Surat Lignite Power Plant - Green Business Centre

1

Gujarat Industries Power Co. Ltd. Surat Lignite Power Plant

Presentation by Vikas R Gupta, DGM (EM Cell)

Nilesh Dhori (Sr. Manager, Opn) Bhavin H Tannarana (Manager, TS)

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TOTAL: 1084.4 MW

4x125 MW Lignite Based CFBC Units Phase-I (Year 2000), Phase II (Year 2010)

Solar Plants 2X40MW (2017), 75MW (2019) At Charankha, Gujarat, 100MW (WIP) at

Raghanesda Gujarat Gas Based Power Plant

145 MW (Year 1992) 165 MW (Year 1997)

At Baroda At Surat An IMS (9001, 14001, 18001, 50001) Company, Established in 1985

Captive Lignite & Limestone Mines 112.4 MW Wind Power (2017)

5 MW Solar Plant at SLPP (2012) 2x1 MW Distributed Solar Power cum

Agriculture Pilot Projects-2016

Condenser

BOILER

LIGNITE HANDLING SYSTEM

STEAM

LIGNITE

LIMESTONE LIGNITE

LIMESTONE HANDLING SYSTEM

LIMESTONE

FUEL OIL HANDLING SYSTEM

TURBINE

FUEL OIL

FIRE WATER

SERVICE WATER COOLING WATER

CLWPH

WATER BED ASH

ASH HANDLING SYSTEM

FLY ASH

DRY ASH DISPOSAL THROUGH CLOSED TRUCKS

DM PLANT

TAPI RIVER RAW WATER

POND

Generator

State Grid

CRH

HRH

BED ASH SILO FLY ASH SILO

SLPP Energy Consumption Overview

Plant Performance: FY 2019-20

– Annual Generation 3359.77 MUs – PLF 76.50% – Availability 85.91% – Gross Heat Rate 2674.85 kCal/kWh – Auxiliary Power 12.80% – DM Water consumption 1.462% – Raw Water Consumption 2.07 M3/MW – Specific Oil Consumption 0.3173 ml/kWh

Type of Renewable

Energy

Installed Capacity

Annual Generation

in MUs for 2016-17

Annual Generation

in MUs for 2017-18

Annual Generation

in MUs for 2019-20

Wind Energy 112.4 MW 13.7 82.1 252.6

Solar Plants (5+1+1+80+75) -162MW 7.73289 8.7921625 131.46

Building Integrated Solar

(25+25+20) kW 0.0 0.0547997 0.097815

Total Re-Newable Energy Generation Year-wise Total Present Re-Newable Power Generation Capacity

274.4 MW

84.32

86.28

85.91

2017-18 2018-19 2019-20

–Availability

2676.6

2658.1

2674.9

2017-18 2018-19 2019-20

–Gross Heat Rate

12.85%

12.45%

12.80%

2017-18 2018-19 2019-20

–Auxiliary Power

Energy Consumption Overview: FY 2017-20

Lower Plant Availability than target due to Increased forced outages owing to non-availability of Lignite and increased forced Outages. Further, Scheduled COH of Unit-2 was carried out after gap of 11 years of Unit’s operation resulting in and performance. Increase in Partial Loading – 1) owing to heavy and continuous rain during monsoon and extended monsoon (up to first week of Nov’19) causing frequent jamming and choking of lignite feeding system. 2) ID Fan loading restriction owing to high moisture content in Lignite/ flue gas path leakages due to Quality of Lignite(Through-out the year), 3) Unit-1 ESP fields' replacement work by isolating one ESP pass to comply with new environmental norms, 4) part load operation of Unit-2 owing to Cyclone-2 refractory damage and 5) increase in Backing down. Increase in APC mainly attributed to Boiler Draft Power

The Journey of

Summary of Energy Savings 2009-19

Summary of Energy Savings: 2009-2020

Finn. Year

Annual Electrical Savings

Annual Thermal Savings

Total Annual Savings

Investment

No of Projects Implemented

Electrical Energy Saving

(in Mus)

Rs Million

Fuel Saving

(in Thousand MT)

