ESSAR POWER GUJARAT LTD (EPGL), Dist : Dev Bhumi Dwarka

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Welcome to the CII17th National Award

for Excellence in

Energy Management - 2016

ESSAR POWER GUJARAT LTD (EPGL),Dist : Dev Bhumi Dwarka, Gujarat

1200 MW ( 2 X 600 MW ) THERMAL POWER PLANT

ISO 9001:2008 - 2014

ISO 14001:2004 - 2014

ISO 18001:2007 - 2014

ISO 50001 :2011 - 2016

INDEX

1. Company Profile - A Walk Through.

2. Young Entrant in Thermal Power Sector

3. Process Flow of EPGL Plant

4. Continual Reduction in SEC in last 4 yrs.

5. Our GOAL- SEC Near to Global Benchmark

6. EPGL Road Map Towards Excellence in Energy Mgmt. System

7. a) Energy Savings Projects : 2012-15 b) Energy Savings Projects :2015-16

8. Innovations in ENCON Projects in 2015-16

9. Efficient Utilization of Renewable Energy

10. a) Environmental Projects for Carbon Emission reduction.b) Productive Utilization of Waste

11. ENCON Projects from ISO 9001 & EMS 14001

12. Replication of ENCON BEST Practices

13. EPGL Journey towards Excellence

14. ENCON Projects -- Next 3 Years

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1. COMPANY PROFILE :ESSAR POWER GUJARAT LTD.

Location Salaya, Dev Bhumi Dwarka District, GujaratCapacity 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

WaterRequirement

• Presently 64 MLD River water• Future-Sea Water - 9375 m3/hr

Power Evacuation • Evacuation at 400 KV – STU Network

2. YOUNG ENTRANT IN THERMAL POWER

Essar Power Gujarat Ltd

UNIT-1 COD : 01st April 2012

UNIT-2 COD : 15th June 2012

New Entrant …. Just 4 YearsPLANT OVERVIEW

Boiler Area

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3. PROCESS FLOW DIAGRAM

71% 69%80%

73%

7.15% 6.60% 5.83% 6.06%

0

1000

2000

3000

4000

5000

6000

7000

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

FY 2012-13 FY 2013-14 FY 2014-15 FY 2015-16

Plant Loading Factor (%) Auxiliary Consumption (%) Generation (MU)

GHR2339

4. CONTINUAL REDUCTION IN SEC IN LAST 4 YRS. OPERATIONAL PERFORMANCE

YOY Improvement • Good and Consistent O&M practices

GHR2451 GHR

2333

4093 MU

5387 MU

6609 MU

5229 MU

GHR2421

GHR - 2423GHR - 2385 GHR - 2339

GHR - 2315AT

Normative Loading

6.85% 6.3% 5.83% 5.76%

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5. OUR GOAL:SEC NEAR TO GLOBAL BENCHMARK

• HEAT RATE ( Kcal / Kwh )

• Specific Oil Consumption ( ml / kwh)

• DM WATER MAKE UP ( % )

• AUX POWER ( % )

CERC NORM5.75 %

O&M 2012-13 2013-14 2014-15 2015-16

Norm 12.1 13.3 14.4 15.3Actual 11.2 10.8 11.3 13.4

CERC NORM15.3 Rs Lac / MW

FY 2012-13 FY 2013-14 FY 2014-15 FY 2015-16

2451 2421 2339 2333CERC NORM

2375 Kcal /kwh

2012-13 2013-14 2014-15 2015-16

ML/ kwh 1.8 0.32 0.23 0.28KL /Start 189 102 67 54

CERC NORM0.5 ML / kwh

2012-13 2013-14 2014-15 2015-16Aux Cons. 7.1 6.6 5.8 6.0Loading 71% 69% 80% 73%

CONTINUAL IMPROVEMENT & EXCELLENCEGross Heat Rate ( GHR )

Specific Oil Consumption

Annual O&M Cost ( Rs in Lac / MW )

Aux Consumption ( % )

0.77

0.94

0.82

1.261.23

0.990.91

1.060.99

0.700.68 0.63

552

424

669

416 431

592

464

62

515

615

552 451

0

100

200

300

400

500

600

700

800

0.60

0.80

1.00

1.20

1.40

1.60

1.80

2.00

2.20

2.40

MU%

Specific DM consumption (%) Generation (MU)

