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Energy Management - 2017 National Award For Excellence in
POWER MINING FERRO AGRI NAVA BHARAT
National Award For Excellence in Energy Management - 2017 GO - - - PowerPoint PPT Presentation
POWER MINING FERRO AGRI NAVA BHARAT National Award For Excellence in Energy Management - 2017 GO - GREEN NBVL Global footprints Company profile NAVA BHARAT Kharagprasad (Odisha): Chromium Alloy Plant & Power Plant Dharmavaram
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POWER MINING FERRO AGRI NAVA BHARAT
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India : Ferro Alloy, Power & Sugar , Corporate Office Singapore : International Office Laos : Development of hydro-electric power project Zambia : Coal Mining & 300 MW Thermal Power Plant Tanzania : Identifying opportunities for mining and setting up agri projects
Kharagprasad (Odisha): Chromium Alloy Plant & Power Plant Samalkota (AP): Sugar Plant & Power Plant Paloncha (Telangana): Manganese Alloy Plant & Power Plant Hyderabad: Corporate Office Dharmavaram (AP): Power Plant
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Ferro Alloy Division
Smelters: 2 x 22.5 MVA Products: Ferro Chrome Output Capacity: 75,000 TPA
Power Division (CPP)
Capacity: 30 MW + 60 MW Type: Coal Based TPP
Fuel: Domestic Coal from MCL
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Reservoir Clarifier
MWPH
RW Pump House
DM Plant Raw Water From
Brahmani River
GEN
SWITCH YARD AUX LOAD
Bunker
DRUM PSH SSH IBSH
Bed Comp
Bed Ash Flue Gas Economizer
Coal Yard CHP
Coal From Mines Coal From Washeries
SILO SILO
ESP
FLY ash APH
HP HEATERS LP HEATERS
UCFT
Deareator
Condenser
STEAM TURBINE
Cooling Tower
Dry ash to Brick plants Ash pond etc. through closed trucks Pneumatic Ash conveying System
Compressor house
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2005 2008 2012 2008 2009 2014 2003
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Commissioning of Unit - 1 ( 30 MW) CPP Implementing 5S concept at workplace Commissioning of Unit - 2 (60 MW ) CPP Commissioning of 175 TR capacity VAM Certified with ISO 9001 and ISO 14001 Certified with OHSAS 18001 and ISO 50001 Commissioning of 100 m3/day green STP
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Energy Effectiveness Greenbelt Development Technology Absorption Renewable Energy Water Management Waste Management GHG Mitigation
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Objectives of Green House Gas Management:
Establishing the Baseline, based on 2013 - 14 activity data Reducing the Intensity of Green House Gas (GHG) Emissions Improving the Gate to Gate energy performance of the Unit Conserving the resources & Utilization of Renewable energy Technology Absorption, Reduce, Reuse and Recycling Waste Including Indirect green house gases in GHG Management Monitoring, Reviewing and real time data transmission of Indirect green house gases to PCB server through RT - DAS Tree Plantation and green belt development Creating Awareness among the employees
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Managing Green House Gas (GHG) emissions :
Nava Bharat Ventures Ltd, Dhenkanal, Orissa adopted Emission based calculation approach for calculating the Co2e and 2013-14 as a base line year Year Scope 1 emissions CO2e (MT) Scope 2 emissions CO2e (MT) Total CO2e (MT) Activity Description Fuel used in power generation and Startup oil consumption Import Power 2013 - 14 680562.03 3.97 680565.9 2014 - 15 589323.12 24.47 589347.6 2015 - 16 654254.37 11.16 654265.5 2016 - 17 613818.85 38.90 613857.7
Activity Data Emission Factor Tonnes
Emission (t) Global Warming Potential (GWP) Carbon Dioxide Equivalent (CO2e) of Emissions X = X =
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0.00 0.20 0.40 0.60 0.80 1.00 1.20 1.40 1.60 1.80 2.00
1.75 0.00 1.84 0.00 1.70 0.00 1.61 0.00
1.12 1.14 1.16 1.18 1.2 1.22 1.24 1.26 Baseline 2014-15 2015-16 2016-17
1.26 1.26 1.23 1.17 Baseline 2014-15 2015-16 2016-17
Green House Gas Emissions Intensity (CO2e / MWh) Reduction GtG Energy Consumption under Iron & Steel Sector (Toe / MT) Reduction
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8.05 % 7.14 %
: Scope-1 Emissions : Scope-2 Emissions
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Way of Energy Effectiveness:
Ensuring quality of raw materials Proper blending of raw materials Ensuring 100 % equipment availability Procurement of energy efficient products Maintaining the power quality and Power Factor Energy conservation projects and management action plans Reducing the idle running of crushers, conveyors and other equipments Efficient operation of plants in accordance with the documented criteria Systematic approach with energy management system (ISO 50001 : 2011)
