Energy Efficiency Management TATA POWER Trombay …greenbusinesscentre.com/energyaward2017presentations/Power/CII... · Energy Efficiency Management – TATA POWER Trombay Unit-7

Energy Efficiency Management –

TATA POWER Trombay Unit-7 18th National Energy Efficient Management Award 2017

30th Aug – 1st Sept 2017, CII- Hyderabad

1

"Cheap and abundant electric power is

one of the basic ingredients for the

economic progress of a city, a state or a

country"

Mr. Jamsetji Nusserwanji Tata ( 3rd March 1839 - 19th May 1904 )

Vision of our founder – Mr. Jamsetji Tata

2

India's largest integrated power company with

presence across the entire value chain –fuel sourcing,

fuel logistics, generation, transmission, distribution,

power trading, power services (O & M), solar panel

manufacturing.

Founded in 1906 to supply power to Mumbai

»First hydro plant commissioned in 1915 at Khopoli

»Set up thermal power plants in Mumbai in 1950s

Expanded in India after private sector reforms

in 1990s

Thrust on renewable including hydro, wind,

solar and geothermal

Successful Public Private Partnerships in

generation, transmission and distribution

The Tata Power Company Limited

Completed Centenary Year

Solar Wind Hydro Waste Heat

936 MW 1140 MW 693 MW 375 MW

3

Total Installed Generation Capacity

10466 MW a

Thermal Generation Capacity

7322 MW

Green Generation Capacity

3144 MW 30 % of the total

installed Generation capacity

Technology Pioneers in Indian Power Industry

First

150

MW

thermal

unit

First

500 MW

thermal

unit

First

gas

insulated

switch

gear

Computerized

grid control

and energy

management

system

220 kV

transmi

ssion

lines in

four

circuit

towers

220 kV

Cable

Transmission

Network Flue Gas

De-

sulphurisation

plant using

sea water

SCADA

and

Fiber Optic

ground wire

communication

Pump

storage unit

in the country

of 150 MW Capacity

First 800 MW

thermal unit Electricity to Mumbai, way back in 1915

Trombay

4

Trombay Thermal Power Station

Trombay Operations

&

Specific Energy Consumption

5

Trombay: Present Generation Capacity

Established in 1956

Total Generation Capacity : 1430 MW

Unit Year Capacity

(MW) Fuel Used

Unit 5 1984 500 Coal, Oil & Gas

Unit 6 1990 500 Oil & Gas

Unit 7

(CCPP) 1993-94

120+60 =

180 Gas

Unit 8 2009 250 Coal, Oil

6

Technology Adopters in Energy Management

Key Energy

Management Initiatives

At Trombay

7

Specific Energy Consumption for last Four Years

8

1998

1968

2136

1996

2052

2019

2194

2056

94% 94% 80% 91%

40%

50%

60%

70%

80%

90%

100%

1800

1900

2000

2100

2200

2300

2400

2013-2014 2014-2015 2015-2016 2016-2017

GH

R &

NH

R K

cal/

kwh

Unit Gross Heat Rate Unit Net Heat Rate Loading Factor

Load

ing

Fact

or

% Open Cycle

operation 1023 Hrs.

Benchmarking

9

Benchmarking Parameters ( 180 MW UNIT 7)

On Monthly Basis best achieved Heat Rate- 1922.3 Kcal/KWH- Jan 12

10

HEAT RATE UoM

Best Performance

NTPC (Faridabad) Tata Power Trombay

Unit 7

Actual Heat Rate Kcal/kwh 1915 1960

Deviation in Heat rate Kcal/kwh 45

Auxiliary Power

Consumption UoM

Best Performance

NTPC (Faridabad) Tata Power Trombay

Unit 7

Actual Auxiliary Consumption

% 2.3 2.3

Deviation in Auxiliary

Consumption % -

Energy Saving Projects

11

Energy Saving Projects : FY14 and FY 15

12

Energy Saving Projects Implemented

Annual Savings Rs Million

Investment. Rs Million

1.4 0.5

0.3 1.3

38.4 2.5

5.1 20

Total 45.2 24.3

Replacement of Fencing Lights with LED lights

Attending Flue gas leakages in HRSG

Replacement of OTC thermocouple

Coro coating of CW Pumps

Energy Saving Projects : FY16 and FY 17

13

Energy Saving Projects Implemented

Savings Rs Million

Investment. Rs Million

7.60 Nil

2.84 Nil

0.008 3.12

- Nil

Total 10.448 3.12

Achieving higher generation on Diffusion

mode at low gas supply pressure (Instead of

lower generation on Premix mode)