Rs Million Rs Million Rs Million

With Investment

Without Investment

2009-10 0.31 0.432 1.80 1.9755 2.41 2.446 4 0

2010-11 0.94 1.311 2.40 2.639 3.95 5.539 3 2

2011-12 2.52 2.52 2.34 2.60 5.12 13.246 3 2

2012-13 12.92 0.00 45.84 0.00 38.78 23.29 17 10

2013-14 16.58 44.83 23.73 20.62 65.44 38.47 8 7

2014-15 23.23 61.49 20.45 19.12 80.60 26.77 23 7

2015-16 30 86 57 74 160 175 7 4

2016-17 12.70 39.50 15.15 22.38 61.87 13.41 7 4

2017-18 14.04 41.13 19.40 24.99 66.12 30.76 9 3

2018-19 19.01 51.97 25.65 27.53 79.50 97.47 11 1

2019-20 20.80 55.28 159.6 166.99 222.27 103.36 12 2

Grand Total 153.21 385.98 376.15 362.45 823.67 580.62 105 42

Impact of Energy saving on Auxiliary Power Consumption

Particulars Unit 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 2018-19 2019-20

Generation MU 3607.485 3017.463 3266.592 3083.904 3178.196 3271.715 3521.714 3359.767

APC of Phase-I&II MU 455.525 400.43 399.809 385.641 408.825 420.524 438.339 430.08

%APC of SLPP % 12.63% 13.27% 12.24% 12.50% 12.86% 12.85% 12.45% 12.80%

Energy Saving MU 12.92 16.58 23.23 30.41 12.70 14.04 19.01 20.80

APC without Energy Saving

MU 468.45 417.01 423.04 416.05 421.53 434.56 457.35 450.88

APC% without Energy Saving

% 12.99% 13.82% 12.95% 13.49% 13.26% 13.28% 12.99% 13.42%

Impact of % of APC 2.84% 4.14% 5.81% 7.89% 3.11% 3.34% 4.34% 4.84%

Energy Savings % of Gen 0.36% 0.55% 0.71% 0.99% 0.40% 0.43% 0.54% 0.62%

Impact of Energy Saving… Since 2009 more than 148 Energy Saving measures have been

Implemented resulted in saving of more than 153 MUs Electrical Energy and 376k MT Lignite.

During FY 2017-18, SLPP had saved total 14.037 MUs Electrical energy and

19401 MT Lignite. During FY 2018-19, total 19.04 MUs of electrical power and 25650 MT of

Lignite was saved During FY 2019-20, total 20.8 MUs Electrical energy and 159.6k MT Lignite

is saved Total Rs 36.8 Cr saved in Last Three Years.

The SLPP has received total five National Awards on Energy Conservation

Total Investment on Energy Saving measures was 9.754 Cr at 0.64% of total

turnover during 2019-20.

Comparison of Specific Energy Consumption Based on same CFBC technology & FBHE Design

Name of Power Station Net Station Heat Rate Kcal/Kwh

Surat Lignite Power Plant 2974.62

Barsingsar Thermal Power Plant, NLC Limited 3002.62

Akrimota Thermal Power Station 3220.36

Kutchh (Lignite) Thermal Power Station 3860.67

Giral Lignite Power Limited, Rajasthan 4804.08 Source: MoP Notification S. O. 1264 (E) – 31 March 2016)

SLPP’s consistent performance (Average PLF 75.9% and Average Availability at 82.9% Since commissioning) is always above National average as well as better than other similar utilities operating on CFBC technology & similar Boiler design is itself a BenchMark for others

1. Approx 10 MUs saving is expected in Boiler Draft Power due to Air ingress arresting at different sections of Flue Gas Path / ESP Casing / TAPH Leaking Tubes Blanking and /or Replacement during BTL Etc (Round the year jobs)

2. Minimize Forced Outage due to Boiler Tube Leakages by adopting Boiler Area Specific Measures

3. Replacement of Old & damaged insulation work is being taken up round the year. Total saving will be calculated at the end of financial year

4. Unit-4 COH will be taken up. Approx. 30 kCal/kWh improvement in Turbine efficiency is expected.

5. Unit-4 Cooling Tower fills will be replaced. Approx. 70 kcal/kWh in Gross turbine Heatrate is expected

6. CW Pump-3 of Unit-4 will be overhauled after which approx. 175kW saving is expected

7. Remaining 3 Condensate Extraction Pumps (Both pumps in Unit-3 and remaining pump 4A in Unit-4) will be de-staged from 7 to 5 stages, which will result in saving of approx. 37kW per hour

8. In instrument air system, replacement of 10 nos. pneumatic positioner with smart positioner will be carried out. Expected saving of 13200kWhr in a year and 13.9MT of Lignite is achievable

9. RW Pump-1 will be overhauled after which at least 12 kW saving is expected. (Work In Progress)

10. Phase–1 Air Compressors ACW circuit modification & Oil Coolers acid cleaning / replacement will be done. This will help in reduction of lube oil temp and increase in outlet flow

11. Interconnection of CW Fore-bay Make-up line with CW system PH-2 (Feasibility being studied)

Details of Energy Conservation Measures Implemented

In 2019-20

Energy Conservation Measures Implemented in 2019-20

Sr. No. Title of Project

Annual Electrical Saving

(kWh)

