1-ntpc sail power company (pvt) ltd bhilai
DESCRIPTION
Power plant descriptionTRANSCRIPT
Presentation For 14th CII National Award For“EXCELLENCE IN ENERGY MANAGEMENT”
19-20 Aug 2013, Hyderabad
M K SINGHA A PRASADM S KARTHIK
• A JV of two Maharatnas, NTPC and SAIL, established in March,2001.
• Company Turnover (2012-13 ) : 1866.8 Cr.
• Total Number of Employees : 817 (as on 30.06.2013).
NTPC-SAIL Power Company (Pvt.) Ltd
Introduction
BHILAI PP-3 2*250MW 500 MW SAIL & DD/DNH/CSEB
BHILAI PP-II 30*2+14 74 MW SAIL Captive
ROURKELA 2*60MW 120 MW SAIL Captive
DURGAPUR 2*60 MW 120 MW SAIL Captive
NSPCL 814 MW (500MW captive rest to Grid)
BHILAI
NTPC-SAIL Power Company (Pvt.) Ltd
Teamwork
InnovationRespect
Integrity & Honesty
People
Sincerity & service
orientation
CORE VALUES
Our Core Values…..
Vision : To be an Efficient Power producer delivering consistent valueto stakeholders
Mission : To be recognized as a reliable power producer in the country.
BHILAI
POWER GENERATION PROCESS
NTPC-SAIL Power Company (Pvt.) Ltd
PERFORMANCE Highlights
• Unit-1 date of Commercial Operation : 22/04/2009
• Unit-2 date of Commercial Operation : 21/10/2009
• 6th rank on All India basis for PLF in 2012-13.
•• 11stst rank rank on All India basis for PLF 103.5 % in Oct’10
•• 11stst rank rank on All India basis for PLF 105.07 % in Dec’11.
•• 1st rank 1st rank on all India basis for best PLF (103.558%) in June’12 and 1st Quarterly (Apr-June’12) PLF of 101.67%
BHILAI
NTPC-SAIL Power Company (Pvt.) Ltd
Innovation……Culture of NSPCL
SEC
Reduce APCControl ParametersAffecting Heat Rate
ENCON
BHILAI
NTPC-SAIL Power Company (Pvt.) Ltd
Key Initiatives to Reduce APC BHILAI
Modification Done(2010-11)
Investment( in Lacs )
Savings In APC( Mu)
Interconnection has been provided between both ESP fluidizing blowers, after which only one Blower is kept in service.
No 0.355
Arresting of Air Ingress in Flue gas duct and APH
12.0 0.769
Condenser Tube cleaning using acid as tubes were very dirty (Poor water quality during initial times)
15.0 11.0
Modification Done(2011-12)
Investment( in Rs )
Savings In APC(Mu)
One of the IAC has been stopped and kept as standby for which a logic is provided for auto start.
NO 2.102
NTPC-SAIL Power Company (Pvt.) Ltd
BHILAI
IAC-1
PAC-2IAC-2
PAC-1
Modification Done(2011-12)
Investment( in Rs )
Savings In APC( Mus )
Interconnection of Ash Handling Compressed air system with that of Main plant Compressed air system, thereby stopping compressors of AHS.
NIL 1.33
Interconnection of Mill Reject conveying air system with Main Plant Service air system thereby stopping Mill Reject conveying Compressors.
NIL 0.164
Reduction of Auto Cut-of and Re-Start pressure of IAC from 7.4/6.8 to 6.4/5.8 Ksc(Reduction by 1 Ksc)
NIL 0.24
NTPC-SAIL Power Company (Pvt.) Ltd
BHILAI
NTPC-SAIL Power Company (Pvt.) Ltd
BHILAI
Modification Done(2012-13)
Investment( in Rs )
Savings In SEC( Mu)
Tap off has been provided from recovery & effluent discharge header into mixing chamber directly. Hence, running of waste water holding pump has been stopped.
NO 1.17
NTPC-SAIL Power Company (Pvt.) Ltd
BHILAI
Modification Done(2012-13)
Investment( in Rs )
Savings In APC ( Mu )
Jockey pump taken in service with provision of pneumatic re-circulation valve. System is running in auto with jockey pump in service. Frequent start / stop of jockey pump / compressor / hydrant pump avoided
NO 0.67
Total APC Savings ( in Mu) 17.8
Equivalent Savings in SEC (Kcal/Kwhr) 4.223
NTPC-SAIL Power Company (Pvt.) Ltd
Efforts To Control Heat Rate
• Daily monitoring of Condenser performance and Unit heat rate deviation
(24hr avg data).
• Timely inspection of Aux. Air Dampers (in every shift) for their
mismatch to have better combustion.
• PA flow through mills are maintained as per coal feeding to avoid
secondary combustion, which increases dry flue gas losses.
• Operational parameters being maintained near to rated value.
• A separate mimic diagram displaying instantaneous Heat Rate Deviation
and helps in keeping vigil on Heat rate deviation due to operating
parameter.
BHILAI
BHILAI
NTPC-SAIL Power Company (Pvt.) Ltd
ENCON…….A Continuous Process BHILAI
Year Of Implementation
ENCON Projects
Implemented
Annual Thermal Savings
Tons of Fuel.
