Safety Management System OHSAS 18001:2007 2015CEA certification for Essar poer learning centre

HR Practicies

2016Training Excellence SILVER Award 2016Young HR Champion GOLD Award

Training excellence

2016CIO of the Year award (Coal Logistics Management COALSCM) 2016Energy Management System (EnMS) ISO 50001:2011

2014 2014 2014 2015 2015 2015 2015 2015 2015 2015 2015 2015 2015 2015 2016 2016 2016 2016

  • 14. ENCON Projects -- Next 3 Years

Sr. No. Future Projects Conservative Estimate Energy Savings Annual Savings MKCAL OR MU Savings Per Annum (Rs in Lacs) Approx. Investmen t (Rs in Lacs)

1 Turbine retrofit for Unit-1 50 kCal/kWh 3,00,000 MKCAL 1250 10000 2 Micro Oil Ignition System installation in both unit Boilers. 0.15 ml/kwh 13245 MKCAL 300 700 3 VFD installation in CEP 780-900 KW according to load 5.9 MU / Annum 5.9 MU 117 325 4 Non conventional energy usage for heating of condensate 2 kcal/kwh 16819 MKCAL 100 400 5 VFD in Seal Air Fans 78 KW 0.55 MU/Annum 0.55 MU 10.9 24 6 SCAPH Bypass during normal

  • peration

4.67 MU 4.67 MU 92 Nil 7 Installation of LED in Plant 1.1 MW/Day 0.4 MU 6 14 8 Solar power on roof top of Power House and Admin building 70 KW Generation 100000 Kwh / annum 0.1 MU 2 45

TOTAL 1878 11508