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

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18th National Award for Excellence in Energy Management -2017

ESSAR POWER GUJARAT LTD (EPGL),

Dist : Dev Bhumi Dwarka, Gujarat 1200 MW ( 2 X 600 MW ) THERMAL POWER PLANT

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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

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1. COMPANY PROFILE

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

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

1. COMPANY PROFILE

Boiler Area

PLANT OVERVIEW

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

Mharo EPGL

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2. PROCESS FLOW DIAGRAM

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

CERC NORM 5.75 % CERC NORM 2375 Kcal/kwh CERC NORM 0.5 ml/kwh CERC NORM 1.5 %

3. SPECIFIC ENERGY CONSUMPTION

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71% 69% 80% 73% 73% 7.15% 6.60% 5.83% 6.06% 6.23% [VALUE] MU [VALUE] MU [VALUE] MU [VALUE] MU [VALUE] MU

1000 2000 3000 4000 5000 6000 7000 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 2012-13 2013-14 2014-15 2015-16 2016-17

Plant Loading Factor % Auxiliary Consumption % Gross Generation MU

GHR 2451 GHR 2333 GHR 2339 GHR 2421 GHR 2368

GHR - 2416 GHR - 2332 GHR - 2304 GHR - 2332 GHR - 2372 6.6% 5.78% 5.66% 5.64% 5.95%

YOY Improvement

Good and Consistent O&M practices

AT

Normative Loading

3. SPECIFIC ENERGY CONSUMPTION

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S. No

Energy Conservation Projects Cost Incurred (INR Lacs) Energy Saving M Kcal/Annum

1 Pre-Ponement of Turbine Capital Overhaul 340 115500

2 Turbine Operation Philosophy – Sequential v/v None 99135

3 Boiler DM make up reduction. Nil 72160

4 HP Exhaust Valve modification None 52872

5 Condenser Vacuum Improvement – Up gradation of Cooling tower 200 24000

6 Start Up Oil reduction None 23710 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 B TOTAL SAVINGS (MU)

Total Savings in two years is 1740 (INR Lacs) 9

4. SUMMARY – ENERGY SAVINGS FY 2014-16

9.23 MU 3,87,377 MKCAL

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Sr. No ENCON Projects

Cost Incurred (INR Lacs) Energy Saving /Annum Total savings /Annum (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 A TOTAL SAVINGS ( MKCAL ) 1 Energy conservation in CEP Operation Nil 1.40 MU 33.1 2 OCCW pump -90 KW replaced with 37 KW CCCW pump. 37 0.6 MU 15 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 B TOTAL SAVINGS ( MU ) Total Savings is 573 ( INR Lacs ) 10

4. SUMMARY – ENERGY SAVINGS FY 2016-17

34390 MKcal 4.01 MU

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13 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 Annual Commercial Savings- INR 15 Lacs

5. INNOVATION : OCCW SYSTEM MODIFICATION

= 0.60 MU

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Lube oil cooler for T-BFP Working

il cooler

M-BFP Lube oil cooler M-BFP To Circulating water O/L pipe

PHE-A PHE-B

From circulating water pipe Filter OCCWA OCCWB CCCW-HE To CW pipe

s OCCW system (Original Scheme)

CCCWP DISCHARGE

OCCW-M 1 OCCW-M 2 OCCW-M 3 OCCW-M - 9 OCCW-M -4 OCCW-M -5 OCCW-M -7 OCCW-M -6 OCCW-M -8

Return to circulating water pipe

90 KW

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Lube oil cooler for T-BFP Working

il cooler

M-BFP Lube oil cooler M-BFP

PHE-A PHE-B

From circulating water pipe OCCWA OCCWB CCCW-HE To CW pipe

CCCWP DISCHARGE

OCCW-M -4 OCCW-M -5 OCCW-M -7 OCCW-M -6

Service water Tank

PHE-A PHE-B

Return to circulating water pipe Filter

s

OCCW-M 1 OCCW-M 3 OCCW-M - 9

Savings of 50 KW

37 KW OCCW system (Modified Scheme)

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16 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

INNOVATION : REDUCTION OF SH SPRAY

Annual Thermal savings/annum = 3928 Tons of coal Annual Commercial Savings- INR 185 Lacs

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17 Overview- Change in operational philosophy of CEP

Details-

Saving of power consumption of condensate

extraction pump at technical minimum loading.