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NBVL follows PDCA methodology :
Identifying the Legal and Other Requirements Conducting energy Review / Audit (Internal / External) Identifying & prioritizing the Opportunities for Improvement Establishing the Baseline, Identifying the EnPI Establishing the Objectives and Targets Establishing the Action Plans Ensuring the Competency of People & creating awareness Establishing and Communicating the Operational Criteria for effective and efficient plant operation Procurement of Energy Efficient Products Maintaining The required Documents Monitoring the Key characteristics Evaluation Of Legal Compliances Conducting regular Internal Audits Identifying potential non conformities & taking C-CAPA Ongoing Energy Review by functional chiefs EnMS Review by management representative Taking decisions for Energy performance improvement Continual Improvement
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3240 3260 3280 3300 3320 3340 3360 3380 3400 Baseline 14-15 15-16 16-17
3399 3399 3378 3299
2860 2880 2900 2920 2940 2960 2980 3000 3020 3040 3060 Baseline 14-15 15-16 16-17
3049.6 3049.6 2985.7 2931.7
90 MW CPP Net Heat Rate (kCal / kWh) reduction 90 MW CPP Gross Heat Rate (kCal / kWh) reduction 2.94 % 3.86 %
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10 10 11 11 12 12 Baseline 14-15 15-16 16-17
10.28 10.28 11.62 11.14
0.80 0.84 0.88 0.92 0.96 1.00 Baseline 14-15 15-16 16-17
0.98 0.98 0.91 0.86
90 MW CPP % Auxiliary Consumption 90 MW Specific Coal Consumption (Kg / kWh) 12.2 %
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3200 3300 3400 PAT Target 16-17
3399 3299
Comparison of Net Heat Rate with PAT Target
Source of National Benchmark: From the data of 1st and 2nd prize winners of BEE National Energy Award 2014 -15 PAT Target: CPP PAT Target was derived from the combined GtG PAT target of NBVL-DKL under Iron & Steel sector
Comparison with nearest competitors and National Benchmark
2.94 %
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Utilizing the day light by Providing Double glazed transparent sheet Performance evaluation of Air Preheater and replacing the damaged tubes Upgrading the Plant lighting with LED lights Changing of bed ash conveying system operation to probe mode instead of timer mode Providing the VFD to one of the CEP in Unit-2 Application of Corrocoat coating to the internals of CWP-1 in Unit-2
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Modification of ESP Hopper Heater area Innovative project-1
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Implemented In 2016-17 Annual savings 0.0098 MU Investment (Rs.) 0.0245 Million GHG Reduction 16.66 Co2e
Description of the Project : In order to maintain the ESP hopper temperature the ESPs of Unit-2 were provided with Hopper Heaters. As the installed area of ESP hopper heaters was exposed to atmosphere the heaters are remaining in ON continuously. Hence the running hours was more and consuming more energy Innovation: A study was conducted and to minimise the heat loss from the hopper heaters area it is decided to provide thermal insulation around the heaters and the same is implemented
Providing Glass wool at ESP Hopper Heaters area ESP Hopper Heaters area with complete Insulation
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Providing Sacrificing Sleeves In Air Preheater Tubes Innovative project-2
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Implemented In 2014-15 Annual savings 0.343 MU Investment (Rs.) 0.03 Million GHG Reduction 583.1 Co2e
Description of the Project : For preheating combustion air, Air pre- heaters are used & due to velocity of the flue gas the APH tubes are eroding. This tube erosion leads to thinning & ultimately results in tube failure, reduces the APH performance & over loads the ID fan. Repairing of eroded tubes involves more time & require long Boiler down time Innovation: A study was conducted and APH entry and exit area pipes are identified as significant eroded areas and it is decided to provide self sacrificing ferrules to avoid the erosion of parent tubes, the same is implemented
APH tubes without sleeves APH tubes with sleeves
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Sleeve
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Utilizing existing Unit-1 ID fan Old VFD, for chilled water pump
VAM Implemented in : 2016-17 Redesigning the Ash silo dewatering pumping system near Fly ash silo in Unit-2 Implemented in : 2015-16 Conserving AHP Compressor energy by changing the bed ash conveying time in Unit-2 Implemented in : 2016-17 Switching off the hopper heaters of ESP 1st field during normal
