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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 1
2
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
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
3
4
UNIT-1 COD : 01st April 2012
UNIT-2 COD : 15th June 2012
1. COMPANY PROFILE
Boiler Area
PLANT OVERVIEW
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
6
2. PROCESS FLOW DIAGRAM
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
8
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
0
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
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
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
11
12
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
Lube oil cooler for T-BFP
Working oil 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
Lube oil cooler for T-BFP
Working oil 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)
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
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
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
ENERGY CONSERVATION COAL HANDLING
SYSTEM
19
1.79
1.14 1.05
0
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 ?
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
ENERGY CONSERVATION IN ASH HANDLING
SYSTEM
21
13.6
10.19 9.34
0
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
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
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)
23
6. FUTURE ENCON PROJECTS – NEXT 3 YEARS
1,50,000
MKCAL
6.92 MU
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
25
ISO 50001:2011 CERTIFICATE & ENERGY POLICY
26
Efficiency Monitoring
Parameters
Heat Rate
APC
Vacuum
Make Up
Temp/Pressure
Testing
Online & offline testing
of 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
27
ENERGY MANAGEMENT SYSTEM
28
ENERGY MANAGEMENT SYSTEM
29
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
of 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 SYSTEMPrevious 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
MISCELLANEOUSAUXILIARIES
OTHERS &TRANSFORMER LOSSES
OUR BELIEF … ENERGY CONSERVATION.
A TEAM EFFORT …….
30
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
31
GLIMPSE OF ISO 50001 AWARENESS TRAININGS
ISO 50001 Audit
Rating 4 from 3
by DNV in just 1
year
32
• 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
• 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- 365*500 units * 1 Kwh = 0.47 MU
33
8. EFFICIENT UTILIZATION OF RENEWABLE
ENERGY
34
2967 MT / Year
CO2 (MT) sequestered in Green Belt at EPGL
84 Hectare
Green Belt
9. ENVIRONMENTAL PROJECTS FOR CARBON
EMISSION REDUCTION
35
EPGL has started experimenting plantation
of sturdy species of Date Palm around it’s
cooling tower which will withstand impact
of 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
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
*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
37
PRODUCTIVE UTILIZATION OF WASTE
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
operator to start as per requirement
0.96 50
1.64 85.3
Our Coal handling Contractor visited EPGL site and replicated various ENCON
Measures.
38
Essar Power Gujarat Ltd. 39
CORPORATE SOCIAL RESPONSIBILITY
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
40
11. WINNING AWARDS REGULARLY…..
(TOTAL 9 AWARDS IN YEAR 2016-17)
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
41
WINNING AWARDS REGULARLY……….
42
AWARD FOR ENERGY EXCELLENCE 2016…..
Let us Not be
Conservative in Energy Conservation
AGGRESIVE APPROACH
REAPS BETTER FRUITS
Articles in Newspaper
Environment Focus
Safety Awards
Recognition at Power Gen
IMS and ISO Certification
CEA Recognized Learning Center
Foreign Delegation
visits
CII Awards
O&M Meet
