18 th National Award for Excellence in Energy Management -2017 ESSAR POWER GUJARAT LTD (EPGL), Dist : Dev Bhumi Dwarka, Gujarat 1 1200 MW ( 2 X 600 MW ) THERMAL POWER PLANT
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 2
1. COMPANY PROFILE Location Salaya, Dev Bhumi Dwarka District, Gujarat Capacity 1200 MW (2 x 600 MW) Fuel Imported Thermal Coal • Sub-Critical Technology Technology / • BTG Package- HEI , China Equipment • BOP- Reputed Vendors ( ABB/Areva/SPIG ) • 1000 MW - Long term PPA with GUVNL Power Off-take • Balance 118 MW - Merchant Power • Presently 64 MLD River water Water • Future-Sea Water - 9375 m3/hr Requirement Power • Evacuation at 400 KV – STU Network Evacuation 3
1. COMPANY PROFILE UNIT-1 COD : 01 st April 2012 UNIT-2 COD : 15 th June 2012 PLANT OVERVIEW Boiler Area 4
Mharo EPGL High Reliability (consistent PAF) Generation Cost highly competitive amongst IPP Recognized as leaders in Energy Efficiency by CII & OSHAI Supply ~ 9% of Gujarat Recognition geographically for our demand environmental clean efforts 5
2. PROCESS FLOW DIAGRAM 6
3. SPECIFIC ENERGY CONSUMPTION Heat Rate ( Kcal / kwh ) FY 2012-13 FY 2013-14 FY 2014-15 FY 2015-16 FY 2016-17 CERC NORM 2451 2421 2339 2333 2368 2375 Kcal/kwh ( LF - 70.9 %) ( LF 68.7 %) ( LF 80.35 %) ( LF 73.40 %) ( LF 72.95 %) Aux Power (%) FY 2012-13 FY 2013-14 FY 2014-15 FY 2015-16 FY 2016-17 CERC NORM 7.1% 6.6% 5.8% 6.1% 6.2% 5.75 % ( 293 MU ) ( 356 MU ) ( 386 MU ) ( 317 MU ) ( 327 MU ) Specific Oil Consumption ( ml / kwh ) FY 2012-13 FY 2013-14 FY 2014-15 FY 2015-16 FY 2016-17 CERC NORM 0.5 ml/kwh 1.8 0.32 0.23 0.28 0.29 DM Water Make up ( % ) FY 2012-13 FY 2013-14 FY 2014-15 FY 2015-16 FY 2016-17 CERC NORM 1.5 % 3.33 % 1.48 % 1.04 % 1.18 % 0.72 % 7
3. SPECIFIC ENERGY CONSUMPTION YOY Improvement • Good and Consistent O&M practices 90% 7000 [VALUE] MU 80% 6000 [VALUE] MU [VALUE] MU [VALUE] MU 70% 5000 [VALUE] MU 60% GHR 4000 50% GHR GHR 2451 GHR 2421 GHR 2368 2339 40% 80% 3000 2333 73% 73% 71% 69% GHR - 2416 GHR - 2372 AT 30% GHR - 2332 GHR - 2332 GHR - 2304 2000 Normative 20% Loading 1000 7.15% 10% 6.60% 6.23% 6.06% 5.83% 6.6% 5.66% 5.78% 5.95% 5.64% 0% 0 2012-13 2013-14 2014-15 2015-16 2016-17 Plant Loading Factor % Auxiliary Consumption % Gross Generation MU 8
4. SUMMARY – ENERGY SAVINGS FY 2014-16 S. No Energy Conservation Projects Cost Energy Saving Incurred M Kcal/Annum (INR Lacs) 1 Pre-Ponement of Turbine Capital Overhaul 340 115500 Turbine Operation Philosophy – Sequential v/v 2 None 99135 3 Boiler DM make up reduction. Nil 72160 4 HP Exhaust Valve modification None 52872 Condenser Vacuum Improvement – Up 5 200 24000 gradation of Cooling tower 6 Start Up Oil reduction None 23710 3,87,377 MKCAL 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 9.23 MU B TOTAL SAVINGS (MU) Total Savings in two years is 1740 (INR Lacs) 9