Modification in Gas Turbine SADC &

subsequently increasing the GT exhaust

temperature (OTC) set point

Installation of VFD for LP BFP (13 Days Saving)

Energy monitoring system of lighting and ACs

Energy Saving Projects Planned In Next Three Years

14

Energy Saving Projects Planned

Savings

Rs Million Investment. Rs Million

4.75 1.5

1.41 5.86

0.07 0.1

3.34 9.0

Total 9.57 16.46

Reduction of HRSG Exhaust Loss by

• Diverter Seal replacement

• HRSG Insulation repair

Installation of VFD for CEP

Installation of VFD for HMP

Overhauling of HPBFP ARC valve

Idea description : Heat rate Saving during low fuel gas supply pressure, by higher

Operating at higher Load on diffusion mode instead of reduced generation on Premix mode.

Before: Unit was operated on lower load during low gas supply Pressure.

After : Unit was operated on higher load during low gas supply Pressure on diffusion load.

Energy Saving Project :Achieving higher generation on Diffusion mode

at low gas supply pressure

KPI impact Low Operating Load & High Heat Rate

KPI impacted Savings (Rs. Million) Investment (Rs. Million) Payback

Gross Heat Rate 14.29* NIL NA

*- Saving Calculated for FY16 & FY17

15

Energy Saving Project :Achieving higher generation on

Diffusion mode at low gas supply pressure High Gen due to

Premix to

Diffusion

Changeover with

low gas Press

Premix mode of Operation

with low gas Press

Low Generation on

Premix Mode

16

Energy Saving Project :Achieving higher generation on

Diffusion mode at low gas supply pressure

UOM FY 16 FY 17

• Total Running Hrs on Diffusion Mode 70 116

• No of Days on Diffusion Mode 1681 2785

• Total Mkcal Saved 5575 9236

• Calorific Value of Gas for FY 16 13 13.17

• Total MT saved 425 702

• Rs/Mkcal for FY16 1201 822

• Total Saving in Rs Million 6.69 7.60

• FY16 Gross Gen 1180 1413

• Annual GHR Reduction 4.73 6.54

UoM MU MU MU % MT Mkcal/MT Mkcal Kcal/Kwh Kg/MWH MU DATE GTG Gen STG Gen TOTAL PLF GAS Cons CV Heat HR SGC APC

24-09-14 2.237 1.443 3.68 85.2% 561.9 13.098 7359.5 1999.9 152.68 0.09

26-09-14 2.480 1.517 3.997 92.5% 603.5 13.102 7907.9 1978.5 151.00 0.086

27-09-14 2.411 1.503 3.914 90.6% 591.8 13.101 7753.9 1981.1 151.21 0.085 1

Excess Gen Excess Heat ∆ HR Saved Mkcal SGC reduction

0.317 548.39 21.41 85.562 1.69

0.234 394.47 18.78 73.501 1.47

For 1 Day 20.29 79.594 1.60

17

KPI impacted Savings (Rs. Million) Investment (Rs. Million) Payback Period Months

Auxiliary Consumption 0.229 0.312 16

Idea description : Auxiliary Consumption Saving by Installing VFD for LP BFP.

Before: LPBFP was running with constant speed motor with Current 83.2 Amp (415 Volt)

After : LPBFP was running with VFD which drawing current 65 Amp (415 Volt)

Energy Saving Project : Installation of VFD for LP BFP

KPI impact Auxiliary Consumption

18

Energy Saving Project : Installation of VFD for LP BFP

(MP under ISO 50001)

19

Project Results

Load STG (MW)

RPM Frequency

(Hz)

CV Opening

(%)

Pressure (bar)

I/P Voltage (Volts)

I/P Current (Amp)

I/P KW

PRE 65 2959 50.0 47% 27 423 83.2 57.7

POST 65 2700 45.8 60% 23.5 415 65.0 46.6

Calculations

• Power Saving 11.1 KW per hr.

