12.gujareat industries · 2018-09-13 · 352&(66 /$
TRANSCRIPT
GUJARAT INDUSTRIES POWER COMPANY LTD
SURAT LIGNITE POWER PLANT
M.Kumaravelu,DGM(EM Cell)Nilesh Dhori,Manager (O&M)
GIPCL COMPANY PROFILEAn IMS (9001, 14001, 18001, 50001) Company, Established in 1985
TOTAL: 1009.4 MW
SLPP 500 MW THERMAL
80 MW Solar Plant (2017),75 MW (U/Implementation) At Charankha
Gujarat
CAPTIVE MINES
112.4 MW Wind Power VADODARA 310MW GAS
5 MW Solar Plant at SLPP (2012)2x1 MW Distributed Solar Power cum Agriculture Pilot Projects
2016
PROCESS LAYOUTSURAT LIGNITE POWER PLANT
Phase-II Lignite storage shed
Phase-I Lignite Stream
Phase-II Lignite Stream
Phase-I Lignite storage shed
Phase-I Primary Crusher House
Phase-II Secondary Crusher House
Phase-I Secondary Crusher House
Phase-I Cooling Water Pump House
CW Fore-bay
Clarifier
BoilerSwitchyard
Phase-I Cooling Tower
Limestone System
Boilers
CFBC technology based Boilers.Main Operating Parameters :Capacity : Phase-I : 390 T/hr, Phase-II : 405 T/hrPressure : 132 kg/cm2,Temperature : 540 Deg C.
Turbine and Generator
Summary of Energy Savings
Annual savingsEnergy conservation
2015-162016-17
2017-182018-19
13.20MU Rs 66.04 million
.
2015-16
2016-17
2017-18
2018-19
9.29 MU Rs.49.8 million
12.79 MU Rs.56.59 million
0
10
20
30
40
50
60
70
2015-16 2016-17 2017-18
9.29 12.79 13.20
49.856.59
66.04
Electrical savings in MU
Total savings in Rs.million
Energy Saving Projects Implemented in FY 2015-16
List of Encon Projects Implemented In 2015-16
S.No. Title of ProjectAnnual
Electrical Saving (kWh)
Annual Electrical
Cost Saving (Rs million)
Annual Thermal Saving
(Ton/year)
Annual Thermal
Saving (Rs million)
Total Annual Savings
(Rs million)
Investment Made (Rs million)
Payback (Months)
Without Investment Projects
1Modification in suction of reciprocating air compressor
22000 0.0668 21.53 0.022 0.088 0 0.544
2U-2 PRDS 10% Line spray valve Modification
0 0 10380 10.38 10.38 0 0.001
3Vacuum pump 3A, 3B & 4A Performance improvement
7876000 11.814 7802.03 7.802 19.616 0 0
4
In Ph-1, Providing CT fans operation from DCS for stopping of CT fan while unplanned partial loading like backing down by SLDC.
27000 0.0401 25.88 0.026 0.066 0 1.818
List of Encon Projects Implemented In 2015-16
S.No. Title of ProjectAnnual
Electrical Saving (kWh)
Annual Electrical
Cost Saving (Rs million)
Annual Thermal Saving
(Ton/year)
Annual Thermal
Saving (Rs million)
Total Annual Savings
(Rs million)
Investment Made (Rs
million)
Payback (Months)
With Investment Projects5
Re insulation of combustor right & left water wall of U-1 boiler
0 0 5315.232 5.315 5.315 2.699 6.094
6Provision of bypass line for CCW pumps in U-4
726000 1.089 719.18 0.719 1.808 0.075 0.498
7Replacement of CT fan blade by energy efficient fan blade
100000 0.1502 99.21 0.099 0.249 0.300 14.432
8
Use of Primary air in ash cooler instead of blower air. This has resulted in reduction of running hours of ash cooler blower
522000 0.7824 516.7 0.517 1.299 0.405 3.741
9Re insulation of combustor right & left water wall of u-2 boiler
0 0 1325.6 1.326 1.326 0.455 4.119
10 Smart positioner 13000 0.0165 12.77 0.013 0.029 0.355 145.574
11U-2 HPH-6 Performance improvement
0 0 9711 9.711 9.711 0.062 0.077
Overall Total 9286000 13.96 35929.14 35.929 49.888 4.367
Energy Saving Projects 2016-17
List of Encon Projects Implemented In 2016-17
S.No. Title of Project
Annual Electrical
Saving (kWh)
Annual Electrical
Cost Saving (Rs million)
Annual Thermal Saving
(Ton/year)
Annual Thermal
Saving (Rs million)