Annual Thermal Saving

(Ton/year)

Total Annual Savings (Rs

million)

Investment Made (Rs million)

1

Energy Saving in Boiler Draft Power due to Plugging of air ingress at different sections of Flue Gas Path /ESP Casing/TAPH Leaking Tubes Blocking during BTL Etc (Round the year jobs in all Units including saving achieved due to COH jobs in U-2 & 3)

15753982 16742 59.39 47.78

2 Phase-II Unit-3 Cooling Towers fills Replacement work. 0 54957.6 57.5166 16.17

3 Unit-2 Turbine Capital Overhauling (improvement of 30.8 kCal/kWh in GTHR) 0 10713.3 11.2121 18.76

4 Unit-3 Turbine Capital Overhauling (improvement of 51.29 kCal/kWh in GTHR) 0 17840.4 18.6711 18.76

5 Condenser tubes cleaning in Unit - 2 & 3 2242560 2383.2 8.4544 0.328

6 HPH-6 Parting plane leakage & tube leakage attending work in Unit-2 &3 resulted in 55 & 22.55kCal/kWh improvement

0 53948.9 56.461 0.125

7 Old PCH Primary Crusher Motors 2 X 132 kW Starter Changing from DOL To Delta-Star (Old PCH PCRS A2-1 & A2-2 Motors)

161280 171.4 0.6080 0.5

8 Relocation of BCN5B tail pulley by 32 mtr resulted in shortening of belt length by 64 mtr. This activity saved 1.0 Amp at Zero Loading of Conveyor

28373.1 30.2 0.1075


Sr. No. Title of Project Annual Electrical

Saving (kWh)


(Ton/year)


million)


10 Replacement of 120 nos. 150 W HPSV Lamps by 70 W LED Fixtures 39420 41.9 0.1486 0.44128

11 Replacement of 471 nos. lamps & Choke coils by different suitable capacity LED lamps 96176 102.2 0.3626 0.08447

12

Replacement of 25 nos. lamps & Choke coils of 80W capacity by 15W capacity LED lamps Replacement of 75 nos. lamps & Choke coils of 80W capacity by 23W capacity LED lamps Replacement of 100 nos. lamps & Choke coils of 40W capacity by 20W capacity LED lamps

55845 59.3 0.2105 0.05272

13

Old Ceiling Fans replacement with New energy efficient 5 Star labelled ceiling fans for all colony resident quarters. Total 1420 fans (500+670+250) were replaced in phase manner during 2017-18, 2018-19 & 2019-20.

145124 154.2 0.5471 0.05272

15 U2 FBHE Blower (Extra) running stopped because of bypassing TAPH Section to avoid leakages of FBHE Air and no change in overall process

2250487.8 2391.6 8.4842 0


In 2018-19



Annual Electrical Saving

(kWh)


(Ton/year)


million)


1 Saving due to improving Capacity Utilization of Lignite Handling System resulted in reduction of Specific Power Consumption from 3.35 to 3.30

190959 201.2 0.7270 0

2

Improved methods of Capacity Utilization of Limestone Handling, Milling & Conveying Systems resulted in reduction of Specific Power Consumption from 32.22 to 29.72 kWh/MT

711551 749.9 2.7088 0

3 Phase 1 Compressor ACW Modification 68672 72.4 0.2614

4 Reduction of Two Stages from Condensate Extraction Pump of Unit–4 (CEP-4B) 273312 288.0 1.0405

5 Plugging of Air ingress at different sections of Flue gas path in all the four boilers, thereby reducing ID Fan loading

16661079 17558.2 63.4272

6

Condenser Cleaning in Unit-1 & 4 by Bullet Cleaning Method and in Unit-2 various Other supportive work like air ingress attending, repair jobs in Cooling Towers resulted in 11.57 kCal/kWh improvement in heat rate

0 1987.7 2.1335 0.477

7 Overhauling of CW Pump-A Phase-II (It was implemented in FY 2017-18 but saving was not claimed at that time)

876356 923.5 3.3362 3.42

8 Old PCH Primary Crusher Motors 2 X 132 kW Starter Changing from DOL To Delta-Star (Old PCH PCRS A2-1 & A2-2 Motors)

161280 170.0 1.3146 0.45


In 2017-18

Major Energy Conservation Measures Implemented in 2017-18


Annual Electrical

Saving (kWh)


(Ton/year)


million)


1 Saving due to improving Capacity Utilization of Lignite Handling System resulted in reduction of Specific Power Consumption from 4.23 to 3.35

3095789 3243.3 13.25 0

2 Change the controller position of Lime Stone Mill A, B & C from Air Fail to close to Air Fail to open position.

76431 80.0 0.33 0

3 Attending Air Pre Heater (APH) Tube leakages and Flue Gas Duct Air in-leakages in Units 1, 2, 3 & 4 during year 2017-18

8570784 8979.00 36.68 28.10

4 New PCH Primary crusher motors 2x160KW changing motor connection from soft starter-Delta to star

1495200 783.20 5.39 0.11

5 Energy efficient LED lightings 4500 4.70 0.02 0.02

6 Use of Primary air in ash cooler instead of blower air in U-4. This has resulted in reduction of running hours of ash cooler blower.