This project got implemented in the month of March-17

• FY 17 Saving period 365 Days

• Energy saved in FY17 97236 Kwh

• Energy Rate as per Tariff Order 2.36 Rs/Kwh

• Total Savings/Annum 2.29 Rs. Lakhs

• Investment 3.12 Lakhs

• Payback Period 16 Months

Trombay Unit 7

Innovative Project

Modification in Gas Turbine SADC

& subsequent increase of GT

exhaust temp (OTC) set point

20

Low Operating Load & High Heat Rate

Idea description : 1) Reducing NOx emission and 2) Subsequently Increasing GT

exhaust temperature (OTC) set point resulting in increased STG generation.

Before: 1) Oil firing circuits were de-commissioned in 2013 but SADC was still in operation

which contributing to bypass air flow. 2) Outlet temperature calculation for OTC was

derived from MBA thermocouples.

After : 1) Bypass air openings were closed and locked. 2) Outlet temperature calculation for

OTC is derived from mainly MBR thermocouples with minor correction from MBA T/C’s.

Energy Saving Project :Modification in Gas Turbine SADC &

subsequent increase of GT exhaust temp (OTC) set point

Heat Rate & APC KPI impact

KPI impacted Savings (Rs. Million) Investment (Rs. Million) Payback

Gross Heat Rate 3.04* NIL NA

*Saving Calculated for FY16 & FY17

21

Energy Saving Project : Modification in Gas Turbine SADC &


Lowered NOx emissions

Premix mode Diffusion mode Before: 117MW--> 27 ppm. Before: 115MW--> 140 ppm.

After 117MW--> 13ppm After 115MW--> 125ppm

NOx not to exceed 150

ppm (MPCB Norm)

22

BYPASS AIR PATH BELOW EACH BURNER SADC WINDOWS BLANKED (CC- INT VIEW)



SLOW RESPONSE MBA THERMOCOUPLE FAST RESPONSE MBR THERMOCOUPLE

Benefits:

• Increase in STG Generation with same GTG Generation because of release of higher

temperature at GT exhaust in view of fast response T/C’s available at MBR plane

• More stable temperature profile as reading at MBR location as compared to MBA

location.

• Stable operation and Reduction in maintenance

23



MBR Correction

BEFORE

AFTER

24



UOM MUS MT Mkcal/MT MKCAL Kcal/KWh

PARAMETER GTG GEN STG GEN TOTAL Gas

cons/day CV Heat Heat Rate

POST 20-10-16 2.837 1.610 4.447 656 13.175 8638 1943 PRE 29-05-13 2.838 1.596 4.434 658 13.157 8659 1953

Excess Gen -0.001 0.014 Heat Rate Improvement 10 Mkcal Saved for the day 46.16

POST 15-10-16 2.800 1.610 4.409 651 13.18 8575 1945 PRE 18-05-13 2.800 1.565 4.365 649 13.16 8532 1955

Excess Gen 0.000 0.045 Heat Rate Improvement 10 Mkcal Saved for the day 43.55

POST 19-10-16 2.856 1.622 4.478 658 13.18 8673 1937 PRE 13-05-13 2.856 1.585 4.441 660 13.13 8662 1950

Excess Gen 0.000 0.037 Heat Rate Improvement 13 Mkcal Saved for the day 60.34

FY 17

Wt. Avg MkCal Saved per day 50.06 Mkcal Saved per day 50.06

No of days having PLF greater than 102% 69

Total Mkcal Saved 3454 Calorific Value of Gas for FY 17 13.17

Total MT saved 262 Rs/Mkcal for FY17 822

Total Saving in Rs Million 2.84

FY17 Gross Gen 1413

Annual GHR Reduction 2.44

Zero Investment Innovative

Project

ENCON Methodology &

Involvement of All

26

Brain Storming Idea

Generation

Techno-Commercial Feasibility

Study

Idea Presentation &

review by Management

Budgeting & Planning

Procurement Implementation

of Idea

Fine Tuning &

Optimisation

Evaluation of the Results

Sharing & Reporting to Management

En-Con Methodology

27

How it all fits together……….

