8.tata power cii energy award u8 - 2018 rev · 6wrsslqj ri rqh &: sxps gxh wr vxe frrolqj...

…Message Box ( Arial, Font size 18 Bold)

Presentation Title ( Arial, Font size 28 )

Date, Venue, etc..( Arial, Font size 18 )Energy Efficiency Management –

TATA POWER TROMBAY Unit # 8 (250 MW)

19th National Energy Efficient Management Award 201829th – 31th August 2018, CII- Hyderabad


"Cheap and abundant electric power is one of the basic ingredients for the

economic progress of a city, a state or a country"

Mr. Jamsetji Nusserwanji Tata( 3rd March 1839 - 19th May 1904 )

Vision of our founder – Mr. Jamsetji Tata

Serving the Nation since last 150 years


India's largest integrated power company with presence across the entire value chain -fuel, fuel logistics, generation, transmission, distribution and power trading

Founded in 1906 to supply power to Mumbai

»First hydro plant commissioned in 1915 at Khopoli

»Set up thermal power plants in Mumbai in 1950s

Expanded in India after private sector reforms

in 1990s

Thrust on renewable including hydro, wind,

solar and geothermal

Successful Public Private Partnerships in

generation, transmission and distribution

The Tata Power Company Limited

Green Generation Capacity

3517 MW

Thermal Generation Capacity

7340 MW

Total Installed Generation Capacity

10857 MW

Solar Wind Hydro Waste Heat

1288 MW 1161 MW 693 MW 375 MW

32% of total Capacity


First 150 MW unit in India (1965) at Trombay

First 500 MW unit in India (1984) at Trombay

First to Use Bombay High Gas in 1977 at Trombay

First to Introduce SCADA and Fiber Optic ground wire communication

First Flue gas Desulphurization Plant for removal of SO2 emission at Trombay

First pump storage unit in the country of 150 MW Capacity at Bhira

First 800 MW supercritical thermal unit at Mundra

First Largest Wind Turbine Generator 2 MW at Visapur

First Largest single location photovoltaic installation 3 MW at Mulshi

MOMENTS

OF

PRIDE

Technology Pioneers in Indian Power Industry

First 25 MW solar power plant in India at Mithapur


Trombay Operations&

Specific Energy Consumption

Trombay Thermal Power Station


LCI drives ( V / F control) for 6.6 KV motors

415 V VFD used for 6.6 KV auxiliary

Pipe Conveyors with VFD’s for coal transportation

Energy efficient coating (Coro coating) & Fluid couplings for pumps

Impeller trimming in HP pumps

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 Process interface (PI)

KeyEnergy

Management Initiatives

ATTrombay

Technology Adopters in Energy Management andISO 50001- 2011 Certification

ISO 50001 Certificate


Trombay (Established in 1956): Present Operating Capacity : 930 MW

Unit YearCapacity

(MW)Fuel Used

Unit 5 1984 500Coal, Oil &

Gas

Unit 7 (CCPP)

1993-94 120+60 =180 Gas

Unit 8 2009 250 Coal

Most Stringent

environment

Max Daily SO2 emissions

24TPDMaximum Ash generation limit

766 MT / Day


Specific Energy Consumption of Last three Years


HEAT RATE UoMDTPS

DahanuTata Power

Trombay Unit 8

Best PerformanceBest Performance

(FY14)Actual Heat Rate Kcal/kwh 2282 2260

Deviation in Heat rate Kcal/kwh -22

Auxiliary Power Consumption

UoM DTPS (Dahanu)

Tata Power Trombay Unit 8

Best PerformanceBest Performance

(FY 16 & FY17)

Actual Auxiliary Consumption % 7.38 6.20

Deviation in Auxiliary Consumption

% -1.18

Benchmarking Parameters ( 250 MW UNIT 8)


Energy Saving projects implemented in FY 15 & FY 16Total Annual

Savings Rs Million

Invest. Made Rs Million

Stopping of one CW pump due to sub cooling (8.8 million saving in FY15)

26.58 Nil

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 location

0.37 0.11

Combustion optimisation 0.5 0.01

Total 28.83 2.45

Energy Saving Projects : FY 15 & FY 16


Energy Saving projects implemented in FY 17 & 18Total Annual Savings Rs

Million

Invest. Made Rs Million

Unit 8 Stopping of one CW pump to avoid sub cooling 31.80 Nil

Unit 8 RAPH basket & seals replacement 6.26 18

Unit 8 RAPH basket & seals replacement and arresting the air infiltration 4.19 6.53

