Presentation Title ( Arial, Font size 28 ) Energy Efficiency Management – Date, Venue, etc ..( Arial, Font size 18 ) TATA POWER Trombay Unit#8 17 th National Energy Efficient Management Award 2016 22nd – 24th August 2016, CII- Hyderabad …Message Box ( Arial, Font size 18 Bold) Technology Adopters in Energy Management Technology Adopters in Energy Management Recommended LCI drives ( V / F control) for 6.6 KV motors ISO 50001 Certification 415 V VFD used for 6.6 KV auxiliary Energy efficient coating (Coro coating) & Fluid couplings for pumps Pipe Conveyors with VFD’s for coal transportation Key Energy Management Impeller trimming in HT pumps Initiatives AT Trombay CFD analysis & its implementation for flue gas ducting Combustion optimization Compressed Air pressure controller, Light Pipes, Turbo ventilators, Micro wind & Hybrid Units In-house developed Energy management system for monitoring using PI …Message Box ( Arial, Font size 18 Bold) �
Trombay: Present Generation Capacity Trombay: Present Generation Capacity Established in 1956 Capacity Unit Year Fuel Used (MW) Unit 5 1984 500 Coal, Oil & Gas Unit 6 1990 500 Oil & Gas 120+60 = Unit 7 1993-94 Gas (CCPP) 180 Unit 8 2009 250 Coal Total Generation Capacity : 1430 MW 4 …Message Box ( Arial, Font size 18 Bold) Specific Energy Consumption of Last three Years Specific Energy Consumption of Last three Years Recovered from major catastrophe …Message Box ( Arial, Font size 18 Bold)
Benchmarking Parameters ( 250 MW UNIT 8) Benchmarking Parameters ( 250 MW UNIT 8) DTPS Tata Power HEAT RATE UoM Dahanu Trombay Unit 8 Best Performance Best Performance (FY12) (FY14) 2282 2259.6 Actual Heat Rate Kcal/kwh Deviation in Heat rate Kcal/kwh -22 Tata Power Trombay DTPS (Dahanu) Auxiliary Power Unit 8 UoM Consumption Best Performance Best Performance (FY11) (FY16) Actual Auxiliary Consumption % 7.38 6.2 Deviation in Auxiliary % -1.18 Consumption � Information Sourced from CII Award PPT, MERC tariff order …Message Box ( Arial, Font size 18 Bold) Energy Saving Projects : FY 14 Energy Saving Projects : FY 14 Total Annual Invest. Made Energy Saving projects implemented in FY 14 Savings Rs Million Rs Million Civil Lighting Saving project by transparent roof tops in three cell 0.1 0.30 collectors Additional O2 Transmitters on both sides of RAPH 1.3 0.5 Installation of COC Power supply switch for to ON/OFF COC in running 0.6 0.01 Feeder condition & replacement of Failed Shear pin in running Feeder Combustion Optimisation 9.2 2 Replacement of Compound Lights with LED lights 1.4 0.5 Cut-in & cut-out set point revised for Station air compressor saved 0.1 NIL auxiliary power consumption Total 12.7 3.31 …Message Box ( Arial, Font size 18 Bold)
Energy Saving Projects : FY 15 & FY 16 Energy Saving Projects : FY 15 & FY 16 Total Annual Invest. Made Energy Saving projects implemented in FY 15 & 16 Savings Rs Rs Million Million Stopping of one CW pump due to sub cooling (22 million saving in 17.8 Nil FY15) Replacement of BFP cartridge 1.08 1.4 Replacing Roof tops of stores with transparent roofs 0.3 0.93 Provision of ON/OFF Push button at various switchgear & unmanned 0.37 0.11 location Combustion optimisation 0.5 0.01 Total 20.05 2.45 …Message Box ( Arial, Font size 18 Bold) Energy Saving Projects Planned In Next Three Years Energy Saving Projects Planned In Next Three Years Estimated Estimated Annual Energy Saving projects Investment Savings (Rs Million) (Rs Million) Arresting Air infiltration in Flue gas path 2.51 2 Combustion optimisation 0.6 Nil Boiler Skin plate insulation improvement 0.1 0.84 Optimisation of Compressed air pressure 0.06 0 Improving Coal conveying system Efficiency using Six Sigma 4 2 Total 7.27 4.84 � Installation of measurement and monitoring system for of AC & Lighting load (strengthening of monitoring systems) ISO 50001 project …Message Box ( Arial, Font size 18 Bold)