521600 546.50 2.23 0.41

ISO-50001: 2011 Implemented Since

Year 2013

(Latest certificate of ISO-50001:2018 is awaited)

Particulars UOM 2017-18 2018-19 2019-20 Total CO2 Emissions Per kW of Generation

Ton/kW 1.2619432 1.278989 1.29127

Absolute CO2 Emission MT 3597800 3938925 3783013 Current SOx Emissions at Full Load

mg/Nm3 67.19 97.36 117.49

Current NOx Emissions at Full Load

mg/Nm3 35.65 46.75 65.75

Particulate Matter mg/Nm3 61.65 81.78 89.31 Mercury mg/Nm3 -- -- <0.03

Environment Management-Emission

Particulars UOM 2017-18 2018-19 2019-20 DM water Consumption of Plant (Unit - %) % 1.412 1.357 1.462

Raw Water Consumption of Plant (Unit – m3/MW) M3/MW 2.02 1.96 2.07

Weather Plant is Zero Liquid Discharge Yes

Best Practices in Water Management Please refer Annexure – Water Conservation by SLPP

Environment Management- Water

Zero Discharge System: We have Two Run-off ponds in which drains from Lignite, Limestone & Ash Handling plants gets collected & fresh water after settling solid contaminations is pumped to Guard pond from where it is used for various purpose after treatment.

Sr. No. Particulars of Scheme Adopted Quantity

(M3/day)

Details of Effluent Water diverted to Guard Pond

1 Water collection from Different plant area pit, collected in guard pond and after treatment this water is reused in fire water system, dust suppression, gardening, lignite water sprinkling etc.

100

2 Reduced blow down from cooling towers condenser cooling system by increasing cycle of concentration (COC) from 2.5 to 5.5 after adopting the chemical treatment

2367

3 DM Plant effluent reuse after treatment trough N-PIT system pumped to Guard pond 100

4 Lignite Run off pond water after treatment through Clarifier. 27

5 Water recovered from Storm water drains 100

Total Effluent Water Re-Utilization (Used in Fire Hydrant System, Dust Suppression Systems at Lignite Handling System, Gardening, Plant area water-washing, water sprinkling over mining haul roads etc)

2694

Details of Fresh Water Re-Utilization

1 Ash handling plant Air compressor cooling water is diverted to be utilized as Phase-I cooling tower make up water

2000

2 Cooling tower side stream backwash water is used as cooling tower make up water after chemical treatment 220

3 3 nos (50 Dia, 32 Dia, 12.5 Dia) Clarifier blow down water reuse in Cooling tower, after treatment through Thickener system

150

4 DM Water after Boiler Hydro-test recovered in CST for reuse as Process DM water. 13

5 Boiler blow down water is used as make-up water of cooling water system 40

Total Fresh Water Re-Utilization 2423

Total Water Saved per Day 5117

Waste Water

Views of Guard Pond

Run-off Pond Water Transfer

Pumping Station

Environment Management- Ash Utilization Particulars UOM 2017-18 2018-19 2019-20

Ash Generated Tons 565843 603310 570772.33

Ash Utilization % 100 100 100

Ash Utilized in Fly Ash Bricks MT, % 423543 400350 281391, 49.3%

Ash Utilized for Road pavements MT, % 565843 202960 289382, 50.7%

Ash Utilized in Mine Filling MT 0 0 0

Ash Utilized in manufacturing of Cement / Concrete-other similar products

% Nil Nil Nil

Expenditure on Ash Utilization* (*Annual -Against Road Pavements)

INR (Lakhs) 122 163 268.56

Remark: SLPP has employed the Dry method for Ash Handling in which Ash is conveyed pneumatically from hoppers to Bed Ash & Fly Ash Silos in Dry condition for collection and distribution to various interested parties Bulkers / Covered Dumpers filled through telescopic chute.