Unit-8 Condenser Vacuum 8.18 0.05

Total 50.43 24.58

Energy Saving Projects : FY 17 & FY 18 Energy Saving Projects Planned

Energy Saving projects PlannedEstimated

Annual Savings Rs Million

EstimatedInvestmentRs Million

Unit-8 Optimizing Air Compressor Set Point 0.92 Nil

Unit # 8 Boiler Skin Insulation 0.61 0.095

Optimization of running hrs of Fly Ash Conveying system for Unit 8 0.43 Nil

Total 1.96 0.095


KPI impacted Savings (FY 16)(Rs. Million)

Investment (Rs. Million)

ROI (%)

Auxiliary Consumption

17.8 0

Method of KPI impact measurement

Auxiliary power consumption of CW Pump

NA

SyndicatedKey enablers:• Higher Auxiliary power

consumption• Higher Turbine cycle Heat

Rate

Idea description : Heat rate & Aux power Saving from condensate system

Before: . Unit was operated at higher vacuum with 4 CW Pumps running.

After : Unit operated at rated Vacuum with 3 CW Pump

Project 1: Stopping of one CW pump due to sub cooling

Trigger : Sub Cooling in the Condenser

Condensate Hot well TemperatureDesign Temperature : 45 Deg C , Actual Temperature : 40 Deg C


Auxiliary Power saving

Heat Rate saving

Description UOM Design Before AfterLoad MW 250 250 250Condenser Vacuum Bar -0.915 -0.927 -0.919Condensate Temperature at Hotwell Deg C 45.0 40.0 42.1Condensate Flow TPH 586 586 586Condensated Enthalpy Kcal/kg 45 40 42Total condensated Enthalpy Kcal 26359695 23404863 24632152Difference in Enthalpy Kcal -2954832 1227289Nos. of CWP Running for U8 Nos 4 3

Gain / Loss in Enthalpy Kcal/kwh -12 5

Description UOM After

CWP A Power Consumption in FY 16 Kwh 2182066

CWP B Power Consumption in FY 16 Kwh 5110379

CWP C Power Consumption in FY 16 Kwh 5635259

CWP D Power Consumption in FY 16 Kwh 5720269

Running hrs of 4 CW Pump combination Hrs 106

Unit 8 running hours in FY 16 Hrs 8136

Running hrs of 3 CW Pump combination Hrs 8030

Average CWP Power Consumption Kwh 737

Saving due to running of 3 CW Pump combination Kwh 5919706

Total Saving Rs. Lakhs 178


(Reduction in Aux Power & Heat Rate)


45

4042 43

-0.915

-0.927

-0.919-0.916

-0.95

-0.95

-0.94

-0.94

-0.93

-0.93

-0.92

-0.92

-0.91

-0.91

-0.90-1

4

9

14

19

24

29

34

39

44

49

Design FY 15 FY 16 FY 17

Cond

ense

r Vac

uum

Cond

ensa

te Te

mper

atur

e (D

eg C

)Condensate Temperature

Final Outcome & Benefits

Improvement in Heat rate due to reduction in sub cooling Reduction in Auxiliary consumption : 5.9 Mus / Annum

Reduction in Sub cooling

Investment : Nil

FY 16 Annual Savings : 17.8 Million Rupees (Over FY 15)FY 17 Annual Savings : 16.4 Million Rupees (Over FY 16)FY 18 Annual Savings : 15.1 Million Rupees (Over FY 17)



4.0

4.5

5.0

5.5

6.0

6.5

7.0

7.5

2500

2700

2900

3100

3300

3500

3700

3900

4100

4300

24-F

eb-1

8

11-M

ar-1

8

26-M

ar-1

8

10-A

pr-1

8

25-A

pr-1

8

10-M

ay-1

8

25-M

ay-1

8

09-J

un-1

8

24-J

un-1

8

09-J

ul-1

8

24-J

ul-1

8

08-A

ug-1

8

23-A

ug-1

8

Dis

char

ge P

r Bar

Ener

gy C

onsu

mpt

ion

Kwh

Kwh vs Discharge Pr.

Kwh Dis. Pr.

Project 2 : Optimization of Air Compressor Discharge pressure setting

Accrued saving Rs 2.4 Lacs (04

months)

Benefits: Huge Saving in auxiliary consumption. Reduced LDO consumption & cold start up time LDO gun sustainability issue solved Same is being replicate in Unit 5 also


SHIM type of adjustor assembly for Sector Plate was changed to precision Adjustor rod assembly.