Vision Emotions Logic Result

28

Sr. No. Source of En-con Idea* Source Idea Originated in

FY**

Extent of

Manpower

Involved*

Progress of

Implementation

1 Replacement of OTC thermocouple

Discussions

with

OEM

2013-14

02 Engineers,

01 Supervisor

02 Workmen

Successfully

Implemented

2 Coro-coating of Unit-7, 6.6 KV

Cooling Water pumps at jetty

Horizontal

Deployment of

idea

2013-14

02 Engineers

01 Supervisor

08 Workmen

Successfully

Implemented

3 Achieving higher generation on Diffusion

mode at low gas supply pressure

Discussions

with

OEM

2015-16 04 Engineers Successfully

Implemented

4

Modification in Gas Turbine SADC &

subsequently increasing the GT exhaust

temperature (OTC) set point

Discussions

with

OEM

2015-16

02 Engineers

01 Supervisor

02 Workmen

Successfully

Implemented

5 Installation of VFD for LP BFP

MP ISO 50001

under Project

Sankalp

2016-17

02 Engineers,

01 Supervisor

02 Workmen

Successfully

Implemented

in FY17

6 Energy monitoring system of lighting and ACs MP ISO 50001 2016-17

02 Engineers,

01 Supervisor

Contractors

Successfully

Implemented

in FY17

Source of Idea Generation & Involvement of All

29

# Sources of Idea Generation: Audits, Brain Storming, Suggestion schemes/competitions, CFTs, Core Groups, Discussions with OEMs &

Periodic Reviews.

ISO 50001:2011 Certification

30

Certificate

Completed first

Surveillance Audit in

month of July-17

31

UNIT-7 Monitoring & Analysis

32

Online Monitoring : Auxiliary Power Consumption-(Replication

from other Units)

Mus % of APC

Date : 20-Jul-17 Mus % of APC CWP 0.0282 25.06%

CEP 0.0083 7.38%

0.070 62.09% HP BFP 0.0334 29.65%

FAA 0.00 0.00%

Mus 0.000 0.00%

% UST 7A 0.0069 6.13%

UST 7B 0.0047 4.21%

PLF % 0.015 13.26% SST 7A 0.0016 1.45%

TOTAL 4.383 101% SST 7B 0.0016 1.46%

GTG 2.830 98%

STG 1.553 108% 0.088 78.31% Miscellaneous 0.024 21.69%

% of Total Aux Consumption Excitation system 0.0033 2.96%Mus

"Energy Management System - Unit 7"

Major Auxiliaries

UNIT 7Auxiliary Consumption Environment

0.113

2.57%

415 V Auxiliaries

Generation (Mus)