Total Annual Savings
(Rs million)
Investment Made (Rs million)
Payback (Months)
Without Investment Projects
1Conversion of old PCH primary crusher motors connection from delta to star
193920 0.58176 186.1632 0.2234 0.80516 0 0.00
2Smart soot blowing in Phase-2 helps to saving of steam and DM water consumption and energy saving
233000 0.699 223.68 0.26842 0.96742 0 0.00
3
Limestone Mill-D compressor ACW line modification was carried out to eliminate operation of Boiler ACW booster pump
680000 2.04 652.8 0.78336 2.82336 0 0.00
4Change in operation philosophy of CW pump
87360 0.26208 83.8656 0.10064 0.36272 0 0.00
List of Encon Projects Implemented In 2016-17
S.No. Title of Project
Annual Electrical
Saving (kWh)
Annual Electrical
Cost Saving (Rs million)
Annual Thermal Saving
(Ton/year)
Annual Thermal
Saving (Rs million)
Total Annual
Savings (Rs million)
Investment Made (Rs million)
Payback (Months)
With Investment Projects
5Modification was carried out in Unit-3 to utilize Primary air in ash cooler instead of separate ash cooler blower
521600 1.5648 500.736 0.60088 2.16568 0.405 6.00
6Replacement of Cooling Tower fan blade by energy efficient fan blade in Unit-3 CT fan – 6 and Unit-4 CT fan – 2
201600 0.6048 193.536 0.23224 0.83704 0.272 1.00
7 Condenser tube cleaning (Unit-1 & 4) 5515000 16.545 5294.4 6.35328 22.8983 0.815 2.00
8Attending Air Pre heater and ESP area leakages; helped to reduce energy saving
5212368 15.6371 5003.873 6.00465 21.6418 11.6 6.00
9In Phase-I units, provision for remote On / Off operation from control room was made for one Cooling Tower fan
133700 0.4011 128.352 0.15402 0.55512 0.06 1.00
10In instrument air system, pneumatic positioner were replaced with smart positioner.
13200 0.0396 12.672 0.01521 0.05481
11In Ph-1 & 2 boilers, energy efficient surface insulation applied in remaining area to improve boiler efficiency
0 2950 3.54 3.54 0.26 1.00
Total 12791748 38.375244 15230.07808 18.27 56.59 13.41
Energy Saving Projects 2017-18
No Title of Project
Annual Electrical Saving (kWh)
Annual Electrical Cost Saving (Rs million)
Annual Thermal Saving
Annual Thermal Cost Saving (Rs million)
Total Annual Savings (Rs million)
Invest mentMade (Rs million)
Payback (Months)
QuantityUnit of Measurement
Without Investment Projects
1Saving due to improving Capacity Utilization of Lignite Handling System
3095789.1 9.5969 3243.3MT of
Lignite3.892 13.4889 0 0
2Change the controller position of Lime Stone Mill A, B & C from Air Fail to close to Air Fail to open position.
76431 0.2369 80MT of
Lignite0.0961 0.333 0 0
Energy Saving Measures Year 2017-18
No Title of Project
Annual Electrical
Saving (kWh)
Annual Electrical
Cost Saving
(Rs million)
Annual Thermal Saving
Annual Thermal
Cost Saving
(Rs million)
Total Annual Savings
(Rs million)
Invest mentMade
(Rs million)
Payback (Months)
QuantityUnit of
Measurement
With Investment Projects
3Use of PA for ash cooler instead of blower air in unit-4
521600 0.7824 546.5MT of
Lignite0.6558 1.4382 0.405 3.38
4New PCH Primary crusher motors 2x160KW changing motor connection from soft starter-Delta to star
747600 5.2482 783.2MT of
Lignite0.9399 6.188 0.113 0.22
5 Energy efficient LED lightings 4500 0.014 4.7MT of
Lignite0.0057 0.0196 0.019 11.32
6
Attending Air Pre Heater (APH) Tube leakages and Flue Gas Duct Air leakages in Units 1, 2, 3 & 4 during year 2017-18
8570784 26.6 8979MT of
Lignite10.7751 37.3445 28.097 9.03
7Use of aerodynamically designed energy efficient cooling tower fan blades in Phase-2.