Benefits: Most efficient arrangement for precise

adjustment of seal which leads to lessleakage

Less manhours for seal setting Adjustment can be done during short

outage also.

Innovative Project: RAPH Leakage Reduction

Before

After



Single Cold end sector plate Static seals converted to innovative Dual sealing system through addition of another set of static seal in the Cold end Sector plate.

Cold end Sector plate Static Seals

Axial Seal plate Static Seals

Addition sealing system (from Ash accumulation) for Guide Bearing housing improve bearing life. – Sealing Air from PA header.



Substantially reduction in RAPH leakage after seal adjustment

Sustainable improvement in leakage

Saving of Rs Million 9.41 in 08 months.

Leakage % after outage

Leakage % after outage


Eco Affection & Carbon Emission Reduction projects


Recovered from major

catastrophe

Reduction in Unit 8 Make Up Water Consumption

Best Achieved

Care for Environment- Resource conservation

(DM-Water)

FY 17 Annual Savings : 3.15 Million Rupees (Over FY 16)FY 18 Annual Savings : 3.61 Million Rupees (Over FY 16)


Waste Management: Plasto Silt (Applied for Patent)

Alternative to Brick masonry Silt/ash filled in bottle Bricks are replaced with these bottle

Road side kerbing work with ash/silt filled plastic bottle

INNOVATIVE & UNIQUE PROJECT

Use of silt/Ash for non structural construction work –by filling Ash/Silt in to plastic bottles


Construction of tool room in Trombay

Construction of protection wall for structure.

Use of silt/Ash for non structural construction work –by filling Ash/Silt in to plastic bottles

TATA POWER Team has wonPar Excellence Gold Award in

NCQC-2015-2016

Waste Management: Plasto Silt (Applied for Patent)

Type of Bricks Traditional Clay

Brick

Dredge silt

Bottle Brick

Cost per number

(In Rs. & in USD)

Rs. 7.5/-

($ 0.11 USD)

Rs. 3.3/-

($ 0.05 USD)

TATA POWER Team has wonPar Excellence Gold Award in

ICQC-2017 (Manila-Philippines)


Before

After

Care For Environment- Renewable & Energy Conservation Project

Replacement of OLD AC sheet with new transparent sheet along with turbo ventilators in Materials Dept and TG roof



Use of polycarbonate transparent sheets – for Natural lighting inside bunker gallery

Lux intensity

Reqd Before After

Non Monsoon Monsoon Non Monsoon Monsoon50-100 108 82 240 207

Benefits

Illumination with natural Sunlight

Improvement in LUX levels

Saving in Auxiliary Consumption


Hybrid Unit1KW Solar wind mill

Solar Panels

Wind Turbine


Located at O & S building terrace

Tube lights ( 7 Nos of 40W ) sourced by the hybrid Unit

Knowledge adopted from FY 15 CII Award Innovative products

…Message Box ( Arial, Font size 18 Bold)3

Pipe Conveyors with VFD ensure transfer of coal without any spillage.

Captive Jetty with Screw Unloader to unload coal without any spillage.

Care For Environment- Fuel Handling(Eliminating Fugitive emission)


Care For Environment- Fuel Storage(Eliminating Fugitive emission)

Creepers are planted around coal storage area in Trombay.

Helps in arresting the coal powder spreading in surrounding community area

Fully grown creepers


Care for Environment : Waste Paper Recycling

Shredding of Papers

Shredded Papers

packed in bags sent for

Recycling Paper Pads from Recycled Paper

(Project under ISO 14001-2015)


Care For Environment- Waste Management

Bio-degradable waste for organic gardening in colony

• Awareness and training sessions for organic waste utilization

were arranged in colony

• Organic waste generated at colony was used for growing nutrient rich vegetables

• Chemical pesticide free vegetables

Awareness

Execution

Outcome

Re-Use of Bio-degradable Waste

1


Treatment of

Domestic

Waste Water

Sewage treatment plant (Project under ISO 14001-2015)Domestic effluent generated at Trombay is collected and treated in to advanced technology domestic sewage treatment plantDaily 60 M3 treated waste water is recycled.

Treatment of

DM waste

water

Effluent Treatment Plant (Project under ISO 14001-2015)Filter backwash water from DM plant is recycled back in to the system. Daily 80 M3 back wash water is recycled in the system.

Automation in

lawn

gardening.

Mist spray system introduced first time in nursery. Automatic operated water spray system.70% saving in water consumption.