TOTAL

IN House Prepared

33

Online Monitoring : AC & Lighting System of Plant

Trombay AC & Lighting Monitoring System

Date : 6-Aug-17

CHP 208

Station A Lighting 1296

Total Lighting load

Unit#5 AC Plant 0

10523

Unit#5 Plant Lighting 4346

Total AC & Lighting Load

Unit#6 Plant AC 9

14124

-


Unit#7 Plant AC 1528

Total AC Load Unit#7 Plant Lighting 455

3601

Unit#8 Plant AC 2064


For Unit-7

34

Online Monitoring : Unit-7 Instant Parameters- IN HOUSE

PREPARED

GTG MW STG MW TOTAL MW PREMIX DIFFUSION VACCUM barBack

Pressure Bar Make Up Kg/S

Gas Flow

M3/Hr

Gas Flow

TPH

SGC

MT/KWH

121 66 186 ON OFF -0.893 0.121 0.29 40582 29.7 153CWP-7A

Disc Press

CWP-7B Disc

Press

CONDENSER &

CW PUMPS

CW Inlet

Temp

CW Outlet

Temp

CW Temp

Diff

Condenser

DP Bar

Inlet Valve

Position %

Outlet Valve

Position %

Debris Filter

DP mbar

VP-1 Temp &

Status

VP-2 Temp &

StatusVaccum Bar

Compressor

Efficiency %1.89 0.01

TOP 27.9 37.8 9.9 0.93 98.7 73.4 103.5 43.2 36.1 -0.888CW Pump-

7A Current59.4

BOTTOM 28.3 38.2 9.9 0.89 99.3 68.3 97.0 ON ON -0.893CW Pump-

7B Current0.0

GAS Press CV

Position %

FG Supply

Pressure Bar

FG Pressure

After CV Bar

Bypass Stack

Temp

Damper

Position %

FG HRSG Inlet

Temp

FG HP Evap

I/L Temp

FG HP Evap

O/L Temp

FG LP Evap

I/L Temp

FG LP Evap

O/L Temp

FG HRSG

O/L Temp

CW Pump-

4A Current0

61 18.5 15.0 185 101 544 453 283 242 192 112CW Pump-

4B Current71

Compr Inlet

Pressure mbar

Compr Inlet

Temp

IGV Position

%

Compr Outlet

Pressure Bar

Compr Outlet

Temp

DP Comb

Chamber-L

mBar

DP Comb

Chamber-R

mBAr

Pressure RatioAir Flow

TPH

Intake DP

mBar

Colascre

Filter DP-1

mBar

Pre Filter

DP-2 mBar

Fine Filter

DP-3 mBar

920.7 28.8 92.0 9.34 340.9 175.8 179.1 10.14 1755 7.94 3.12 2.24 2.91

Hotwell Level

mm

CEP 7A

Current Amp

CEP 7B

Current Amp

CEP 7A

Strainer DP

Bar

CEP 7B

Strainer DP

Bar

CEP Discharge

Pressure Bar

CEP Discharge

Temp

CEP Discharge

Flow Kg/S

Discharge

Pressure After

CV %

CCWP-1

Status

CCWP-2

Status

CCWP-3

Status

CCWP-4

Status

1055 28 0 0.126 0.044 22.5 49.8 67.5 9.2 OFF ON OFF ON

Temp at CPH

I/L

Temp at CPH

O/L

FWT Level

mm

FWT

Pressure BarFWT Temp

LP Drum

Pressure Bar

LP Drum Sat

Temp

HP Drum

Pressure Bar

HP Drum Sat

Temp

Booster

Pump-1

Status

Booster

Pump-2

Status

Booster

Pump-3

Status

Booster

Pump-4

Status

50.7 164.2 1701 6.4 164.2 5.9 164.2 67.0 283.9 OFF ON OFF ON

LP-7A SpeedLP-7A

Current Amp

LP-7A

Discharge Pr

Bar

LP-7B SpeedLP-7B Current

Amp

LP-7B Discharge

Pr Bar

LP Header

Pressure Bar

LP Header

Temp

LP Header

Flow Kg/S

LP Steam

Press Ahead

ESV Bar

LP Steam

Flow Kg/S

LP Steam

Turbine

inlet temp

2618 68 23.6 32.8 1.7 21.0 21.2 162.4 12.0 5.8 11.7 214.7

HP-7A Current

Amp

HP-7A Disch

Pr Bar

HP-7A Leak

off Pr Bar

HP-7B

Current Amp

HP-7B Disch

Pr Bar