Design philosophy of CEP operation is 2

Working and 1 stand by.

Stopping one CEP running of unit on only one

CEP at low load (Technical minimum-330 MW) in case of SLDC back down condition. Energy savings/annum = 1.404 MU Annual Commercial Savings- INR 33.1 Lacs

INNOVATION : CONDENSATE EXTRACTION __PUMP OPERATION OPTIMIZATION

CONDENSATE WATER SYSTEM

M M CEPA CEP B Con den sate Pum p C M M M

CPU

M M M M M M M M M M M M M M M M M M M

Ho t We ll

M M M

Total Running Hours (FY 16-17) Technical minimum hours @ 330 MW Unit 1 6458 934 Unit 2 5453 1069

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18 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

INNOVATION : ENERGY CONSERVATION COAL HANDLING SYSTEM

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ENERGY CONSERVATION COAL HANDLING SYSTEM

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1.79 1.14 1.05 0.2 0.4

0.6 0.8 1 1.2 1.4 1.6 1.8 2

2014-15 2015-16 2016-17

Sp. Consumption Kwh/Ton of coal

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

While Road logistic is being monitored in Rs/MT/KM Why not coal conveying in Kwh/MT/KM ?

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20 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

INNOVATION : ENERGY CONSERVATION IN ASH HANDLING SYSTEM

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ENERGY CONSERVATION IN ASH HANDLING SYSTEM

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13.6 10.19 9.34 2 4 6 8 10 12 14 16 2014-15 2015-16 2016-17

SP. Consumption Kwh/Ton of Fly Ash

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

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22 Overview- Energy conservation in HVAC system Details-

Continuous monitoring of temperature

profile, zone wise being monitored every 2 hours.

Heat Load profile, season wise and across

the day prepared based on monitored and recorded data.

Based on temperature profile we are

proactively optimizing operation of AHU, chiller and connected accessories over and above automation system.

Zone wise losses identified and arrested for

reduction in power consumption of HVAC.

Sp. Consumption/Day 2015-16 = 7.95 MW/Day
Sp. Consumption/Day 2016-17 = 7.08 MW/Day

Annual Energy savings = 0.32 MU Annual Commercial Savings = INR 7.5 Lacs

INNOVATION : ENERGY CONSERVATION IN HVAC SYSTEM

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Sr. No. Future Projects Conservative Estimate Energy Savings Annual Savings MKCAL OR MU OR MT Saving s Per Annum (INR in Lacs) Approx. Investment (INR in Lacs)

1 Turbine retrofit for Unit-1 50 kCal/kWh 1600 10000 2 VFD installation in CEP 780-900 KW according to load 5.9 MU / Annum 5.9 MU 117 325 3 VFD in Seal Air Fans 78 KW 0.55 MU/Annum 0.55 MU 10.9 24 4 Installation of LED in Plant 1.1 MW/Day 0.4 MU 10 14 5 HFO forwarding pumps modification 200 KW/Day 0.07MU 1.9 4.1

TOTAL SAVINGS ( MU)

6. FUTURE ENCON PROJECTS – NEXT 3 YEARS

1,50,000 MKCAL 6.92 MU

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24 Designated Consumer (PAT-2) Baseline Net Heat Rate Consumption 2014-15 Target Net Heat rate for PAT-2 2018-19 Actual Net Heat Rate FY 2016-17 STATION (Kcal/Kwh) (Kcal/Kwh) (Kcal/Kwh) ESSAR POWER GUJARAT LIMITED 2512 2506 2451

ENCON OBJECTIVE ARE ALIGNED TO

_TECHNOLOGICAL DEVELOPMENT

BENCHMARKING WITH BEST IN INDUSTRY
ZERO TOLERANCE TO INEFFICIENT EQUIPMENTS
7. EPGL ROAD MAP TOWARDS EXCELLENCE IN

__ENERGY MANAGEMENT

CHALLENGING SELF

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ISO 50001:2011 CERTIFICATE & ENERGY POLICY

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26 Efficiency Monitoring

Parameters

Heat Rate APC Vacuum Make Up Temp/Pressure

Testing

Online &

ffline testing
f Boiler,

Turbine, Condenser & APH etc.