Care For Environment- Resource Conservation (Water)


Care For Community : Renewable & Energy Conservation Project in the Community

70 Solar lights ( MV-3 model- 11 W) have been installed in dark areas of communities of Trombay to address safety of women

Installation of Solar Lightsin the

Neighbouring Community


Care For Community & CustomersEnergy conservation Awareness Programme

Energy conservation campaign For

Schools, Colleges, Employees & Contractors

1


Brain Storming/Audit

RecommendationIdea Generation

Techno-Commercial

Feasibility Study

Idea Presentation & review by

Management

Budgeting & PlanningProcurementImplementation of

IdeaFine Tuning & Optimisation

Evaluation of the Results

Sharing & Reporting to Management

En-Con Methodology


LASER & QC

Sankalp

SPS(Structured Problem

Solving Projects)

SIX SIGMA

Top

Middle Mgmt

Front-line

• Improve U8 coal mill performance• To reduce U8 make up • Improve availability of U8 BFPs

•To Improve Heat rate of Unit 8

• Unit 8 – Availability & Reliability

• Reduction of Aux Power in CW system

• Reduction in Wall blower down time

An ExampleVision

Logic

Emotions

Involvement In Encon Projects

How it all fits together……….


Source of Idea Generation & Involvement of All

Sr. No.

Source of En-con IdeaSource of Idea

GenerationYear of Idea Origination

Extent of Manpower Involved

Progress of Implementation

1Unit-8 Optimising Air Compressor Pressure Set Point

Brainstorming 2018-1902 engineer and 02

workmenUnder

Implementation

2Unit-8 Boiler Skin Insulation

Energy Audit Recommendation

2018-192 Engineers and 2

Workmen along with contractors

Under Implementation

3Unit-8 RAPH Leakage Reduction

Brainstorming 2018-192 Engineers and 4


Successfully Implemented

4 HVT holder Brainstorming 2015-16 02 engineer andSuccessfully Implemented

5Stopping of CW pump due to sub cooling

Discussions with OEM

2014-1505 engineer

including group heads & HOD’s


6Replacing Roof tops of stores with transparent roofs

Energy Audit Recommendation

2014-152 Engineers and 10



7 Combustion OptimisationEnergy Audit

Recommendation2013-14

08 Engineers and 20 workmen



Unit 8 Dash Board –Online Monitoring Unit Parameters

29-Jul-18 16:46:05 Gen MU's 156.76 3.7621 73.569 178.7 42.28% 2.05Load MW Coal TPH HFO flow Steam pr Throttle pr Steam flow T/Hr MS temp RH Temp North

216 105.51 0.0 123.39 122.90 648.86 530.67 527.9Plant Load Factor Aux Consumption Aux Consumption % BFP A BFP B BFP C Ist Stage Pr 528.9

86.31% Calc Failed Calc Failed 65.0 59.0 62.2 119.8 528.41Makeup 3.91 #VALUE! 321.1 317.9 0.0 FGET 8A 175.4SH Spray 14.6 20.3 259.9 267.3 0.0 FGET 8B 170.3Coal Mill Bowl DP Coal Flow PA flow Current HAG Pos Bunker level Coal Air TempMill # A 135.7 25.1 62.0 29.9 57.0 368.0 62.7Mill # B 0.7 0.0 0.0 0.0 0.1 456.3 38.0Mill # C 134.6 26.1 61.4 29.3 78.6 359.4 58.9Mill # D 112.7 28.1 60.7 28.9 65.0 388.8 62.6Mill # E 159.8 26.5 61.4 27.0 61.9 371.2 61.4

CW Current 76.7 70.4 0.0 80.1 Tilt Pos 21.8 Soot Blowing steam5.76 Motor Current Blade pitch Power cons Excess Air RH Spray 0.0 0.22

PA fan A 48.0 48.5 0.467 3.8 Feed Flow 645.1 240.66PA fan B 49.3 32.2 0.479 2.8 Aux Steam Flow 0.76FD fan A 36.3 71.6 0.352 Vacuum -0.915 43.68FD fan B 33.7 75.7 0.328 Cw inlet temp 27.88 27.95ID fan A 88.2 50.9 0.857 -262.9 Cw outlet temp 38.34 38.34ID fan B 85.1 55.8 0.827 -255.9 DT 10.5 10.4

Sec. air flow 630.6 72% 298.8 -259.4 U8 HOTWELL SP COND (L) 3.4Pri Air flow 245.5 28% 328.8 U8 HOTWELL SP COND (R) 3.7

Total Air Flow 876.0 PA Header pressure 751.4 Furnace pressure -8.6Water In Water Out drain Temp Ext Temp Ext Pr DT across the Exchanger DCA