Top Few Power

Stations

DM WATER CONSUMPTION TREND

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6. EPGL ROAD MAP TOWARDS EXCELLENCE IN ENERGY MANAGEMENT

Designated Consumer

(PAT-2)

Baseline Net Heat Rate Consumption

2014-15

TargetNet Heat rate

2018-19

ActualNet Heat Rate

FY 2016-17( YTD till July ‘16)

STATION (Kcal/Kwh) (Kcal/Kwh) (Kcal/Kwh)ESSAR POWER

GUJARAT LIMITED 2512 2506 2497

INGRAINED IN CULTURE : EVERY KCAL COUNTS - MEASURED DAILY

• CHALLENGING SELF – ENCON OBJECTIVE IN IMS• ALIGNED TO TECHNOLOGICAL DEVELOPMENT• BENCHMARKING WITH BEST IN INDUSTRY• ZERO TOLERANCE TO INEFFICIENT EQUIPMENTS

ESSAR POWER GUJARAT LTD - ENERGY POLICYOpportunities Register

Sr. NO.

Date of Identificat

ionPlant/ Unit

Area/ Activity

Identified

Energy Use

Opportunity Implementable (Yea/No) A B C D

*Priority No. (Greater the number = higher the priority) Priority Number

Calculation

Energy Wastage*/

Energy Loss

If Yes, Describe benefit

Target Date

Action

Plan ref no.

Completion date/Status

1 Oct-15 EPGL TurbineHeat

(Kcal/kwh)

Improvement in turbine performance

Yes 4 3 3 3 108 Energy Loss

Major annual overhauling of Unit-2 Turbine

Apr-16 3

To start from 25 Feb 2016

and to complete in

50 Days

2 May-15 EPGL

Vaccum improvement by Cooling Tower

modification

Heat (Kcal/k

wh)

Improvement in condenser vaccum and heat rate


1) Increase in No. of fan blades2) Increasing height of recovery cone 3) Nozzle replacement with new design 4) Structure strengthening

Oct-16 1 12.5 % completion

3 Dec-15 EPGLConden

sate extraction pumps

Electrical

powerReduction in Energy use Yes 4 2 3 3 72 Energy

Loss

1) Installation of VFD in CEPs for reduction in energy use

Feb-17 2Technical

Discussion under

progress

4 Dec-15 EPGL Seal Air Fan

Electrical

power

Reduction of Electrical energy


Installation of VFD in seal air fans

Aug-16 8

Technical Discussion

under progress

5 Aug-15 EPGL LED Lighting

Electrical

power

Reduction in Light consumption


Under ImplementationJun-16 4

Under Implementation

6 Feb-16 EPGL AHP Electric

al power

Reduction in Energy use

Decision after feasibility

study

Energy Loss

Feasibility study under progress


7 Sep-15 EPGL

Non conventi

onal energy usage

for heating

of condens

ate

Heat (Kcal/k

wh)

Reduction plant heat rate


study0 Energy

Loss


5Party visted site. Offer awaited

8 Sep-15 EPGLSolar Street Lights

Electrical

power

Use of Solar Energy for street lights


study0 Energy

LossFeasibility study under progress

6Party visted site. Offer awaited

Doc. No: EPGL/EnMS/F/025 Rev. Date: 20-02-2016 Rev. No: 01

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

Target

Evaluate Options

Analyze and Apply

Monitor and Maintain

ENERGY

CON

E

T

A

M

ENCON --- Driven across Levels

21 Energy Auditors / Managers

ENGRMD COO MGRHOD

ENERGY MANAGEMENT SYSTEM & REPORTING

Continuously Collating HMBD with Actual DataFor Timely Intervention

AUTOMATED DAILY EFFY. REPORT

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7 A. Summary- Energy Savings ( MU / Annum ) FY 2012-15

S. No Energy Conservation Projects Cost Incurred (Rs in Lacs)

Energy Saving MU/Annum

1 Coal Mill Utilization None 3.50

2 Plant Air compressor None 2.41

3 Coal conveying system None 0.13

4 Ash Handling system None 1.28

5 DM Hot well pump None 0.1

6 Compressor cooling system None 0.35

7 Lighting Load Optimization None 0.06

A TOTAL SAVINGS ( MU ) 7.83Energy Saving M Kcal/Annum

1 HP Exhaust Valve modification None 52872

2 Turbine Operation Philosophy None 99135

3 Start Up Oil reduction None 19088

B TOTAL SAVINGS ( MKCAL ) 171095A+B :Total Savings (Rs in Lacs) 1648

7 B. Summary- Energy Savings ( MU / Annum ) FY 2015-16

Sr. No ENCON Projects

Cost Incurred

(INR Lacs)