Stopping of one CW pump due to sub cooling Stopping of one CW pump due to sub cooling Idea description : Heat rate & Aux power Saving from condensate Key enablers: Syndicated system • Higher Auxiliary power consumption Before: . Unit was operated at higher vacuum with 4 CW Pumps • Higher Turbine cycle Heat running. Rate After : Unit operated at rated Vacuum with 3 CW Pump Trigger : Sub Cooling in the Condenser Condensate Hot well Temperature Design Temperature : 45 Deg C , Actual Temperature : 40 Deg C KPI impacted Savings Investment ROI (%) (Rs. Million) (Rs. Million) Auxiliary 1.7 0 NA Consumption Auxiliary power consumption of CW Pump Method of KPI impact measurement …Message Box ( Arial, Font size 18 Bold) Final Outcome & Benefits Final Outcome & Benefits Condensate Temperature Sub cooling Reduction 49 -0.95 45 Condensate Temperature (Deg C) 42 44 -0.95 40 39 -0.94 Condenser Vacuum 34 -0.94 29 -0.93 -0.927 24 -0.93 19 -0.92 -0.919 -0.915 14 -0.92 9 -0.91 4 -0.91 -1 -0.90 Design FY 15 FY 16 � Improvement in Heat rate due to Investment : Nil reduction in sub cooling Reduction in Auxiliary consumption : � FY 16 Annual Savings : 17.8 Million Rs 5.9 Mus / Annum …Message Box ( Arial, Font size 18 Bold)
Innovative Project : High Velocity Traverse Test Holder Innovative Project : High Velocity Traverse Test Holder Trigger Risk of the Probe getting bend due to CW failure resulting n Unit outage Significance: High � Accurately measure O 2, CO 2 , CO at Temperature goose-neck Probe � Measure furnace exit temperature � Detects unbalanced heat transfer and flame propagation …Message Box ( Arial, Font size 18 Bold) Innovatively In-house Designed HVT holder Innovatively In-house Designed HVT holder Before After What makes it Innovative � Its in-house Design & fabrication of HVT probe holder with pulley arrangement � Utilisation of Scrap for fabrication of above probe holder. …Message Box ( Arial, Font size 18 Bold)
Benefits & Costing Benefits & Costing ���������������������������������� � �������������������������� ���� ���� ���������������������� ���� ���� �������������������������� � ������������������������ ���� ���� ������������������������� �������� ���� �������������� ���� ��������������������� ���� ���� ���� � ����������������������� ���� ���� ��������� ���������� ���������������������� ���� ���� � FY 14 FY 14 FY 15 FY 15 FY 16 FY 16 FY 16 FY 16 FY 17 ����������������������� Q1 Q3 Q3 Q4 Q1 Q2 Q3 Q4 Q1 ���������� ������ � ��������������������� • 0.1 Lakhs Investment ����������������� ���������� Annual • 5 Lakhs Savings …Message Box ( Arial, Font size 18 Bold) Care For Environment- Renewable & Energy Care For Environment- Renewable & Energy Conservation Project Conservation Project Before After Replacement of OLD AC sheet with new transparent sheet along with turbo ventilators in Materials Department …Message Box ( Arial, Font size 18 Bold)
Care For Environment- Renewable & Energy Care For Environment- Renewable & Energy Conservation Project Conservation Project Use of polycarbonate transparent sheets – for Natural lighting inside bunker gallery Benefits � Illumination with natural Sunlight � Improvement in LUX levels � Saving in Auxiliary Consumption Lux intensity Before After Reqd Non Monsoon Monsoon Non Monsoon Monsoon 50-100 108 82 240 207 …Message Box ( Arial, Font size 18 Bold) Care For Community : Renewable & Energy Care For Community : Renewable & Energy Conservation Project in the Community Conservation Project in the Community Installation of Solar Lights in the Neighbouring Community � 70 Solar lights ( MV-3 model- 11 W) have been installed in dark areas of communities of Trombay to address safety of women …Message Box ( Arial, Font size 18 Bold)
Care For Environment- Fuel Handling Care For Environment- Fuel Handling (Eliminating Fugitive emission) (Eliminating Fugitive emission) � Captive Jetty with Screw Unloader to unload coal without any spillage. � Pipe Conveyors with VFD ensure transfer of coal without any spillage. …Message Box ( Arial, Font size 18 Bold) 3 Care For Environment : Waste Management Care For Environment : Waste Management (Development of greenbelt Using Bottom Ash) (Development of greenbelt Using Bottom Ash) ������������������������������ Base formation using bottom ash Covering base level with red soil Planting green carpet grass for landscaping …Message Box ( Arial, Font size 18 Bold)
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