91296 0.1269 95.6MT of
Lignite0.1148 0.2417 0.475 23.59
8In U-2&3 condenser tubes cleaning and vacuum pump servicing was carried out.
0 0 4054MT of
Lignite4.8648 4.8648 0.434 1.07
Energy Saving Measures Year 2017-18
No Title of Project
Annual Electrical
Saving (kWh)
Annual Electrical
Cost Saving
(Rs million)
Annual Thermal Saving
Annual Thermal
Cost Saving
(Rs million)
Total Annual Savings (Rs million)
Invest mentMade
(Rs million)
Payback (Months)
QuantityUnit of Measurement
9
In instrument air system, 9 nos. pneumatic positioners replaced with smart positioners. This helped to reduce consumption of instrument air and saving of electrical energy
11878 0.0333 12.4MT of
Lignite0.0149 0.0482 0.327 81.53
10In Unit 2& 3 boilers, energy efficient surface insulation applied
0 0 1425MT of
Lignite1.71 1.71 0.828 5.81
11
In Phase-I units, provision made for remote On / Off operation from control room for Two additional Cooling Tower fans. This will help to stop CT fans during unplanned partial loading like backing down by SLDC, outage of equipment, etc. for prolonged period.
81855 0.2538 85.8MT of
Lignite0.1029 0.3567 0.06 2.02
Total 13201733 42.8924 19401.07 0 23.172 66.0336 30.758 137.97
Energy Saving Measures Year 2017-18
SPECIFIC POWER CONSUMPTIONYEAR 2015-2017
Fin Year Net Station Heat Rate
Auxiliary Power Consumption
in %Remarks
2015-16 2943.32 12.5
2016-17 2995.49 12.9Higher APC and Heat rate due to higher moisture(2 % rise)
in lignite
2017-18 3042.22 12.9Higher APC and Heat rate due to higher moisture(2 % rise)
in lignite
Information on Competitors, National & Global
benchmark
Similar capacity CFBC Plants
HEAT RATE- 2598APC - 10.44
Raj west Power Ltd GIPCL-SLPP NLC barsingsar ATPS akrimota
HR -2581.2APC -12.24
HR -2547.36APC -12.65
HR -2675APC -15.6
Road Map
&
Action plan for 2018-19
Sr. No. Energy Saving Measures
Invest ment
in Lacs
Annual Energy Savings Annual
Energy Saving Lacs
Simple Pay back Period
(months)
Action planCoal
in MT
Electricity in kWh 2018-19
1
Overhauling of Raw Water Pump and providing energy efficient coating on impeller 1 353320 10.6 1.13
overhauling done for pump 2June 18
2Install Variable Frequency Drive in ETP Ground Pond Pumps 0 72,708 2.18 Immediate study u/P.
3 Phase 1 Compressor ACW Modification 1 68672 2.06 5.8one compressor completed
4Reduce Single Stage of Condensate Extraction Pump of Unit – 3&4 6 273312 8.19 8.8
One pump completed in unit-4 in May 18
5Running hour optimization of ETP Guard Pond pump by arresting leakages 0.5 27664 0.83 7.2 work u/p
6Replacement of 120 nos. 150 W HPSV Lamps by 70 W LED Fixtures 16.8 51903 1.56 120 Procurement U/P
Energy Saving Proposals and Action Plan for the Year 2018-19
Sr. No. Energy Saving Measures
Invest ment in Lacs Rs.
Annual Energy Savings Annual
Energy Saving
Lacs Rs
Simple Pay back Period
(months)
Action planCoal Electricity in kWh
2018-19
7
Arresting of Air ingress at different sections of Flue gas path in all the four boilers, thereby reducing ID Fan loading 80 2563147 76.89 12.5 work u/p
8Providing insulation on poor insulated surface 5.18 1102.6 11.53 5 work u/p
9Condenser Cleaning by Bullet cleaning Method 11 10524 110 1.2 2 units planned
10Phase-II CT Fan blades replacement with energy efficient blade 3 85497.6 2.56 14.06 2 nos planned
11
In instrument air system, replacement of 10 nos. pneumatic positionerswith smart positioners is planned
3 13200 0.41 7
10 nos plannedTotal 127.48 11626.6 3,509,424 226.81
Energy Saving Proposals and Action Plan for the Year 2018-19
Innovative-project 1PCH motors to Start In Delta Connection With Soft Starter & Running In
Star Connection
Motors operates at loads below 40-45 % of rated capacity running in STAR mode is an inexpensive and effective measure.