Total Savings
In SEC
(Kcal/Kwhr)
2010-11 Attending APH and Flue Gas Duct air ingress
496 0.4188
Condenser Tube Cleaning
9900 8.3612
Sub Total 10396 8.78
NTPC-SAIL Power Company (Pvt.) Ltd
BHILAI
Year Of Implementation
ENCON Projects
Implemented
Annual Electrical Savings
Units
Total Savings
In SEC
(Kcal/Kwhr)
2011-12 Attending APH and Flue Gas Duct air ingress
0.88 0.599
Reduction of IAC & PAC air Pressure
0.235 0.161
Sub Total 1.115 0.76
NTPC-SAIL Power Company (Pvt.) Ltd
BHILAIYear Of
ImplementationENCON Projects
Implemented
Annual Thermal Savings
Tons of Fuel
Total Savings
In SEC
(Kcal/Kwhr)
2012-13 Attending APH and Flue Gas Duct air ingress
4000 3.402
Insulation Survey
1220 1.038
Condenser Tube Cleaning
9750 4.44
Sub Total 14970 8.88
NTPC-SAIL Power Company (Pvt.) Ltd
Future ENCON Projects…..Impact On CER BHILAI
Year Project Investment(in Lacs)
Savings In SEC
Savings of CO2(tons)
2013-14
Installing VFD in Condensate Extraction Pumps.
230 1.0 2815
Avoiding continuous running of Condensate Make up Pump
0.25 0.246 410
Providing Orifices in selected Equipment in cooling water lines to reduce DM water flow, thereby reducing loading of DMCW pump.
0.23 0.141 237
Year Project Investment(in Lacs)
Savings In SEC
Savings of CO2(tons)
2013-14Replacement of normal Tube light and Halogen lamps with LED lamps in selected areas.
7.5 2.1 6000
Auxiliary power consumption Audit
5.0 NIL
2014-15
Replacing Hydraulic Scoop of ID fan with VFD.
6250 0.837 2725
5MW Solar Power Plant at Daman Diu has been planned.
(as per CERC rate)
34065
NTPC-SAIL Power Company (Pvt.) Ltd
BHILAI
NTPC-SAIL Power Company (Pvt.) Ltd
BHILAI
Year Project Investment(in Lacs)
Savings In SEC
Savings of CO2(tons)
2014-15
Addition of one layer of baskets in APH for more heat recovery
7.5lakhs 2.1 6000
Helium leak detection test.
Optimization of PA fan operation by Installing VFD in PA Fan
Attending air ingress in APH and Flue gas duct
NTPC-SAIL Power Company (Pvt.) Ltd
Parameter 2010-11 2011-12 2012-13
All India Rank 16 12 6
Generation (MU) 4019.7 3978 4029.76
PAF % 92.72 92.95* 98.88
PLF % 91.73 90.57 * 92
APC % 8.55 8.456 8.643**
* Lower PAF/PLF in 2011-12 was due to coal shortage
** Backing down of Generation led to Higher APC and SEC.
Performance Highlights BHILAI
NTPC-SAIL Power Company (Pvt.) Ltd
BHILAI
Our Target……Benchmark SEC
NTPC-SAIL Power Company (Pvt.) Ltd
Design Station Net Heat Rate – 2457 Kcal/Kwh
BHILAI
NTPC-SAIL Power Company (Pvt.) Ltd
BHILAIImplementation Methodology
STATION LEVEL
NTPC-SAIL Power Company (Pvt.) Ltd
BHILAI
• Quality Circle
• Professional Circles
• Suggestion Schemes
• Participation in Energy Conservation Campaigns
•Cost Control Campaigns
•Water Saving Campaigns.
Employee Involvement Activities
NTPC-SAIL Power Company (Pvt.) Ltd
BHILAIMonitoring……Key to Energy Management
• Checklist to compare trends of critical parameters.
• Timely Energy audit of Equipment to access their performance.
• Weekly Review by Senior Management
• Real time measurement of Heat Rate Deviation
• Preventive Maintenance of Machines to avoid energy loss due to sudden Outage of Machines.
NTPC-SAIL Power Company (Pvt.) Ltd
Waste Utilization & Environmental Projects
• Utilization of Ash
Fin. Year Ash Gen. (MT) (Approx.)
Total Utilization
(MT) (Apprx.)
Fly Ash Utilizn %
Total Utilizn %
09-10 598593 28132 4.70 3.76
10-11 950307 229638 24.16 19.33
11-12 1144528 325209 35.52 28.41
12-13 994534 697635 88 70.15
13-14 229144 179,434 97.88 78.31
BHILAI
NTPC-SAIL Power Company (Pvt.) Ltd
• Zero Effluent Discharge- ETP and STP has been installed in the plant to have zero discharge. The water is recycled for use in Ash water system.
• 120 KLD- STP has been installed in township to avoid ground water contamination & to reduce water consumption by using treated water for gardening purpose.
• Rain water harvesting system-06 nos rain water harvesting pits constructed across township for recharging ground water at a depth of -15m.
• Tree Plantation -Total sapling plantation till 2012-13 is 2.20 Lakhs.
BHILAI
NTPC-SAIL Power Company (Pvt.) Ltd
Awards & Accolades
• NSPCL received 10th Best Employer award, and “Best HR Strategy in Line with Business” from World HRD congress-2013
• Great Place to Work-2012 (Top 20 companies in India) and 3rd in Manufacturing sector.
• Edward D Buno HR Innovative practices Award-2012
• CEO of NSPCL was conferred with “Exemplary Leader Award” .
BHILAI
NTPC-SAIL Power Company (Pvt.) Ltd
BHILAI