GIPCL-Surat Lignite Power Plant has achieved 100% ash utilization since 2004 and also got the “National Award for Fly Ash Utilization (first prize)” jointly awarded by Ministry of Power, Ministry Environment & Forests and Department of Science & Technology, Government of India in 2005. Bagged National Awards for 100% Fly Ash Utilization in succession for 2016, 2017, 2018, 2019, 2020 conferred by Mission Energy Foundation.

Ash Disposal to Outside Parties

The major utilization of Fly Ash is in manufacturing of Bricks, AAC blocks, paver blocks, AC sheets and tiles etc by outside

parties. Other use of Ash is for filling of low lying areas, partly in construction of roads etc.

A view of Nursery developed near Industrial Canteen inside the plant – saplings are being grown using Vermi compost produced.

In Plant premises, we have developed vermin compost project in which biodegradable waste from Industrial canteen, Guest Houses Mess and kitchen waste from colony residents is being collected and converted in to Compost. This compost is utilized as a fertilizer in the garden and enhances fertility of soil as well as growth of the plants.

Innovative Projects

Risk taking / Beyond OEM Application

( C a t e g o r y - C I n n o v a t i o n )

Why Innovative : In our CFBC boilers, Tubular Air Pre-heater is a vertical column of eleven different sections to preheat combustion air are connected in series for Secondary & Primary Air handling 90% of Combustion Air. Remaining 10% air is fed by positive displacement FBHE blowers is preheated in 5 parallel sections before feeding it to Fluidizing Bed Heat Exchangers sections of boiler. The Sulphur & Chlorides present in lignite coupled with high moisture results in corrosion even in higher temp zone also where these parallel sections are installed in flue gas path. The leaking tubes were being blanked initially when in less numbers. By the passage of time, it become imperative to replace the tubes bundle when large no of tubes got damaged because it needed to run extra FBHE blower to meet required flow at combustor. So it was decided to bypassed these FBHE sections, however it was against normal operating guidelines by OEM and a risk was taken by feeding colder air at 100OC in place of 250OC. After bypassing, all relevant parameters were observed for long time and no adverse effect in Combustion process was observed. Trigger for implementing the project Only 10% air is preheated in 5 tiny parallel U-tube sections and fed to Fluidizing Bed Heat Exchangers sections (4 for FBHEs Bundle Chambers & one common for all Empty Chamber) of boiler. This tiny sections of TAPH, contains special U type tubes and in very less quantity. Manufacturing of these typical tubes is costly, difficult & takes longer lead time. Frequent leakages due to accelerated corrosion owing to sulphur & chlorides present in lignite coupled with high moisture Have to run extra FBHE blower to meet required flow at combustor Corrosion in higher temp zone. Re-Applicability Yes. It is replicated in our other Units also because no adverse effect of feeding cold air to FBHEs in Combustion process is observed till now. In Unit-3 & 4 all five sections of TAPH for FBHEs are bypassed, In Unit-2 except FBHE-2, all other sections have been bypassed and in Unit-1 two sections of FBHE-1 &3 have been bypassed. Impact on SEC : Extra FBHE Blower (HT Auxiliary) running due to leaking tubes is avoided in future. Annual Savings: Rs. Rs 84.84 Lacs Investment : NIL

Bypassing FBHE Air Pre-heater Sections (Category C Innovative project - Risks Taken/Self Driven/Beyond OEM)

Project-1:

Trigger for implementing the project 1) Unit-3 & 4 Cooling Towers fills had been completely choked up within 9 years of installation may be due to poor cross flute design. 2) The fills in bottom layer had gained up to 21 times higher weight then original due to heavy clogging. Cooling range had been reduced from 11 deg to 5 Deg. 3) Easy cleaning is possible in New fills with vertical flute in bottom layer by water jet. Re-Applicability Yes. The combination of this type of flute design in different layers may be replicated in other Unit cooling towers where dust loading is higher in ambient air. The same idea is being implemented in Unit-4 also. Impact on SEC : 79 kCal/kWh saving is achieved in GTHR of one Unit Annual Savings: 54958 MT of Lignite. Investment : Rs 1.67 Cr

Why Innovative: Unit-3 & 4 Cooling Towers fills had been completely choked up within 9 years after installation. The fills in bottom layer had gained up to 21 times higher weight then original due to heavy clogging. Cooling range had been reduced from 11 deg to 5 Deg. So it was decided to replace them but no supplier was ready to provide fills as per original design. So the problem was studied & consultation OEM/Experts was done and it was decided to install Offset Vertical flute in bottom layer only and new different type Cross-Corrugated flute in Middle & Upper layers. This idea was risk taking / beyond OEM as it was a tough decision to implement a different design. After implementation, the cooling tower effectiveness was fully achieved.