HP-7B Leak off

Pr Bar

HP Header

Pressure Bar

HP Header

Flow Kg/S

HP Eco-1 O/L

Temp

HP ECO-2 O/L

Pr Bar

HP ECO-2

O/L TempHP FCV 30% HP FCV 100%

0 5.0 0.4 130.8 115.7 9.4 115.7 53.3 168.4 110.1 271.3 1 8

HP Steam

Press before

DSH Bar

HP Steam

Temp before

DSH

HP Steam

Temp after

DSH

DESH Line

Flow Kg/Sec

Final SH

Temp

HP Steam

Pressure Ahead

ESV Bar

HP Steam

Flow Kg/S

HP steam

Temp before

Valve-1

HP steam

Temp before

Valve-2

HP Control

Valve-1

Position %

HP Control

Valve-2

Position %

IP Exhaust

Temp

HP FCV 100%

BYPASS

63.9 437.7 416.4 1.4 523.5 62.7 54.2 519.1 519.4 99.5 99.8 55.9 48

CW Pumps

HP Steam

GAS & FLUE

GAS

Compressor

CEP

FWT, LP Drum

& HP Drum

LPBFP & LP

Steam

HPBFP

21-07-17 12:39

90.8%

35

Online Monitoring : Unit-7 Performance Parameters

Comparison-IN HOUSE PREPARED

1-7-2017 29-7-2017

1h 22-7-2017 1-8-2017

PARAMETER UOM PRE POST DEVIATION

GTG LOAD MW 119.5 119.5 0.0

STG LOAD MW 64.9 67.7 2.8

TOTAL LOAD MW 184 187 2.9

Vaccum BAR -0.890 -0.924 -0.034

Back Pressure BAR 0.123 0.080 0.043

Compressor Inlet Pressure mBar 921 996 75

Compressor Inlet Temperature Deg C 27 28 1.0

Compressor Outlet Pressure Bar 9.16 9.19 0.02

Compressor Outlet Temperature Deg C 338 337 -1.07

Pressure Ratio 9.95 9.23 -0.72

Compressor Efficiency % 89.7% 86.6% -3.13%

Total Air Flow TPH 1740 1702 -38

Inlet Guide Vane Position % 86.2 81.6 -4.6

Combustion Chamber DP-L mBar 179 179 -0.5

Combustion Chamber DP-R mBar 179 183 4.0

Overall Intake DP across Filters mBar 9.43 3.76 -5.67

Coalescer Filter DP mBar 3.37 1.62 -1.76

Pre Filter DP mBar 2.61 1.05 -1.56

Fine Filter DP mBar 3.45 1.63 -1.82

'\\trombaypi\TR U7 GTG MW FINAL'>115

COMPRESSOR PARAMETER

1-7-2017 29-7-2017

1h 21-7-2017 1-8-2017


CW Inlet Temp Deg C 28.4 28.8 0.3

CW Outlet Temp Deg C 39.2 38.9 -0.3

CW Temp Difference Deg C 10.8 10.1 -0.6

Condenser DP MBAR 0.798 0.234 -0.6

CW Inlet Valve Position % 98.7 64.8 -33.8

CW Outlet Valve Position % 67.8 25.2 -42.7

Debris filter DP MBAR 100.6 85.3 -15.4

CW Inlet Temp Deg C 28.9 29.1 0.2

CW Outlet Temp Deg C 38.5 38.6 0.1

CW Temp Difference Deg C 9.67 9.51 -0.2

Condenser DP MBAR 0.758 0.550 -0.21

CW Inlet Valve Position % 99.3 65.1 -34.2

CW Outlet Valve Position % 64.6 31.0 -33.6

Debris filter DP MBAR 73.3 77.0 3.7

CWP-7A Discharge Pressure Bar 1.72 1.80 0.1

CWP-7ABDischarge Pressure Bar 1.72 1.78 0.1

CWP-7A Motor Current Amp 60.5 60.9 0.4

CWP-7B Motor Current Amp 59.7 60.7 1.0

'\\trombaypi\TR U7 GTG MW FINAL'>115

CONDENSER TOP SIDE

CONDENSER BOTTOM SIDE

CW PARAMETER

Gas Flow M3/HR 40295 39370 -925

Gas Flow TPH 29.4 28.7 -0.7

Specific Gas Consumption Kg/MWH 153 149 -3

Fuel Gas Supply Pressure BAR 22.6 18.0 -4.7

GAS PARAMETER

36

Online Monitoring : Unit-7 Performance Parameters

Comparison-IN HOUSE PREPARED

'\\trombaypi\TR U7 GTG MW FINAL'>115 1-7-2017 29-7-2017