condition Implemented in : 2014-15
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Annual savings 0.28 MU Cost Savings (Rs.) 0.77 Million
Benefits achieved by implementing the above projects:
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Reducing the running hours of CT fans in Unit-1, during part load
Implemented in : 2014-15 Utilizing existing unused bed ash cooler fan VFD for Clarifier pump -1 (30 kW) Implemented in : 2013-14 Fine-tuning of VFD % of CW Pumps in Unit-1 (30 MW CPP), during single boiler operation Implemented in : 2014-15 Reducing the running hours of packaged AC units by improving the VAM performance Implemented in : 2013-14
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Annual savings 0.78 MU Cost Savings (Rs.) 2.03 Million
Benefits achieved by implementing the above projects:
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Normalizing the sp. steam consumption, Vacuum & heat rate of U-2 by improving the CW quality & arresting the leakage from TG bottom casing
Implemented in : 2016-17 Evaluating the performance of LP Heaters in Unit-2 &
replacing of damaged
tube bundles Implemented in : 2015-16
Conducting insulation
survey & fixing the identified damaged insulated areas in Unit-2 Implemented in : 2016-17 Evaluating the performance of HP Heater-1 in Unit-2 and Plugging
leakage tubes Implemented in : 2014-15
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Annual coal savings 24975 MT Cost Savings (Rs.) 50.61 Million
Benefits achieved by implementing the above projects:
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Measures taken for reducing the Plant lighting consumption:
Replacing the 27 W, T5 tube lights with 18 W LED lights Replacing 250 W flood lights with 45 W LED lights Replacing the 85 W street lights with 45 W LED lights Replacing of 400 W HPSV lamps with 200 W induction lights
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Annual savings 0.05 MU Investment (Rs.) 0.13 Million
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Measures taken for reducing the compressor power consumption:
Changing the bed ash conveying time and increasing vessel pressure of bed ash conveying system in Unit-2 Utilizing Trans vector nozzles for cleaning of silo vent filter bags Optimizing the compressed air flow for Boilers Bed thermocouples Utilizing FD fan discharge air instead of compressed air for bearing cooling in Power Plant Optimizing the Compressed air consumption in Bed Ash System in Unit-2 (By blocking 5 nos. of orifice plate holes & 44 nos. of air tapings taken from density stabilizer)
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Objectives of Water Management:
Reducing the Specific Raw Water Consumption Reducing the Per Capita Water Consumption Reducing the Generation of Effluent Reusing & Recycling of Waste Water Harvesting the Rain Water Sustaining Zero Liquid Discharge Procuring Water Efficient Products Creating Awareness among the Employees
0.5 1 1.5 2 2.5 3 3.5 4 2014-15 2015-16 2016-17
3.6 3.4 2.91
19.16 %
90 MW Sp. Raw Water Consumption (Liter / kWh)
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NBVL believes that advances in technology are necessary to reduce greenhouse gas emissions, so the following technology pathways are adopted by NBVL to reduce greenhouse gas emissions Replacing conventional AC units with 175 TR VAM Installing 100 m3/day Sewage Treatment Plant using Bio- digester and Phytorid Technology Providing intelligent flow controller in Compressed air line Utilizing Portable Oil purification machine for superfluous purification of Turbine oil
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The sun provides a tremendous resource for generating clean and sustainable electricity without toxic pollution or global warming emissions Recognizing the importance of solar energy, NBV harnessing solar energy in following ways: Installing solar water heaters at guest house and Bachelor hostel Utilising passive sun lighting at applicable areas in the plant Installation of NoriKool double glazed transparent sheet Construction of office building with Eco Friendly lighting
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NBV believes that waste prevention, reusing and recycling are important practices to reduce greenhouse gas (GHG) emissions, so following initiatives were taken in waste prevention and recycling Utilizing coal washery rejects, Extracted coal fines from coal yard discharge water and rejected coal fines from FAP Utilizing slag and fly ash in manufacturing of fly ash brick Vermiculture Programme by using canteen and colony waste Recycling and Reusing the waste water Reusing the bed ash as bed material after proper sieving Reusing the waste Turbine Lube Oil and Transformer oil for mud gun preparation in Furnace Reusing the damaged conveyor belts after reconditioning