4. SUMMARY – ENERGY SAVINGS FY 2016-17 Cost Energy Saving Total savings Sr. Incurred /Annum /Annum No ENCON Projects (INR Lacs) (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 34390 MKcal A TOTAL SAVINGS ( MKCAL ) 1 Energy conservation in CEP Operation Nil 1.40 MU 33.1 2 OCCW pump -90 KW replaced with 37 37 0.6 MU 15 KW CCCW pump. 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 4.01 MU B TOTAL SAVINGS ( MU ) 10 Total Savings is 573 ( INR Lacs )
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5. INNOVATION : OCCW SYSTEM MODIFICATION 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 = 0.60 MU Annual Commercial Savings- INR 15 Lacs 13
OCCW system (Original Scheme ) OCCW-M 3 CCCWP DISCHARGE OCCW-M -6 OCCWA Filter OCCW-M -4 s OCCW-M 1 OCCW-M 2 From circulating To CW pipe PHE-A water pipe CCCW-HE OCCW-M -7 OCCW-M - 9 OCCW-M -5 OCCWB PHE-B 90 KW Return to circulating water OCCW-M -8 To Circulating pipe water O/L pipe Working oil cooler M-BFP Lube oil Lube oil cooler for T-BFP cooler M-BFP
OCCW system (Modified Scheme ) OCCW-M 3 CCCWP From circulating DISCHARGE OCCW-M -6 OCCWA Filter water pipe OCCW-M -4 s OCCW-M 1 To CW pipe PHE-A CCCW-HE Return to OCCW-M -7 OCCW-M - 9 OCCW-M -5 circulating water OCCWB pipe PHE-B Service water Tank PHE-A PHE-B 37 KW Savings of Working oil cooler M-BFP 50 KW Lube oil Lube oil cooler for T-BFP cooler M-BFP
INNOVATION : REDUCTION OF SH SPRAY 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 Annual Thermal savings/annum = 3928 Tons of coal Annual Commercial Savings- INR 185 Lacs 16
INNOVATION : CONDENSATE EXTRACTION __PUMP OPERATION OPTIMIZATION Overview - CONDENSATE WATER SYSTEM Change in operational philosophy of CEP M Details- Saving of power consumption of condensate extraction pump at technical minimum loading. M Design philosophy of CEP operation is 2 M Working and 1 stand by. Ho M M M M t Stopping one CEP running of unit on only one M We M CEP at low load (Technical minimum-330 MW) ll M M M M in case of SLDC back down condition. M M M M Total Running Technical minimum Con CEP M den Hours (FY 16-17) hours @ 330 MW B M CEPA M sate Unit 1 6458 934 M Pum p C Unit 2 5453 1069 M Energy savings/annum M M M M = 1.404 MU M Annual Commercial Savings- INR 33.1 Lacs CPU 17
INNOVATION : ENERGY CONSERVATION COAL HANDLING SYSTEM 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 18
ENERGY CONSERVATION COAL HANDLING SYSTEM Sp. Consumption Kwh/Ton of coal 2 1.79 While Road logistic is being monitored in Rs/MT/KM 1.8 Why not coal conveying in Kwh/MT/KM ? 1.6 1.4 1.14 1.2 1.05 1 0.8 0.6 0.4 0.2 0 2014-15 2015-16 2016-17 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 19
INNOVATION : ENERGY CONSERVATION IN ASH HANDLING SYSTEM 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 20
ENERGY CONSERVATION IN ASH HANDLING SYSTEM SP. Consumption Kwh/Ton of Fly Ash 16 13.6 14 12 10.19 9.34 10 8 6 4 2 0 2014-15 2015-16 2016-17 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 21
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