12.gujareat industries · 2018-09-13 · 352&(66 /$

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


S.No. Title of ProjectAnnual

Electrical Saving (kWh)

Annual Electrical



(Ton/year)

Annual Thermal

Saving (Rs million)


(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


S.No. Title of Project

Annual Electrical

Saving (kWh)

Annual Electrical



(Ton/year)

Annual Thermal

Saving (Rs million)


(Rs million)


Payback (Months)


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


S.No. Title of Project

Annual Electrical

Saving (kWh)

Annual Electrical



(Ton/year)

Annual Thermal

Saving (Rs million)

Total Annual

Savings (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 Cost Saving (Rs million)

Total Annual Savings (Rs million)

Invest mentMade (Rs million)

Payback (Months)

QuantityUnit of Measurement


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

Cost Saving

(Rs million)


(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


No Title of Project

Annual Electrical

Saving (kWh)

Annual Electrical

Cost Saving

(Rs million)


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


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

12.gujareat industries · 2018-09-13 · 352&(66 /$

Documents