Phase-II Unit-3 Cooling Tower fills replacement work (Category C Innovative project - Risks Taken/Self Driven/Beyond OEM)

Project-2:

Energy Management Cell

Activities

1. Energy Management Cell was established in the year 2010. Company Energy Manager is the convener of the cell.

2. Total 28 BEE certified Energy Auditors/Energy Mangers of various departments are members of the cell.

3. Energy Management Cell meetings are conducted under the chairmanship of Station Head, which held once in a three months. All the suggestions received are reviewed and implementable projects are accepted and conveyed to the concerned department for implementation.

4. Suggestion format designed by core team of EM Cell is kept in the common server and all the employees can access the format. Employees who wish to put their suggestions can send through e-mail.

5. Suggestion boxes have been provided at various locations to enable wide participation of the employees.

6. Energy E-magazine is being circulated on daily basis quarterly for creating awareness and sharing the information related to energy conservation.

7. Energy conservation day is celebrated every year and EM cell is conducting quiz program, Slogan competition, Painting competition etc among the employees & their family members.

Quiz organized on Energy Conservation Day

Oath Taking Ceremony on EC Day Energy Conservation Day Celebration

1. Daily monitoring system – Through EMS Screens available to all as Intranet Website and Daily Planning Meetings

2. Review meeting – Every Three Months chaired by Station Head

3. Separate budget for Energy Conservation – No, having different budgeting system, identify during review meeting &

procedures laid.

4. Energy efficiency / awareness training program –Being arranged on EC Day

5. Projects implemented through Kaizens (Workers and Supervisor level) – not exactly, but on similar methodology, involves everyone

6. Major Areas of concern in terms of energy efficiency and reliability - Boiler

Teamwork, Employee Involvement & Monitoring

Dept: Name of equipment

Concept behind Energy conservation: Date:

Brief Description of the energy conservation measure:

Picture/ sketch/ drawing before modification

Picture/ sketch/ drawing after modification

Name of Department / Agency that will execute the project:

On annual basis

Electricity(kWh)

Coal (Tonnes)

Gas (Nm3)

Oil (kL)

Actual Energy consumption (Avg. of last 12 months) Theoretical Energy consumption per year after implementation Expected Saving of energy Energy tariff, Rs/ (kWh or Tone or Nm3 or Kl) Expected saving in Rs./year Other savings (Rs.) Investment required (Rs.) Proposer name: Contact No.: Signature

Energy Conservation Suggestion format (To be filled up separately for each Energy Conservation Measure)

Power (KWH)

Coal (Tones)

Gas Nm3

Oil (KL)

Other

A. Annual Consumption of Energy prior to the proposal (Actual)

A. Annual Consumption of Energy if proposal is implemented.(Theoretical)

A. Energy saving (A-B)

A. Energy cost saving (Rs/year)

A. Other cost saving (Rs/Year)

A. Total Cost saving (D+E) (Rs/year)

A. Proposed investment (Rs.)

A. Payback period (Year)

A. Sign for acceptance of the proposal

Energy Mgr. MR AGM (SLPP)

A. Action plan for implementation of proposal after acceptance.

SL. NO. ACTIONS PLANNED

RESPONSIBILITY TARGET DATE

Completion Date

Resource

requirement

Power (KWH)

Coal (Tones)

Gas Nm3

Oil (KL)

Other

A. Consumption of Energy after implementing the proposal (Actual)

A. Total cost saving (Actual)

A. Remarks: A. Closing of

Management program Date

Sign of MR

Sign of AGM

(SLPP)

Energy conservation program

Energy Aspect identification & Prioritization register.

Doc. No: F/SLPP/27 Rev. Date: 01.01.2013 Rev. No: 00

BC= Business Concern, LC= Legal Concern, SEU Significant Energy Use, S = Significant, NS Non Significant (860 Kilo Calories = 1 KWH) C = Consumption Level, E = Envisaged saving potential, P = Potential for Renewable Energy, I = Potential for increased exchange with Society

Sr. No. Area

Main Equipment/

Auxillary

Capacity in KW / HP*

Energy Aspect (Use)

BC LC SEU

Renewable Energy P

Existing Consumption

Running Hrs./

Day

Total Consumpti

on Level (Per Day)

C

Potential % of

Saving

Envisaged

saving potenti

al Score =(C*E)

S / NS

Existing Controls Adition

al Measur

e

Steam

Power

Coal NG

Overriding Facto

r

Kg/ Hr kW MT

/ hr SM3/

hr G Cal KWH % <= (E)

Operational Contr

ol

Engineeri

ng Control

Energy monitoring Format adopted

Procurements with insistence of Energy Efficient specifications

Reduction in paper consumption by adopting E-procurement and FLM

Use of Intranet & internet for all communication

“Switching off the lights before leaving” awareness created by sign boards and stickers near the switch board