Audit

Energy Audit Insulation Audit Valve leak/passing

Assessment

Pre & Post Overhaul/ Maintenance jobs assessment

MIS

Daily, Monthly & Yearly MIS Statutory Reporting

EFFICIENCY MONITORING APPROACH

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ENERGY MANAGEMENT SYSTEM

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ENERGY MANAGEMENT SYSTEM

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ENERGY MANAGEMENT SYSTEM

20-Apr-16 Load 1151 MW Aux 5.17 % DATE 23-Apr-16 Avg Aux 113 MW GCV 5967 Kcal/kg Parameters Performance Units MWh % Share of Total APC % of APC Plants Equipments MWh % Share

f Total

APC % of APC MWh % Share of Total APC % of APC Generation 27204 MWh ID (VFD) 169.4 11.7% 0.62% 175.0 12.3% 0.63% Avg Load 1134 MW 596 41.2% 2.2% ID (BY PASS) 0.0 0.0% 0.00% 0.0 0.0% 0.00% Avg Aux 64 MW PA 139.6 9.7% 0.51% 141.6 9.9% 0.51% Aux 5.32 % COAL MILL 120.1 8.3% 0.44% 121.7 8.5% 0.44% GCV 6085 kCal/kg 601 41.5% 2.2% FD 92.9 6.4% 0.34% 93.5 6.6% 0.34% Moisture 13.3 % ESPST 16.6 1.1% 0.06% 16.6 1.2% 0.06% BCP 35.9 2.5% 0.13% 35.6 2.5% 0.13% 89 6.2% 0.3% BST 21.7 1.5% 0.08% 21.8 1.5% 0.08% MDBFP 0.0 0.0% 0.00% 0.0 0.0% 0.00% Projected Aux 5.95 % 596.1 41.2% 2.19% 605.7 42.5% 2.19% Deviation 0.63 % 160 11.1% 0.6% CWP 300.8 20.8% 1.11% 300.4 21.1% 1.09% CTST 107.8 7.5% 0.40% 103.3 7.2% 0.37% CEP 94.8 6.6% 0.35% 94.3 6.6% 0.34% BFPT BOOSTER 52.9 3.7% 0.19% 52.7 3.7% 0.19% TGST 26.1 1.8% 0.10% 25.9 1.8% 0.09% CCCW 14.5 1.0% 0.05% 14.1 1.0% 0.05% Excitation Trafo Consumption 3.8 0.3% 0.01% 3.9 0.3% 0.01% 600.6 41.5% 2.21% 594.5 41.7% 2.15% ER-4 O\G BKR 33.7 2.3% 0.12% 24.4 1.7% 0.09% AHPS 7.9 0.5% 0.03% 9.4 0.7% 0.03% CICO 8.0 0.6% 0.03% 13.0 0.9% 0.05% AIR COMPRESSOR 11.4 0.8% 0.04% 11.5 0.8% 0.04% AC&Vent.ST 9.4 0.7% 0.03% 9.2 0.6% 0.03% SST 8.7 0.6% 0.03% 10.3 0.7% 0.04% WCST 5.0 0.3% 0.02% 5.1 0.4% 0.02% Putzmeister Pump-(UAT) 0.0 0.0% 0.00% 0.0 0.0% 0.00% Return Water Pump 5.2 0.4% 0.02% 0.0 0.0% 0.00% 89.3 6.2% 0.33% 82.9 5.8% 0.30% 160.0 11.1% 0.59% 143.6 10.1% 0.52% 160.0 11.1% 0.59% 143.6 10.1% 0.52% Others & Transformer Losses Total OTHERS & TRANSFORMER LOSSES Total T U R B I N E Total

M I S C E L L A N E O U S

Total

ENERGY MANAGEMENT SYSTEM

Previous Date BOILER AUXILIARIES B O I L E R TURBINE AUXILIARIES MISCELLANEOUS AUXILIARIES 41% 42% 6% 11%

% Share of Total APC

BOILER AUXILIARIES TURBINE AUXILIARIES MISCELLANEOUS AUXILIARIES OTHERS & TRANSFORMER LOSSES

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OUR BELIEF … ENERGY CONSERVATION. A TEAM EFFORT …….