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Objectives of Supply Chain Management:
Creating Awareness among the Vendors, Associates and Equipment suppliers Evaluating the vendors and suppliers on the basis of Energy and Environmental performance Defining and documenting the purchasing specifications of Energy Efficient and Eco friendly products Procuring the Energy Efficient and Eco friendly Green products and materials Procuring the materials / Equipments which have low environmental impact Providing the required inputs / Services to vendors, associates and suppliers Learning about new energy efficient and Eco friendly green products through external knowledge sharing sessions
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Replacing of D-50 dozer with D-80 dozer for coal compacting Name of vendor : M/S Samal Builders
Using cycle rickshaw
for collection
scrap from shop floor in place of tractor Name of Vendor: M/S B Ramana Replacing
Conventional Tube lights with EE lights at contract workers colony Name of vendor : Related Vendors Utilizing Portable sweeping machine in place
compressed air at Coal Handling Plant Name of Vendor: M/S Maa Bhavani
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Creating awareness, Distributing Energy Efficient lights, Providing sweeping Machine Type of inputs / projects provided:
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Replacing of 3 ph. Jet cleaning machine with 1 ph. small jet machine Name of vendor : M/S Utsab Samal Replacement
Existing welding transformers with welding rectifiers Name of vendor :
Replacing the petrol
weed cutter with Electric
weed cutter Name of vendor : M/S B Ramana Providing monorail for PA Fan motor lifting instead of using Hydra Name of vendor : Precision Engineers
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Creating awareness, Providing weed cutter, sweeping machine, quality power and required technical assistance Type of inputs / projects provided:
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EnMS Structure: NBVL-CPP has formed a team for implementation of EnMS, the team under the guidance of MR and Designated Energy manager will work for resource conservation, implementation of projects and action plans
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V Rama Krishna – Head - PP
S K Dash B Padhi M Gadnayak A P Singh D B Lalla P Maharana Shop Floor / Workmen Representatives S K Nanda M B Rao N Swain C Pradhan M R Bhutia R K Sahoo B J Rao Certified Energy Manager C Thakur Certified Energy Auditor M K Patra Certified EnMS lead Auditor / MR S K Nanda Certified Energy Auditor N SK SK Rao Certified EnMS lead Auditor A P Singh Certified Energy Auditor M K Patra Chief- TG (O&M) B J Rao Chief-Boiler (O&M) K Srinivasa Rao Chief-E&I (O&M) N Prabhakar Chief - Utility
Y Pattanaik– Unit Head
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We believe that employees / workers involvement is important to improve the energy efficiency, so we are creating an environment for the Employees and Workers to involve in the EnMS activities
RESCON suggestion scheme (RSS): We invite Resource conservation suggestions from all the employees, Contract workers and vendors Internal Energy Audit: EnMS team will conduct the internal energy audit to identify the opportunities Knowledge Sharing: Conducting internal training classes and knowledge sharing sessions Rewarding the performance : Rewarding performance of Employee / Worker on the eve of Energy conservation day celebrations
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S. no Title Of the Project Source of Idea Year Status 1 Replacing of conventional tube lights with T5 lights Electrician 13-14 Completed 2 Utilization of FD fan discharge air instead of compressed air for self- cooling of bearing Workmen 14-15 Completed 3 Replacing the 22 kW silo pump with existing old 15 kW pump at Ash settling pit near ash silos Mechanica l Fitter 15-16 Completed 4 Changing of bed ash conveying system operation from timer mode to probe mode in Unit-2 Boiler 2nd class
16-17 Under Progress
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: 9
: 8
: 1
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S. no Title Of the Project Source of Idea Year Status 1 Replacing of 54 nos. of 250 W MH lamps with 85 W CFL Supervisor 13-14 Completed 2 Switching off of first field ESP hopper heaters during normal