1h 22-7-2017 1-8-2017


CEP-A Motor Current AMP 28.0 28.1 0.10

CEP-A Strainer DP mBar 0.126 0.129 0.00

CEP-B Motor Current AMP 23 22 -0.59

CEP-B Strainer DP mBar 0.043 0.056 0.01

Condensate Header Temperature Deg C 50.3 43.2 -7.02

Condensate Header Pressure Bar 22.5 22.7 0.15

Condensate Flow Kg/S 67.2 66.8 -0.44

Condensate Temp at CPH Inlet Deg C 51.1 44.1 -6.96

Condensate Temp at CPH Outlet Deg C 163.8 163.6 -0.21

Temp Gain Across CPH Deg C 112.7 119.4 6.75

Feed Water Tank Pressure BAR 6.32 6.26 -0.07

Feed Water Tank Temperature Deg C 164 163 -0.37

LPBFP-A Motor Current Amp 68 67 -0.60

LPBFP-A Discharge Pressure Bar 23.3 25.2 1.87

LPBFP-B Motor Current Amp 71 0 -71.39

LPBFP-B Discharge Pressure Bar 21.4 24.2 2.83

LP FW Header Temperature Deg C 162.1 161.2 -0.88

LP FW Header Pressure Bar 21.5 23.8 2.25

LP FW Flow Kg/S 12.0 12.0 0.06

LP Drum Pressure Bar 5.8 5.8 -0.03

LP Drum Saturation Temp Deg C 163.7 163.5 -0.20

LP Steam Flow Kg/S 11.7 11.5 -0.19

LP Steam Pressure BAR 5.5 5.5 -0.01

LP Steam Temperature Deg C 217.2 221.7 4.55

Temperature Gain Across LP SHtr Deg C 53.5 58.2 4.76

HOTWELL TO FWT

LP CIRCUIT

'\\trombaypi\TR U7 GTG MW FINAL'>115 1-7-2017 29-7-2017

1h 22-7-2017 1-8-2017


HPBFP-A Motor Current Amp 133 0 -133

HPBFP-A Discharge Pressure Bar 111.6 114.8 3.22

HPBFP-B Motor Current Amp 132 134 2.10

HPBFP-B Discharge Pressure Bar 115.6 115.2 -0.46

HP FW Header Temperature Deg C 166.9 166.6 -0.26

HP FW Header Pressure Bar 115.7 115.5 -0.21

HP FW Flow Kg/S 53.4 53.8 0.36

HP FW Temperature at ECO-2 Outlet Deg C 270.5 270.5 -0.01

HP FW Pressure at ECO-2 Outlet Deg C 110.0 110.0 -0.01

Temperature Gain Across ECO-1 & ECO-2 Deg C 103.6 103.9 0.25

HP Drum Pressure BAR 66.5 66.6 0.13

HP Drum Saturation Temp Deg C 283.4 283.5 0.11

Temperature Gain Across HP Evaporator Deg C 12.9 13.1 0.12

HP Steam Temperature at SH-1 O/L Deg C 437.7 438.2 0.52

Temperature Gain Across HP SH-1 Deg C 154.2 154.6 0.41

HP Steam Temperature at SH-2 I/L Deg C 401.5 404.3 2.82

HP Steam Temperature at SH-2 O/L Deg C 523.0 523.1 0.17

Temperature Gain Across HP SH-2 Deg C 121.5 118.8 -2.65

SH Spray Kg/S 1.53 1.46 -0.07

Temperature drop at DSH Station Deg C 36.2 33.9 -2.30

HP Steam Flow Kg/S 54.0 54.3 0.25

HP Steam Pressure BAR 62.2 62.4 0.15

HP Steam Temperature @ Boiler Outlet Deg C 523.0 523.1 0.2

HP Steam Temperature @ Turbine Inlet Deg C 518.8 519.0 0.2

HP CIRCUIT

37

Monthly Review

YTDFY18

ABPFY18

YearFY17

April May June July Aug Sept Oct Nov Dec Jan Feb Mar

YTD FY18 2351

FY 18 (Plan) 2370

FY 17 (Actual) 2337

FY 18 (Actual) 2314 2336 2348 2415

ABP FY 18 2365 2361 2359 2402 2379 2368 2367 2375 2378 2335 2380 2368

FY 17 2334 2348 2367 2370 2341 2352 2316 2323 2383 2241 2330 2301

2351 2370

2337

2000

2050

2100

2150

2200

2250

2300

2350

2400

2450

2500

2550

2600

KC

AL

/ K

WH

STATION HEAT RATE (KCAL /KWH)