L P Heater # 1 48.0 70.6 70.3 22.6 22.3L P Heater # 2 70.6 89.0 75.7 117.4 0.0 18.4 5.2L P Heater # 3 89.0 117.9 96.6 119.7 1.2 28.8 7.6

Dearator 117.9 160.2 292.4 2.7 42.3H P Heater # 5 160.2 197.3 168.3 406.8 13.4 37.1 8.2H P Heater # 6 197.3 240.8 201.3 345.6 33.3 43.5 4.0


Inhouse Developed Online Monitoring : Aux Power


Unit 8 Heat Rate Dash Board – Daily Monitoring

0

20

40

60

80

100

0

2

4

6

8

31-0

7-18

01-0

8-18

02-0

8-18

03-0

8-18

04-0

8-18

05-0

8-18

06-0

8-18

07-0

8-18

08-0

8-18

09-0

8-18

10-0

8-18

11-0

8-18

12-0

8-18

13-0

8-18

HEA

T RA

TE L

OSS

IN K

CAL/

KWH

HEA

T RA

TE L

OSS

IN K

CAL/

KWH Heat Rate loss due to Parameters

MS Temp RH Temp HRH Pr. Deviation SH SPR

PARAMETER 01-08-18 02-08-18 03-08-18 04-08-18 05-08-18 06-08-18 07-08-18 08-08-18 09-08-18 10-08-18 11-08-18 12-08-18

PLF 88.1 90.3 87.6 87.5 83.6 86.9 90.1 89.6 86.9 87.5 86.4 86.5Loss due to PLF 28.91 22.66 30.50 30.55 42.96 32.52 23.03 24.43 32.41 30.55 34.10 33.59

MS Temp 537 4.91 5.00 4.85 4.65 4.86 4.86 4.91 4.85 4.80 4.76 4.84 4.73

RH Temp 537 6.22 6.40 5.35 6.57 4.07 5.82 4.92 6.23 4.56 5.01 5.39 4.92

Throttle pr. Deviation

HRH Pr. Deviation 10% 0 0 0 0 0 0 0 0 0 0 0 0

SH SPR 0 2.24 2.17 2.35 2.00 2.54 2.30 2.53 2.25 2.81 2.68 2.34 2.41

RH SPR 0 0 0 0 0 0 0 0 0 0 0 0 0

Vacuum 0.0979 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

Make up loss 0 2.22 2.60 2.63 2.65 2.55 2.71 2.55 2.77 2.62 2.45 2.54 2.59

FGET 145 25.0 26.5 24.6 24.7 22.7 23.8 26.8 25.9 25.6 26.2 23.9 23.8


Monthly Review

YTDFY19

ABPFY19

YearFY18

April May June July Aug Sept Oct Nov Dec Jan Feb Mar

YTD FY19 2362

FY 19 (Plan) 2346

FY 18 (Actual) 2352

FY 19 (Actual) 2335 2396 2350 2367

ABP FY 19 2350 2349 2351 2375 2367 2357 2348 2348 2357 2281 2299 2345

FY 18 (Actual) 2314 2336 2348 2415 2368 2404 2399 2323 2336 2294 2335 2337

23622346 2352

2000

2050

2100

2150

2200

2250

2300

2350

2400

2450

2500

2550

2600

KCAL

/ K

WH

STATION HEAT RATE (KCAL /KWH)


Monthly Review

YTD FY19ABPFY19

YearFY18

April May June July Aug Sept Oct Nov Dec Jan Feb Mar

YTD FY19 5.35%

FY 19 (Plan) 5.52%

FY 18 (Actual) 5.48%

FY 19 (Actual) 5.05% 5.33% 5.31% 5.81%

ABP FY 19 5.47% 5.40% 5.41% 5.91% 5.71% 5.59% 5.40% 5.51% 5.50% 5.46% 5.51% 5.40%

FY 18 (Actual) 5.0% 5.3% 5.6% 5.7% 5.7% 5.5% 6.0% 5.3% 5.7% 5.9% 5.4% 5.1%

5.35%

5.52% 5.48%

4.0%

4.3%

4.5%

4.8%

5.0%

5.3%

5.5%

5.8%

6.0%

6.3%%

STATION AUXILIARY CONSUMPTION (%)


Website: www.tatapower.com

Email ID: [email protected]@[email protected]

8.tata power cii energy award u8 - 2018 rev · 6wrsslqj ri rqh &: sxps gxh wr vxe frrolqj...

Documents