Energy Saving /Annum

Total savings(INR Lacs)

1 Pre- Ponment of Turbine Capital Overhaul

340 115500 Mkcal 850

2 Condenser Vacuum Improvement – Up gradation of Cooling tower

200 24000 Mkcal 200

3 Boiler DM make up reduction. Nil 72160 Mkcal 6004 Specific oil reduction during Boiler

startup.Nil 432 KL

( 9 X 48 KL)150

5 Optimization of SEC - AHP None 1.06 MU 21.26 Optimization of SEC - CHP None 0.105 MU 2.17 Optimization of SEC - Chlorination

System. None 0.13 MU 2.5

8 LED Lighting installation 11.5 0.10 MU 2.0

Total Savings (INR Lacs) 1827.8ENERGY SAVING CALCULATED AT NORMATIVE LOAD AND OVER BASELINE OF 2012-13

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8. Innovations in ENCON Projects in 2015-16.Innovation-1: Pre-ponement of Unit 2 Capital Overhaul

Overview -• Preponing Turbine capital overhaul for heat

rate improvement.

• Details-• Turbine COH without OEM support• Shutdown executed in 37 days against

schedule of 55 days

• Improvement of GHR by 35 Kcal/kwh• Steam path audit – Third Party Expert

• Major jobs executed are :• Optimised Steam flow path clearances• Use of Fresh seals with intact profile• Rectification of identified problems • Rotor cleaning• Routine Maintenance.

Total Energy Savings = 1,15,500 MKcal / Annum

Innovation-1: Pre-ponement of Capital Overhaul

19.1

5.6 9.3 9.1 7.8 6.3

57.1

2.1 1.9 3.5 4.7 4.2 3.4

19.817.03.7 5.8 4.4 3.5 2.8

37.2

HPT IPT LPT-1 (T) LPT-1 (G) LPT-2 (T) LPT-2 (G) TOTAL

Heat Loss Recovery – Casing wise

OPENING CLOSING

3.7 14.5 11.8

26.6

0.2

56.8

2.8 5.0 1.0 11.1 0.019.9

1.0 9.4 10.8 15.5 0.2

36.9

INTERSTAGE PACKING

TIP SPILL STRIPS

SHAFT END PACKINGS

SURFACE ROUGHNESS

COVER DEPOSITS

TOTAL

Heat Loss Recovery – Category wise

OPENING CLOSING

2025

1990

1960

1970

1980

1990

2000

2010

2020

2030

2040

2050

SUBSTANTIALHEAT RATE

IMPROVEMENT

Turbine HeatRate before COHTurbine HeatRate after COH

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Innovation-2 : Condensor Vacuum improvement by up gradation of Cooling tower

Overview-

• Modification of cooling tower to achieve reduction of cooling water temperature by 1.5 Deg. for improvement of condenser vacuum

• Details of Innovation-

• Increasing• Fan blades from 8 to 10• Height of Fan stack for preventing of

hot air recirculation.• Spray nozzle with Modified design.• Structure strengthening

Total Energy Savings = 24,000 MKcal / Annum

Innovation-3 : Boiler DM water Make up reduction

• Overview-

• Reduction in DM make up from 3.0% to 1.0% in last 3 years.

• Make up further reduced to current value of 0.63 % in 2016-17

• Details of Innovation-

• Adoption of ultra pure DM water regime and rigorous monitoring of consumption.

• Boiler blowdown optimization

Total Energy Savings = 72,160 MKcal / Annum

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Innovation-4 :Specific oil reduction during startup.

Overview -• The boiler cold startup procedure was

studied in detail and scope was identified toreduce the boiler startup time by-

•

•

Details Result Oilreduction

Pre-heating of Feed water

Start up time reduced by @ 25 Mins

5 KL / Start

Introducing coal in Furnace ~180 deg C

Cold Startup OilConsumption reduced by26 KL.

26 KL / Start

Oil Gun Nozzle Modification Leads to reduction in

Oil Firing time before start of Coal Firing.