Attending energy leakages (Steam, water, fuel, air) on top priority

Utilization of renewable energy sources by promoting Solar Cookers for colony residents and Use of Bicycle by employees

Increasing use of LED lightings & Solar street Lighting in Solar Plant. Switching off CT fans during low load condition and during Winter Season & Low Load conditions: Power saving of 35 kW per CT fan

Switching off SA Fan during low load condition: Power saving of 440 KW /Hr Per Fan

Optimization of excess air during low load operation to reduce loading of SA and ID fans

E n e r g y C o n se r vation : O t h e r R e g u la r P r a c t ic e s

Running of minimum required axillaries during Unit / Station shutdowns Optimization of auxiliary running hours during start up and shut down of unit

Stopping of one CCW pump in each unit during Winter season or at least in Night

hours

Stopping of air washery fans during winter season and pumps during Night hours

Running of one fuel oil pump instead of two between both phases

Energy saving by reduction of SA fan header pressure

Change in operating pressure of Seal & Purge air blowers and stopping of one blower

Reduction of Discharge pressure of Air compressors by 0.5 kg/cm2 (from 7.7 existing to new setting at 7.2 Kg/cm2)

Reduction in suction air temp of Instrument air compressor

E n e r g y C o n se r vation : O t h e r R e g u la r P r a c t ic e s

Awards Received to SLPP in Recognition & efforts towards Energy Efficiency

Awards Received to SLPP in Recognition & efforts towards Ash Utilization & Water Consumption

Awards Received to SLPP in Recognition & efforts towards Environment Management

2x1 MW Distributed Solar Power cum Agriculture Pilot Projects

The company has adopted the Cultivation of Crops & Vegetables in 2x1 MW Distributed Solar Power cum Agriculture Pilot Projects: • 1MW commissioned at Village Amrol, Dist.: Anand in Central Gujarat region on

28.04.2016 • 1MW commissioned at Village: Vastan, Taluka: Mangrol, Dist.: Surat in South

Gujarat on 03.05.2016 • Both Power Plant are first of its kind to implement the innovative idea of direct

connectivity in 11 KV network. • Developed on novel concept of cultivation of agriculture crops under the Solar

Panels. • The unique advantage is water being utilized for dual purpose – Panels Washing

& Irrigation both.

BEST PRACTICES IN PLANT (OTHER AREAS)

Following topics have been covered in next 5 slides in brief

Maintenance and Reliability

Asset Management

Digitization

Biodiversity

Afforestation

Research

New Initiatives – Flexibility

Beyond the fence Best Practices for Community & Others

Planning and Defects Management One of the pioneer company adopted SAP for O&M of Thermal Power Plant for following activities like Raising & Monitoring

Plant’s Defects, Permit To Work System, Spares Management, Budgeting, Payroll System, E-tendering system for material

procurement and service contracts, Advanced preparation for generation budget & setting up targets. Best Operation Practices Adopting change in Operation Philosophy For Process Improvement, monitoring & review Plant Efficiency and Plant Heat

Rate, Review of plant logics, permissive & interlocks etc., Total Covering of Monsoon Stocks of Lignite & Limestone

Best Maintenance Practices

Like shielding of Boiler tubes in different areas, Thickness Survey of Combustor Tubes during opportunities, Employing

smart scaffoldings, Attending Bed material leakages on-line, Converting Metallic Expansion Joints to Non Metallic Expansion

Joints

Optimization of Resource Utilization

Continuous monitoring for effective use of resources, minimizing the losses by identifying leakages, insulation condition

etc., Recovery of wastes etc.

Environment Management through ISO-14001:2018,

Adoption of Environment Friendly CFBC Technology to control emission of NOx & SOx by adding limestone powder in

Combustor. Continuous Monitoring of Electro-Static Precipitators (ESP) performance & Repair & Replacement, Maintaining

COC above 5.5, Maintaining Zero Water Discharge System, Green Belt Development & Maintenance, Waste (water, ash,

Kitchen waste) Management

Maintenance & Reliability and Asset Management: Through Various Productivity Enhancement Practices &Techniques

Health and Safety Management through ISO-45001:2018 Significant risks are determined in HIRA (Hazard identification and risk assessment) register by each departmental as per their process/function and being monitored & mitigated through Management program and additional measures, if required. Some highlights showing how safety is ensured in day to day works are 1732 Reportable accident free days of Operation up to 30.06.2020 Department wise safety coordinators are trained to monitor safety compliances, Creating

