Excellence in Energy Management -2017 ESSAR POWER GUJARAT LTD - PowerPoint PPT Presentation

18 th National Award for Excellence in Energy Management -2017 ESSAR POWER GUJARAT LTD (EPGL), Dist : Dev Bhumi Dwarka, Gujarat 1 1200 MW ( 2 X 600 MW ) THERMAL POWER PLANT

INDEX Sr. No. 1 Company profile --- A Walk Through. 2 Process flow of EPGL Plant. 3 SEC Trend in last 5 yrs. 4 a) Energy Savings Projects : 2014-16 b) Energy Savings Projects : 2016-17 5 Details of ENCON Projects of 2016-17 6 Future ENCON Projects -- Next 3 Years 7 EPGL Road Map Towards Excellence in EnMS 8 Efficient Utilization of Renewable Energy 9 Environmental Projects 10 Replication of ENCON BEST Practices 11 Awards & Accolades 2

1. COMPANY PROFILE Location Salaya, Dev Bhumi Dwarka District, Gujarat Capacity 1200 MW (2 x 600 MW) Fuel Imported Thermal Coal • Sub-Critical Technology Technology / • BTG Package- HEI , China Equipment • BOP- Reputed Vendors ( ABB/Areva/SPIG ) • 1000 MW - Long term PPA with GUVNL Power Off-take • Balance 118 MW - Merchant Power • Presently 64 MLD River water Water • Future-Sea Water - 9375 m3/hr Requirement Power • Evacuation at 400 KV – STU Network Evacuation 3

1. COMPANY PROFILE UNIT-1 COD : 01 st April 2012 UNIT-2 COD : 15 th June 2012 PLANT OVERVIEW Boiler Area 4

Mharo EPGL High Reliability (consistent PAF) Generation Cost highly competitive amongst IPP Recognized as leaders in Energy Efficiency by CII & OSHAI Supply ~ 9% of Gujarat Recognition geographically for our demand environmental clean efforts 5

2. PROCESS FLOW DIAGRAM 6

3. SPECIFIC ENERGY CONSUMPTION Heat Rate ( Kcal / kwh ) FY 2012-13 FY 2013-14 FY 2014-15 FY 2015-16 FY 2016-17 CERC NORM 2451 2421 2339 2333 2368 2375 Kcal/kwh ( LF - 70.9 %) ( LF 68.7 %) ( LF 80.35 %) ( LF 73.40 %) ( LF 72.95 %) Aux Power (%) FY 2012-13 FY 2013-14 FY 2014-15 FY 2015-16 FY 2016-17 CERC NORM 7.1% 6.6% 5.8% 6.1% 6.2% 5.75 % ( 293 MU ) ( 356 MU ) ( 386 MU ) ( 317 MU ) ( 327 MU ) Specific Oil Consumption ( ml / kwh ) FY 2012-13 FY 2013-14 FY 2014-15 FY 2015-16 FY 2016-17 CERC NORM 0.5 ml/kwh 1.8 0.32 0.23 0.28 0.29 DM Water Make up ( % ) FY 2012-13 FY 2013-14 FY 2014-15 FY 2015-16 FY 2016-17 CERC NORM 1.5 % 3.33 % 1.48 % 1.04 % 1.18 % 0.72 % 7

3. SPECIFIC ENERGY CONSUMPTION YOY Improvement • Good and Consistent O&M practices 90% 7000 [VALUE] MU 80% 6000 [VALUE] MU [VALUE] MU [VALUE] MU 70% 5000 [VALUE] MU 60% GHR 4000 50% GHR GHR 2451 GHR 2421 GHR 2368 2339 40% 80% 3000 2333 73% 73% 71% 69% GHR - 2416 GHR - 2372 AT 30% GHR - 2332 GHR - 2332 GHR - 2304 2000 Normative 20% Loading 1000 7.15% 10% 6.60% 6.23% 6.06% 5.83% 6.6% 5.66% 5.78% 5.95% 5.64% 0% 0 2012-13 2013-14 2014-15 2015-16 2016-17 Plant Loading Factor % Auxiliary Consumption % Gross Generation MU 8