5 KL / Start

Better O&M Practice

12 KL / Start

48 KL /Start

Innovation-4 :Pre-heating of Feed water during startup and reduction of Boiler startup time

Amongst Top Few CEA

monitored stations

1.84

0.320.23 0.28

0.00

0.20

0.40

0.60

0.80

1.00

1.20

1.40

1.60

1.80

2.00

FY 2012-13 FY 2013-14 FY 2014-15 FY 2015-16

Cold Start-9

Cold Start-9Cold Start-5

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Innovation 5 :Optimization of SEC in Ash Conveying System

Overview -• Due Diligence done for ash conveying system

and scope identified for reduction in power consumption by increasing pressure.

• Details-• Optimised jet pump running time

• Ash conveyed at increased air pressure from 1.92 Kg/cm2 to 2.3 Kg/cm2

• Result• Compressor running hours reduced• SEC reduced from 13.6 Kwh/T to 9.8 Kwh/T• Evacuation time reduced: 8 hrs to 6 hrs per day

Total Energy savings – 1.06 MU / Annum

• Overview -• Reduction in power consumption in coal

handling system

• Details-

• Reduced the idle belt running.

• Sequential and synchronized operation of coal belts.

• Increased Coal Reclaiming.

• Increased coal conveyor loading from 800 TPH to 1100 TPH .

Innovation-6 :Optimization of SEC in Coal Conveying system

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• Total savings-BeforePower Consumption for the Period of October 2014 - March 2015Coal Reclaimed - 1.11 Million MTPower Consumed - 2045 MWHPower consumed /Ton - 1.84 Kwh/TonAfterPower Consumption for the Period of April 2015 - Mar 2016Coal Reclaimed - 2.01 Million MTPower Consumed - 3597 MWHPower Consumed / Ton - 1.79 Kwh/TonPower Saved (in 12 months) - 100 500 Kwh

Innovation-6 :Optimization of SEC in Coal Conveying system


Innovation 7:Optimization of SEC in Chlorination system

• Overview-• Optimization of CW chlorination

booster pump operation

• Details -

• Using CW discharge header for maintaining FRC of 0.2 to 0.3 with a flow of 20 Kg / Hr to 30 Kg/Hr.

• As per current scenario water chemistry parameters being maintained by CW header Pressure resulting into stoppage of HP chlorination booster pump.


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Innovation 8- Lighting Load Optimization- LED

Overview -• Plant lighting load optimization by LED

lamps

• Details-

• 200 Nos. of lights in BTG area replaced with LED lamps last year . Additional 600 Lights to be replaced in the current year.

• Maintaining the lighting lux level above 100 Lux which is industrial safety standard.

Total Energy savings (Existing) – 0.10 MU / Annum

9. Efficient Utilization of Renewable Energy

Installed Turbo –driven Fans in the O&M Building and Power House in

place of Ventilation fans.Total Savings : 70 kwh

Capex Planned for installing Solar heaters in our Power Castle Colony

near to Plant.Total Savings : 30 kwh

ESSAR POWER OWNS1 MW Solar based Power plant

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10 A) Environmental Projects for CarbonEmission reduction

Green Belt @ EPGLBy Energy Conservation, Last 3 Yrs ( 2012-15 ) CO2 saved:2,40,522 MT

CO2 sequestered (MT)/Year Total CO2 sequestered (MT) till date6972 45320

Total CO2 (MT) sequestered in Green Belt at EPGL

85000+

By Energy Conservation, Annual ( 2015-16 ) CO2 emissions saved : 94,607 MT

Efforts towards Environment Protection

EPGL has started experimenting plantationof sturdy species of Date Palm around it’scooling tower which will withstand impactof sea water.

Acoustic covering for TG Deck

Rain Water Harvesting Green Belt Development

Deaerator Vent silencer

Injection - Ammonia in Flue Gas

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10 B) Productive Utilization of Waste

*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 Two Year’s SaleSale of Fly Ash : 4,49,000 MT - Rs 136 LacsSale of MS Scrap : 519 MT - Rs 145 LacsSale of Wood / Garbage : 149 MT - Rs 6 Lacs

SWACHHTA ABHIYAN** CEA Statistics 2013-14

CW BD

AHS System Makeup

Construction activity for Plant & EBTSL area

Guard Pond (ETP)

• Coal Handling system• Coal pile dust

suppression • Fire fighting• Service applications

Boiler Blowdown & DM Plant Waste water

Green Belt dev at plant, & Stockyard corridor

Tanker fill arrangement to sprinkle on road

Productive Utilization of Waste:Zero Effluent Discharge

Cooling Tower(10 COC)

EVAPORATION

MAKE - UP

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11. ENCON PROJECTS FROM ISO 9001 &EMS 14001

MGMTSystem

TARGET 2015-16

ACTUAL2015-16

ENCON PROJECTS

ISO 9001 Aux Cons:6.00 %

(Loading 80%)

Achieved:5.76 %

( with equivalent 80% LF )

• Annual Savings of 1330 MWH by various ENCON Proj. mentioned above.