In case of New PCH Primary Crushers, we have Soft Starters for starting the motors.
With soft starter, total starting current of both motors remains around 2600-2700 Amps, while without soft starter it will reach more than 4000 Amps.
The main challenge was to keep soft starter in line during starting & to convert motors in STAR during running.
This was unique & perhaps first of its kind of modification as two different types of motor starters i.e. Soft Starter & Delta-Star starter is used for limiting initial current and running in STAR mode.
Innovative-project 1
Reduction in Power for both the motors = 70 x 2 KW = 140 KWh
SAVING PER YEAR Rs.52,48,152
Innovative Project-2Air ingress checking in APH and flue gas ducts
It is very difficult to find out air ingress inside insulation in flue gas duct fromAPH to ID fan
Conventional practice to measure the O2 in different areas to find out the airingress but exact location could not be identified.
Innovative idea to find out exact location by pressurization.Immediately after unit shutdown pressurization of flue gas path is carried out toidentify exact air ingress points and same will be attended during shutdown.
Benefits : Reduction in fan loading will help in energy saving
Innovative Project 2Air ingress checking in APH and flue gas ducts
Flue gas coming out during pressurization Flue gas leakage area
Flue gas leakage after insulation removal
Innovative Project 3Change the controller position of Lime Stone Mill A, B & C from Air Fail to
close to Air Fail to open position.
In PH-1 for FO initial heating in recirculation line (to reach permissibleFO Temp for firing ) we have to run mill compressor (motor rating 37 KW)at and average 03 hrs idle daily only for recirculation valve opening as it isair fail to close type.
Logic of HFO recirculation valve modified from air fail to open to air failto close.
Innovative Project 3
By changing the valve Logic from Air Fail to Close to Air Fail to open position it is possible to stop 3 compressors for 3 hrs daily.
Energy Saving per annum = 35260 kWh
Energy Saving Rs. Per annum = 63468/- Rs.
Pneumatic valve in HFOrecirculation line
YearCO2 Emission
(MT)Specific CO2 Emission
(MT/MWhr)
2015 - 16 3,395,183 1.258
2016 - 17 3,592,271 1.297
2017 - 18 3,684,810 1.292
BEST PRACTICES
Energy Management CellInvolvement of Employees, Team work
Energy Management Cell Established in the year 2010
Company Energy Manager -convener of the cell
.
Total 28 BEE certified Energy Auditors/Energy Mangers of
various departments
Energy Management Cell meetings conducted under chairmanship of Station Head
Review and implementation of suggestions
Suggestion format kept in the common server
Best practices Switching off the lights before leavingawareness created by sign boards and stickersnear the switch board
Any energy leakages (Steam, water, fuel, air) attended on top priority.
Auxiliary equipments running duringshutdown reduced by changing the operationand maintenance practices
Procurements are being made withinsistence of Energy Efficient specifications.
Intranet & internet is being usedextensively for all communication purpose,this has resulted in energy & environment saving
Best PracticesEnergy Management Cell
Suggestion box
Suggestion boxes at various
locations to enable wide participation of the employees
Energy Conservation Day
Celebration of Energyconservation day -
conducting quiz / Slogan / Painting competition amongst employees & their family members
Awareness programs
Energy awareness camps in schools of the surrounding
villages
LED lightings
Colony street lighting replaced
with LED lightings & use of Solar
street Lighting in Solar
.