4. SUMMARY – ENERGY SAVINGS FY 2014-16 S. No Energy Conservation Projects Cost Energy Saving Incurred M Kcal/Annum (INR Lacs) 1 Pre-Ponement of Turbine Capital Overhaul 340 115500 Turbine Operation Philosophy – Sequential v/v 2 None 99135 3 Boiler DM make up reduction. Nil 72160 4 HP Exhaust Valve modification None 52872 Condenser Vacuum Improvement – Up 5 200 24000 gradation of Cooling tower 6 Start Up Oil reduction None 23710 3,87,377 MKCAL A TOTAL SAVINGS ( MKCAL ) MU/Annum 1 Coal Mill Utilization optimization None 3.50 2 Plant Air compressor Pressure reduction None 2.41 3 Other Projects 11.5 3.315 9.23 MU B TOTAL SAVINGS (MU) Total Savings in two years is 1740 (INR Lacs) 9

4. SUMMARY – ENERGY SAVINGS FY 2016-17 Cost Energy Saving Total savings Sr. Incurred /Annum /Annum No ENCON Projects (INR Lacs) (INR Lacs) 1 SH Spray reduction in Boiler Nil 17400 MKcal 185.3 2 DM Make up Reduction Nil 14701 Mkcal 210.6 3 Startup Oil Reduction- 229 MT Oil Nil 2290 Mkcal 79.5 34390 MKcal A TOTAL SAVINGS ( MKCAL ) 1 Energy conservation in CEP Operation Nil 1.40 MU 33.1 2 OCCW pump -90 KW replaced with 37 37 0.6 MU 15 KW CCCW pump. 3 Energy conservation in HVAC system Nil 0.31 MU 7.5 4 Energy conservation in AHP system Nil 0.16 MU 3.8 5 Energy conservation in CHP system Nil 0.21 MU 5.1 6 LED Lighting installation 14 0.47 MU 11.8 7 LDO Forwarding Pump Optimization Nil 0.55 MU 13.0 8 CCCW pump Optimization Nil 0.37 MU 8.9 4.01 MU B TOTAL SAVINGS ( MU ) 10 Total Savings is 573 ( INR Lacs )

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5. INNOVATION : OCCW SYSTEM MODIFICATION Overview- Energy Saving by modifying OCCW system by installing a closed cycle cooling system for BFP’s oil system. Details-  OCCW system modified for TD BFP and M BFP oil coolers and working oil coolers.  For these coolers system converted from OCCW system to CCCW system.  A 37 KW pump installed for supply CCCW for BFP cooler thus enabling stoppage of 90 KW OCCW pump.  Hence a saving of 50 KW is achieved. Energy savings- Total Energy savings/annum = 0.60 MU Annual Commercial Savings- INR 15 Lacs 13

OCCW system (Original Scheme ) OCCW-M 3 CCCWP DISCHARGE OCCW-M -6 OCCWA Filter OCCW-M -4 s OCCW-M 1 OCCW-M 2 From circulating To CW pipe PHE-A water pipe CCCW-HE OCCW-M -7 OCCW-M - 9 OCCW-M -5 OCCWB PHE-B 90 KW Return to circulating water OCCW-M -8 To Circulating pipe water O/L pipe Working oil cooler M-BFP Lube oil Lube oil cooler for T-BFP cooler M-BFP

OCCW system (Modified Scheme ) OCCW-M 3 CCCWP From circulating DISCHARGE OCCW-M -6 OCCWA Filter water pipe OCCW-M -4 s OCCW-M 1 To CW pipe PHE-A CCCW-HE Return to OCCW-M -7 OCCW-M - 9 OCCW-M -5 circulating water OCCWB pipe PHE-B Service water Tank PHE-A PHE-B 37 KW Savings of Working oil cooler M-BFP 50 KW Lube oil Lube oil cooler for T-BFP cooler M-BFP