GHR Target :

2365 Kcal /kwh(Loading 80%)

Achieved:

2315 kcal /kwh( with equivalent

80% LF )

• Annual Savings of 217802MKCAL by Various ENCON Proj. mentioned above

ISO 14001 Reduction in DM Water cons.

to 1.5%

Achieved :1.2 %

• DM Water Conservation Audit

• Stringent Water chemistry Monitoring

12. Replication of ENCON BEST Practices implemented through EBTSL

ENCON PROJECTS IMPLEMENTEDBY EBTSL

AnnualMU

Saved

AnnualSavings

In Rs in Lacs

Yard Conveyor – 1 and 3 running in slow speed as perFeed requirement . Approx. saving 24 unit / hour

0.10 2.1

SCR3 luff motor running in Star connection.Approx. saving 10 unit / hour

0.02 0.4

SCR1 / SCR3 during stacking switching off Luff and Hagglund motor. Approx. saving - 115 unit / hour

0.41 8.4

0.53 10.9

EPGL ENCON Team visited EBTSL site and suggested various ENCON Measures.

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13. EPGL Journey towards Excellence18 Awards /Certificates in 4 Years.

EPGL Journey Continues………. EnMS ISO 50001:2011

CIO of the Year

2014AIMA award for training excellenceYoung HR Champion2014Greentech Gold Award in HR Practicies Excellence

2014Greentech Gold Award for Innovation in retantion strategiesTraining

Excellence

CEA certification for

EPLC

2015Lowest So2 Emissions from amongst the coal based power plants in India2015Lowest Nox Emissions from amongst the coal based power plants in India

OHSAS 18001: 20072015Geentech Gold safety award

2015Greentech Gold Environment Award

ISO 14001:2004

2015Next 100 future CIO award2015Digital Transformation of technology award (e-negotiations for Coal Procurement)2015Data quest Award (e-negotiations for Coal Procurement)

ISO 9001:2008

Data quest Award

Digital Transformation of

technology

Next 100 future CIO

Environment Award

Safety award

Lowest Nox Emissions

Lowest So2 Emissions

2015 Quality Management Standard in terms of ISO 9001:20082015 Environment Management System in terms of ISO 140001:2004

Innovation in retantionstrategies

2015 Occupational Health and Safety Management System OHSAS 18001:20072015 CEA certification for Essar poer learning centre

HR Practicies

2016 Training Excellence SILVER Award 2016 Young HR Champion GOLD Award

Training excellence

2016 CIO of the Year award (Coal Logistics Management COALSCM)2016 Energy Management System (EnMS) ISO 50001:2011

2014 2014 2014 2015 2015 2015 2015 2015 2015 2015 2015 2015 2015 2015 2016 2016 2016 2016

14. ENCON Projects -- Next 3 Years

Sr. No.

Future Projects Conservative EstimateEnergy Savings

Annual SavingsMKCALOR MU

SavingsPer

Annum(Rs in Lacs)

Approx.Investmen

t(Rs in Lacs)

1 Turbine retrofit for Unit-1 50 kCal/kWh 3,00,000 MKCAL 1250 10000

2 Micro Oil Ignition System installation in both unit Boilers. 0.15 ml/kwh 13245 MKCAL 300 700

3 VFD installation in CEP 780-900 KW according to load 5.9 MU / Annum 5.9 MU 117 325

4 Non conventional energy usage for heating of condensate 2 kcal/kwh 16819 MKCAL 100 400

5 VFD in Seal Air Fans 78 KW0.55 MU/Annum 0.55 MU 10.9 24

6 SCAPH Bypass during normal operation 4.67 MU 4.67 MU 92 Nil

7 Installation of LED in Plant 1.1 MW/Day 0.4 MU 6 14

8 Solar power on roof top of Power House and Admin building

70 KW Generation100000 Kwh / annum 0.1 MU 2 45

TOTAL 1878 11508

Documents

ESSAR POWER GUJARAT LTD (EPGL), Dist : Dev Bhumi Dwarka