Engineer 14-15 Completed 3 Providing window opening at BFP area in U-2 for utilizing day light Engineer 15-17 Under Progress 4 Modification
ESP Hopper Heater area and providing thermal insulation Supervisor 16-17 Completed
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Improving awareness through internal training : Conducting Internal training classes to all employees and contract workers Display of awareness posters: Display of energy policy, resource conservation and GHG awareness posters with in the plant for immediate attention Showing the external presentations to core team: Showing the presentations down loaded from different forums to create the awareness among the core team members Providing Training on SEU and its Variables: Identification of significant energy uses and providing awareness training to the concerned on the variables & controls affecting the SEU Deputing the staff to External Seminars: Improving the knowledge by deputing the employees for external training classes /seminars conducted by BEE, CII,TERI, BSI etc… Utilizing the whatsApp for sharing the Tips: Sharing the energy conservation tips and best practices through “whatsApp”
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Installation of Energy meters / Flow meters: Energy meters / Flow meters were installed at preferred points of consumption & for all the identified Significant energy uses Utilizing Portable Measuring Instruments: Utilizing portable instruments like Power Quality analyzer and Thermal imager for condition monitoring of equipments Logging the consumption data in SAP: Energy consumption in plant is logged daily in SAP, reviewed by Section Heads and appropriate action taken Monitoring of Energy performance indicators , Variables & Controls: EnPI, Variables & Control were reviewed by departmental chiefs and appropriate action on significant deviation will be taken Reviewing the Status of Action Plants, Objectives & Targets : Review of area wise Specific energy consumption, status of energy objectives & targets and Energy management action plans
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Submitting of Energy performance report to top management: Daily, monthly and annual performance reports are submitted to top management for information and necessary review Submitting the Form-1 to BEE: Details of information regarding total energy consumed ( FORM - I ) submitted to BEE Submitting the monthly returns to CEIG: A Statement indicating the monthly self-consumption details is submitted to CEIG - Odisha NBVL has installed Stack gas analyzer for monitoring of indirect greenhouse gases and the analyzers are connected to PCB server One real time display board is provided at the Plant main gate for the Public
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Monitoring of Indirect Green House Gases:
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The operating facility of Nava Bharat group have been certified with following Accreditations & Certificates for it’s constant endeavor as an Environmentally responsible corporate citizen & Strong believer of Corporate Social Responsibility ISO 9001 for adhering to stringent international quality norms ISO 14001 for adhering to environmental management standards OHSAS 18001 for adhering to stringent Occupational health and safety management system ISO 50001 for adhering to stringent Energy management system
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ISO 9001 ISO 14001 ISO 18001 ISO 50001
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Non-Conformity : An energy monitoring and measurement equipment for Compressors,
CHP and other places which are the key characteristics of its operation that determine energy performance have not been put in place
Corrective and Preventive Action: Providing suitable measuring instruments and
monitoring the energy performance of all identified significant energy uses
Non-Conformity : The findings of the internal audits though are good and focused on the
energy performance, the closure of these non conformities are based on corrections and not
Corrective and Preventive Action: Refresher training was provided on Auditing
process, identification NC's/Observation and subsequent actions to be taken for closure & verification of effectiveness Minor Non-conformities raised by EnMS External Auditor in last two assessments:
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Power Plant EnMS Management Review Format
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Energy Conservation Opportunity Identified and Management Action Plan (ECOMAP) Format