INNOVATION : REDUCTION OF SH SPRAY Overview- Spray reduction at low load from 80 TPH (as per OEM manual) to 22 TPH by implementing innovative solutions. Details- • Boiler combustion optimization through - Balanced coal mill velocity - Higher fineness. - Burner tilt operation - Soot blowing fine tuned. • SADC damper adjustment • Lower elevation mill operation. • Bottom elevation firing with high FC coal during mixed coal firing Total low load operation hours = 2334 Hours Annual Thermal savings/annum = 3928 Tons of coal Annual Commercial Savings- INR 185 Lacs 16

INNOVATION : CONDENSATE EXTRACTION __PUMP OPERATION OPTIMIZATION Overview - CONDENSATE WATER SYSTEM Change in operational philosophy of CEP M Details-  Saving of power consumption of condensate extraction pump at technical minimum loading. M  Design philosophy of CEP operation is 2 M Working and 1 stand by. Ho M M M M t  Stopping one CEP running of unit on only one M We M CEP at low load (Technical minimum-330 MW) ll M M M M in case of SLDC back down condition. M M M M Total Running Technical minimum Con CEP M den Hours (FY 16-17) hours @ 330 MW B M CEPA M sate Unit 1 6458 934 M Pum p C Unit 2 5453 1069 M Energy savings/annum M M M M = 1.404 MU M Annual Commercial Savings- INR 33.1 Lacs CPU 17

INNOVATION : ENERGY CONSERVATION COAL HANDLING SYSTEM Overview- Energy conservation in coal handling system Details-  Optimizing utilization factor of coal handling system  The main parameter on which continuous efforts are being made are : 1. Highest capacity Utilization of Conveyors 2. Effective synchronization of coal feeding with coal stacking and reclaiming 3. Innovative monitoring of Sp. Power consumption in terms of Kwh/Ton/Km Annual Energy saving = 0.22 MU Total Commercial Savings = INR 5.1 Lacs 18

ENERGY CONSERVATION COAL HANDLING SYSTEM Sp. Consumption Kwh/Ton of coal 2 1.79 While Road logistic is being monitored in Rs/MT/KM 1.8 Why not coal conveying in Kwh/MT/KM ? 1.6 1.4 1.14 1.2 1.05 1 0.8 0.6 0.4 0.2 0 2014-15 2015-16 2016-17 Specific consumption (2015-16) - 1.14 Kwh/MT of coal Specific consumption (2016-17) - 1.05 Kwh/MT of coal Total reduction in Sp. Power - 0.09 Kwh/MT of coal Total coal conveyed (MT) - 2384575 MT Total Energy savings (Mkwh) - 0.22 MU 19

INNOVATION : ENERGY CONSERVATION IN ASH HANDLING SYSTEM Overview- Optimizing operation processes in AHP, Fly ash conveying and in bottom ash conveying Details-  Maintaining ash conveying by full accumulation of ash in transporter vessel by operating on level mode instead of on timer mode.  Conveying compressor maximum capacity utilization by clubbing of system.  Increasing ash conveying pressure for reduction in conveying time Reduction in Sp. Consumption from 10.19 to 9.34 Kwh/Ton Annual Energy saving = 0.16 MU Annual Commercial Savings = INR 3.8 Lacs 20

ENERGY CONSERVATION IN ASH HANDLING SYSTEM SP. Consumption Kwh/Ton of Fly Ash 16 13.6 14 12 10.19 9.34 10 8 6 4 2 0 2014-15 2015-16 2016-17 Specific consumption (2015-16) - 10.19 Kwh/MT of Ash Specific consumption (2016-17) - 9.34 Kwh/MT of Ash Total reduction in Sp. Power - 0.85 Kwh/MT of Ash Total Fly ash conveyed (MT) - 190000 MT Total Energy savings (Mkwh) - 0.16 MU 21