Quiz organized on Energy Conservation Day
Oath Taking Ceremony on EC Day
Energy Conservation Day Celebration
Painting Competition on EC Day
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(Tonn
es)
Gas(Nm3)
Oil(kL)
Actual Energy consumption (Avg. of last 12 months)Theoretical Energy consumption per year after implementation
Expected Saving of energyEnergy tariff, Rs/ (kWh or Tone or Nm3
or Kl)Expected saving in Rs./yearOther 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)
GasNm3
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 GM (SLPP)
A. Action plan for implementation of proposal after acceptance.
SL. NO.ACTIONS PL
ANNEDRESPONSIBIL
ITYTARGET DATE
Completion Date
Resource re
quirement
Power (KWH) Coal(Tones)
GasNm3
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 Energy Manager
Sign of GM (SLPP)
Energy Conservation Program
% Investment for Energy Conservation Projects on
Turnover
Year Investment Made (Rs Lacs)
% on Turnover
FY 2015-16 43.66 0.03%
FY 2016-17 134.12 0.10%
FY 2017-18 307.58 0.22%
ISO-50001 Implemented in 2013
Energy Aspect identification & Prioritization register.
Doc. No: F/SLPP/27Rev. Dat
e: 01.01.2013
Rev. No: 00BC= 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. AreaMain Equipment/
Auxillary
Capacity in KW
/ HP*
Energy Aspect (Use)
BC LC SEU
Renewable
Energy P
Existing Consumption
Running Hrs./ Day
Total Consumption Level
(Per Day)C
Potential % of Saving
Envisaged saving potenti
alScore =(C*E)
S / NS
Existing Controls
Aditional Measure
SteamPow
erCoa
l NG
Overriding
FactorKg/ Hr kW
MT/ hr
SM3/ hr G Cal KWH % <= (E)Operational Co
ntrol
Engineering Con
trol
Energy Monitoring Format adopted
Renewable EnergyThe Company is concerned towards Global Climate Change andventured in to generation of power using following renewable energysources.
Total 112.4 MW Wind Power Generators
Total 87 MW (2x40, 5, 2 X1 MW) Solar power plants
5 MW Solar Power Plant
2 x 1 MW Distributed Solar Power cum Agriculture Pilot Project
75 MW Solar Power Plant - The plant is under construction at GujaratSolar Park at Charankha
Total 70 kW Solar power is being tapped from plants installed over
School & Town Center Rooftops
During cleaning activity at LHS plant, the water gets contaminated with lignite dust. Contaminated water is collected in two run-off water ponds and allowed for settling of the dust. Lignite dust collected /removed and dumped into the in-plant lignite stock yard . The overflow water after dust settlement is pumped back to clarifier. After clarification, it is sent to guard pond and it is pumped to plant for various use.
Runoff Pond Lignite dust recovery Guard Pond
Nursery developed using Vermi compost produced.
Biodegradable waste from Industrial canteen,Guest Houses Mess and kitchen waste from colonyresidents is being collected and converted in toCompost.
Food Waste ManagementFly ash Utilization
100 % Ash utilization in brick manufacturing and road construction
Best practices onGreen Supply chain
Mentioning energy efficient criteria in the purchaserequisition. Energy Manager shall support for determination& identification of energy efficient criteria.
The applicability of energy purchasing specifications mayvary from market to market. Energy purchasingspecification elements could include energy quality,availability, cost structure, environmental impact and renewable sources.
While evaluating all technical & commercial offers fromvarious suppliers, Purchase shall also evaluate the supplieron the basis of energy performance of Equipment, Systemor Machinery, before finalizing..
After receipt of material/ equipment/machinery its energy use,energy consumption & variables shall be measured &monitored as per the define energy review & planningprocedure.
Amount Of Replication Arising Out Of Best Practices Implemented On Energy Front In Green Supply Chain
Energy Efficient Purchase Benefits
Boiler Surface insulation Around 3 MT of lignite saving per m2 area/year
Air conditioners 5 star rating
LED lightings 20 KW/Fixer
CT fans 30% reduction in existing consumption
Ceiling fans 5 star rating
Smart positioners 0.1507 KW / positioner
National Energy Conservation Award
Year 2013
Excellence in Energy Management Award
Year 2014
First prize in “BEST IN WATER USE”
Energy ConservationAward FY 2014-15 bySGCCI, Surat
Energy Efficient Unit Awarded By CII in 2017
‘‘Golden Peacock Eco-Innovation Award’ for the year 2017 for Distributed Solar Power Project (DSPP)
Winner of “National Fly Ash Utilization Award-2018”
Environment Excellence Award-2017
Outstanding performance in environment conservation and pollution
control-2017 “Power Plant Performance –2018– Lignite”
Awards
Thank you!!There is always scope for further improvement