38

Monthly Review

YTDFY18

ABPFY18

YearFY17

April May June July Aug Sept Oct Nov Dec Jan Feb Mar

YTD FY18 5.38%

FY 18 (Plan) 5.89%

FY 17 (Actual) 5.64%

FY 18 (Actual) 5.01% 5.33% 5.60% 5.67%

ABP FY 18 5.75% 5.51% 5.59% 6.33% 6.14% 5.95% 5.77% 5.91% 5.84% 5.99% 6.09% 5.95%

FY 17 5.7% 5.5% 5.5% 5.8% 5.7% 5.8% 5.5% 5.5% 5.6% 6.4% 5.9% 5.2%

5.38%

5.89%

5.64%

4.0%

4.3%

4.5%

4.8%

5.0%

5.3%

5.5%

5.8%

6.0%

6.3%

6.5%

6.8%

%

STATION AUXILIARY CONSUMPTION (%)

39

Eco Affection & Carbon Emission

Reduction projects

40

Reduction in Unit 7 Specific Make Up Water Consumption

Care For Environment- Resource Conservation (Water)

“Specific Water Consumption for Trombay Site for FY17: 0.216 M3/MWH

5.000

10.000

15.000

20.000

25.000

30.000

35.000

FY09 FY10 FY11 FY12 FY13 FY14 FY15 FY16 FY17

31.387

21.7

17.4

14.9

19.1

15.4

20.4 20.7

12.0

Specific Water Consumption M3/MU

41

Care for Environment : Water Management

Series of surface aerators are

placed in the discharge channel to

reduce the temperature of cooling

water.

Treated sewage is collected in storage

tanks from where it is pumped up to

coal berth and used for coal dust

suppression by using sprinkler system.

This has reduced consumption of

equivalent amount of fresh water.

42

Care For Environment- Renewable & Energy

Conservation Project

Usage of Light Pipes in Training Centre

Usage of LED Lights in Compound Wall

43

Use of Bottom Ash in

Landscape Garden and

Brick Making

Recycling of waste papers Oil Filters to Reduce

Generation of Waste Oil

Care For Environment- Waste Management

44

Use of Scrap Steel within the

plant


45

Before

After


• Construction of 4 Nos. of Beautiful Garden in place of un-used, scraped stored, jungle like area.

• Material Used-Bottom ash, Ash Clinkers, Old RCC precast slabs / tiles , Old structural steel is used to fix the gate for garden.

• Saving – 17.15 Lakhs.

46

Care For Environment- Waste Management (Place to

Store Oil Drums)

47

Before

After



Replacement of OLD AC sheet with new transparent sheet along with turbo ventilators in Materials Department

48

Hybrid Unit 1KW Solar wind mill

Solar Panels

Wind Turbine



Located at O & S building terrace

Tube lights ( 7 Nos of 40W ) sourced by the hybrid Unit

Knowledge adopted from FY 15 CII Award Innovative products

49

Care For Community : Renewable & Energy

Conservation Project in the Community

70 Solar lights ( MV-3 model- 11 W) have been installed in dark areas of communities of Trombay to

address safety of women

Installation of Solar Lights in the

Neighbouring Community

50

Waste Management

Bio-degradable waste for organic gardening in colony

• Awareness and training sessions for organic waste utilization

were arranged in colony

• Organic waste generated at colony was used for growing nutrient rich vegetables

• Chemical pesticide free vegetables

Awareness

Execution

Outcome

Re-Use of Bio-degradable Waste

51

Care For Community & Customers Energy conservation Awareness Program

Energy conservation campaign are done by Trombay Employees voluntarily at many Schools, Colleges, Housing Societies & Offices in Mumbai.

Science

Laboratory

at Chembur

Welfare

Marathi

School

Mobile Medical

Van

Tree

plantation

drive

Employee

Voluntary

Program

Energy

Conservation

and Electrical

Safety

52

53

Website : www.TATAPOWER.com

EMAIL ID : [email protected]

CONTACT NO : 9223501513

Documents

Energy Efficiency Management TATA POWER Trombay …greenbusinesscentre.com/energyaward2017presentations/Power/CII... · Energy Efficiency Management – TATA POWER Trombay Unit-7