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Installation of Oil traps: Installation of Oil traps at LDO pump house , coal stacking system (CSS) , gate-5 area and Unit-3 GT yard Installation
dust extraction system: Erection and commissioning of dust extraction system at Unit-2 CHP secondary crusher house Installation of Ammonia dosing system: Installation of Ammonia dosing system in both the ESP’s of Unit-2 to reduce stack emissions Providing Water Spray System: Providing and enhancing Water Spray System for fugitive dust suppression at applicable areas Installation of Ambient Air Quality Monitoring Stations: Erection of 3 no of Ambient Air Quality Monitoring Stations and its RT-DAS Installation of On-Line Effluent Monitoring System: Installation of
On-Line Effluent Monitoring System and real time data transmission to PCB server
Providing Atomizing water spray nozzles at ash silos: Providing
Atomizing water spray nozzles at fly ash and coarse ash Silos
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Trees remove carbon dioxide from the atmosphere through the natural process of photosynthesis Hence NBVL taken a initiative towards plantation & development of green belt in and around the Plant area, Peripheral villages and development of social forestry No. of trees planted so far : 57767 Survival percentage : 96.5 %
NBVL Nursery Sapling Distribution to Employees
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Plantation With in the Fence Plantation Beyond the Fence
Plantation in 42 Acres of Land-DKL
Plantation At Balanda Ash Pond Plantation At Nimidha Ash Pond Plantation By MP at Balanda Green Belt In and Around the Plant Floral Plants with in the Plant
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Migrating Birds
Migrating Birds
Employees Quiz Competition Inter Plant Knowledge Exchange Drawing Competition in School
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Group Photo with School Children's Drawing Competition (Colony Kids) Prize Distribution to Employees Prize Distribution to Children's Rewarding Employee Contribution
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Debate Competition
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Education: Providing Grant Aid, Library books , Play and Lab equipments to Brahmani Public School Donating Furniture and Distribution Of Blankets to Sibapur sevasram students Construction of boundary wall to Government and private schools Development of Play ground and Construction of Toilets in near by schools Health: Conducting Rural Health , Free Diabetic , Eye Checking , Dental and Blood Donation Camps Construction of community health center Livelihood: Plantation of Medicinal plants , Construction of Drains, Installation of Bore well, Providing Street Lights and Supply of Fly Ash Bricks to villagers and Schools
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We make constant efforts for development of communities around our plant and our CSR initiatives focus on Education, Health and Livelihood
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Pollution Control Excellence Award By Odisha SPCB for 2007 Prakruthi Mithra award by Odisha Forest and Environ Department for 2011 National award as Water Efficient unit by CII for FY 2011 - 12 National award as Water Excellent unit by CII for FY 2012 - 13 Pollution Control Appreciation Award By Odisha State PCB for 2013 National award as Energy Efficient unit by CII for FY 2013-14 (General Category) Pollution Control Excellence Award By Odisha SPCB for 2015 National award as Energy Excellent unit by CII for FY 2015-16 (Metal Category)
Rewards In the Field of Environment and Resource Conservation
NBVL has won numerous Awards from prestigious professional bodies & state government for its performance in energy management, water management, environment protection, safety
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State Safety award by Odisha –Director of Factories & Boilers for the year 2007 State Safety award by Odisha –Director of Factories & Boilers for the year 2008 State Safety award by Odisha –Director of Factories & Boilers for the year 2009 Best Performance in Safety & Environment Management for the year 2011 Kalinga state Safety Award in power category for 2012 Best Performance in Safety & Environment Management for the year 2012 Winner of First prize in Longest Accident free period for the year 2012 Best Performance in Safety & Environment Management for the year 2013 Winner of Second prize in Longest Accident free period for the year 2013
Rewards In the Field of Safety, Health and Environment
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Water Conservation Zero Accident Energy Conservation Eco Friendly