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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

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GLIMPSE OF ISO 50001 AWARENESS TRAININGS

ISO 50001 Audit Rating 4 from 3 by DNV in just 1 year

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Forecasting of Demand based on Weather Condition & Renewable Gen.
Preference for Low Moisture coal.
Maintaining High COC of 9 to 10 in Cooling tower

Periodical Practice Followed at EPGL : 1) Annual Cleaning of Condenser and Heaters 2) On line cleaning of Cooling Tower fills 3) Helium leak detection for Air ingress in Condenser 4) Checking and Resetting of Air – Preheater seals. 5) Insulation healthiness audit 6) Coal mill velocity online monitoring. Clean and dirty air test annually 7) Condition Monitoring of all Mechanical & Electrical equipment.

Modulating the plant operation to achieve best performance on actual running

condition

Automated Daily Station Energy Monitoring Report .
Alarm analysis through dedicated software developed In-house
Equipment Performance report.
Daily Aux Power Consumption report.
Boiler & Turbine start up report.

KEY BEST PRACTICES AT EPGL

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ESSAR POWER OWNS

1 MW Solar based Power plant

Installed Turbo –driven Fans in the O&M

Building and Power House in place of Ventilation fans. Total Savings : 70 kwh

Replacing 900 units of sodium lamps by 500

units of LED lights

Annual Energy savings/annum = 365*900

units* 2Kwh- 365500 units 1 Kwh = 0.47 MU

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8. EFFICIENT UTILIZATION OF RENEWABLE

ENERGY

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2967 MT / Year

CO2 (MT) sequestered in Green Belt at EPGL

84 Hectare Green Belt

9. ENVIRONMENTAL PROJECTS FOR CARBON

EMISSION REDUCTION

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35 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

Organic waste converter at site Injection - Ammonia in Flue Gas

EFFORTS TOWARDS ENVIRONMENT PROTECTION

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100% Reuse of treated wastewater

Celebrating World Environment Day in Horticulture Use of Waste Water in CHP Dust Free Ash loading to reduce Fugitive emissions

Received continuously Five Year Water Cess Rebate from GPCB

BEST ENVIRONMENTAL PRACTICES IMPLEMENTED

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*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 Year’s Sale Sale of Fly Ash : 206106 MT Sale of MS Scrap : 30.7 MT Sale of Wood / Garbage : 7.67 MT

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PRODUCTIVE UTILIZATION OF WASTE

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10. AMOUNT OF REPLICATION DUE TO BEST

PRACTICES IMPLEMENTED THROUGH ASSOCIATES

ENCON PROJECTS IMPLEMENTED BY COAL HANDLING CONTRACTOR Annual MU Saved Annual Savings In Rs in Lacs

Luff motor (18.5 kw) Delta connection converted to star connection.

0.027 1.4

YC-1 conveyor is being run on low speed of 1200 rpm compared to 1400 rpm full speed as per the Belt loading.

0.105 5.4

Dust Suppression Spray run in place of Fire Pump

0.547 28.5

During stacking in Stacker Reclaimer-1/2/3 Slew / bucket wheel power pack ( 200 kw ) and luff power pack (18.5 kw) was running continuously in auto mode. Both power packs removed from auto sequence enabling

perator to start as per requirement

0.96 50

1.64 85.3

Our Coal handling Contractor visited EPGL site and replicated various ENCON Measures.

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Essar Power Gujarat Ltd. 39

CORPORATE SOCIAL RESPONSIBILITY

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2016-17

Training Excellence SILVER Award CII Excellent Energy Efficiency Award IPPAI best innovative practices award in Energy efficiency Young HR Champion GOLD Award CII Most useful presentation Award Mission Energy Award for O&M Excellence CIO of the year (Coal Logistic Management ) OSHAI innovation in HSE award 2016 Mission Energy Award for 100% Ash Utilization

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11. WINNING AWARDS REGULARLY…..

(TOTAL 9 AWARDS IN YEAR 2016-17)

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2014 2015

IIMA award for Training Excellence Greentech Gold safety award Digital Transformation of technology award (e-negotiations for Coal Procurement) Greentech Gold Award for Innovation in retention strategies Lowest SO2 Emissions amongst Power plant in India Data Quest Award (E Negotiation for coal procurement) Green-tech Gold Award for HR Practices Greentech Gold Award for Environment Next 100 Future CIO Award

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WINNING AWARDS REGULARLY……….

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AWARD FOR ENERGY EXCELLENCE 2016…..