Awareness, keeping vigilant everyone in their respective area. Advanced Safety gears like Arc Protection Suits, Illuminated Windsock, LOTO system etc are

procured. Training on basic safety, fire fighting & first aid being imparted to company & contract

employees as time to time. Permit to work system is maintained effectively. Regular Safety Meeting, Conducting Safety Audits, NDT & Load Testing of Pressure vessels,

T&P, Cranes, Hoists, EOT load Testing, Conducting Electrical Safety Audit etc Conducting various Mock drills Periodic safety training to all employees and contract workers Safety related defects separately categorized in Defects Management System (in SAP)

Maintenance & Reliability and Asset Management : Through Various Productivity Enhancement Practices &Techniques

Various modules of SAP are being used for Payroll System, Attendance System, Plants Defects Monitoring, Work Permit System, Resource Management, Finance Management etc. Day to day maintenance activities, Spare management & Procurements. Various day to day work like security gate pass issue for men & materials, attendance system, Fly Ash & Bed Ash distribution are automated.

Company owns internet website & internal email system, intranet websites like ABT monitoring, APC Monitoring etc.

Plants Design Drawing of various systems & equipment as well as O&M Manuals have been converted into soft formats and being used extensively.

Use of Video conferencing & Microsoft Meeting App is being used extensively for all sorts of meetings

Use of Window based platforms for Main plant, BOP & Equipment Operations. Solar & Wind Power generation plant data on-line monitoring using SCADA system.

Maintenance & Reliability and Asset Management : Through Various Productivity Enhancement Practices &Techniques

Digitization

Housekeeping SLPP considered as one of the companies maintaining best housekeeping Very challenging task due to Lignite handling and operating pressurized boilers Nomination of housekeeping coordinators from each department Conducting regular meetings and Housekeeping Interdepartmental Audits at regular interval. Adopted various measures to maintain cleanliness, prevent fugitive emission after

identification and attending root cause

Company's innovative thinking towards adopting new technology and flexibility in implementation: Keeping with the theme as above the Company has implemented total 61 measures during 2019-20, 39 measures during 2018-19 and 32 measures during 2017-18. These includes outcome of adoption of new technology, new ideas, equipment, improvisations, change in MOC, methods etc. which has resulted in improving plant availability, economy, ease in O&M, Indirect / Intangible benefit in Energy Conservation/Environment Protection/ Safety Enhancement. For any details anyone can visit the company website (www.gipcl.com), download the Annual Reports of corresponding years in which particulars of each and every implemented idea has been given along with the benefits derived as a result (Due to limitation of no of slides can not be described here)

Green Belt Development Activity: GIPCL-SLPP has shown its commitment towards developing, mentoring & protecting environment since its establishment. The Company has planted more than 12.08 Lacs trees in 719 hectares area of Plant, Colony, Mines, Mine dumps since 1997-`98 with an average survival rate of 83.74%. Plants of different local species like Sissoo, Simea, Neem, Desi Babool, Ashok, Jatropha, Bamboo, etc. have been grown between the year 1998 to 2017. Seeds spraying activities were also taken up in 235 hectare area. Now the Power Plant Area (Apporx 30 Ha area has been covered and almost saturated) & Colony surrounding area, Mines area, Mine’s Dump area has been converted into a forest. Bio-diversity has also maintained in these areas because of dense plantation and greenery developed and maintained by GIPCL, herd of Nilgai, flocks of peacocks etc coexist in and around our plant & Mines premises. Large no of Peacocks can be witnessed here and even leopards are spotted in Mines & its dump (OB) areas.

Afforestation & Bio-Diversity

New Initiatives – Flexibility & Research

Beyond the fence - Best practices for community and Others The GIPCL-SLPP established & promoted - Development Efforts For Rural Economy And People (DEEP), is a Trust exclusively to undertake its Corporate Social Responsibility's (CSR) activities. DEEP operates independently under the visionary and professional guidance of the Board of governors. It work towards holistic development of the communities through integrated social development approach in nearby villages with a focus on multiple thematic sectors such as Health, Education, Social Up-liftment, Livelihood, Infrastructure Development, Environment Protection and helping in Land-Loser’s development also. It works at grass-root level, Ensures active participation of communities at all stages of project development and implementation by employing consultative processes. It is working since commissioning of the plant. ……………………………………………………………………………………… Approach The approach of DEEP is founded on Pillars shown in adjacent figure ………………………………………………………………………………………… The Deep has made large no of Toilets, Water Tanks, Small Stop Dams, School, Roads inside Villages, Self Help Individuals, Arranging various types of Programs for Social Uplift & Education. Please refer the attached annexure to know the details of work done by DEEP

Documents

Surat Lignite Power Plant - Green Business Centre