18 national award for excellence in energy...

18th National Award for Excellence in Energy Management-2017

JSW Energy Limited, Toranagallu

2x130 MW + 2x300 MW

30th Aug-1st Sep, 2017 CII, Hyderabad

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VIJAYANAGAR PLANT

860 MW

RATNAGIRI PLANT

1200 MW

BARMER PLANT 1080 MW

HYDRO POWER PLANT

1391 MW

JSW ENERGY POWER GENERATION BUSINESS IN INDIA

The existing operational capacity of 4,531 MW with a vision to achieve 10,000 MW by 2020

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JSW ENERGY VIJAYANAGAR JOURNEY TOWARDS…

EXCELLENCE..

Jindal Tractebel Power Company Ltd. formation

SBU1 U2 & SBU1 U1 - 2x130 MW Power Plant - COD Mar, 1994

Jan & Aug, 2000

April & Sept, 2005

CPP1 - 100 MW & CPP2- 130 MW Power Plant – COD (O&M Services)

May, 2006

Incorporation of JSW Energy (Vijayanagar) Ltd. as a subsidiary

SBU2 U1 & SBU2 U2 - 2x300 MW Power Plant - COD

July & Sept, 2009

CPP3 & CPP4 – 2X300 MW - COD ( O&M Services)

Mar, 2011 & 2012

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July, 2017

400 kV Ballari Pooling Station

JSW ENERGY, VIJAYANAGAR PROCESS

BUSINESS UNIT CAPACITY, (MW) FUEL MAKE

SBU-I 2 X 130 MW IMPORTED COAL + WASTE GAS BHEL

SBU-II 2 X 300 MW IMPORTED COAL SEC,CHINA 4

AWARDS & ACCOLADES

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Silver Award by The Royal Society for the Prevention of Accidents - 2016.

AWARDS & ACCOLADES

CSR Impact Award - 2016

Best Livelihoods Initiative for Watershed Programs

CBIP Award - 2016

Best Performing Utility in Thermal Power Sector

CII Award - 2015

Excellence in Energy Management

IPPAI Power Award - 2016

Installation of Spacer Coupling at ID Fans Innovation

Shrishti Good Green Governance Award - 2016

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AWARDS & ACCOLADES

Golden Peacock Award - 2016

Environment Management Award

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CII-ITC Sustainability Award - 2015

Corporate Excellence

AWARDS & ACCOLADES

The Five Leaves Award - 2015

Centre for Science & Environment Green Rating

Project Rated 2nd Best in Environment Performance

ENERGY CONSERVATION PROJECTS

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ENERGY CONSERVATION FOR LAST THREE YEARS

Year of Implementation

No. of Encon

Annual Electrical Savings achieved

Annual thermal savings

Total Annual Savings

Invest. Made Payback

months Million Units

Rs Million

Tons of Fuel

Rs Million

Rs Million

Rs Million

2016-2017 8 4.5 13.4 - - 13.4 23 Within 2 year

2015-2016 12 4.4 14.0 5950 41.0 56.0 48 Within year

2014-2015 4 5.6 28.1 2238 15.2 43.3 18 Within year

Total 24 14.5 55.5 8188 56.2 112.7 89 Within year

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POWER SAVING WITHOUT INVESTMENT

Energy Saving Projects Saving

Instrument air compressor Power consumption by changing load set point

100 Kwh

BFP recirculation valve passing arrested by servicing 219 Kwh

Reduction in fly ash unburnt by improving mill

performance & tuning combustion at SBU2 Units 7116 T/year

Ash Water pump stoppage by changing source of water

supply to Cooling pond pump which is common for all

units

10000 Units / Year

S No Description Saving (KWH) /

Unit

1 Second BFP Stopping 3130

2 Second CWP Stopping 1434

3 PA Header Pressure Optimization 206

4 Seal Air Fan IGV Throttling 10

5 Ash Conveying Optimization 35

6 6.6KV Bus Voltage Optimization

POWER SAVING WITHOUT INVESTMENT

During Part Load Operation (300 MW Unit)

ENERGY SAVING PROJECTS IMPLEMENTED

Energy Saving Projects Savings Investment

Payback Months Million

(Rs.) Million

(Rs.)

Installation of variable frequency drives (VFD) & Spacer Coupling between Motor & Fan eliminating Voith coupling in SBU-1, Unit-1ID fan motors (2 nos.)

2.9 2.3 10

Installation of Spacer Coupling between Motor & Fan eliminating Voith coupling in SBU-2, Unit-2 of ID fan motors (2 nos.)

2.8 2.3 10

Installation of Energy efficient fan blades in CT fans of SBU2 300 MW Unit.

3.6 3.0 10

Installation of variable frequency drives (VFD) in SBU-1, Unit-1 PA fan motors (2 nos.)

2.8 9.3 40

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ENERGY SAVING PROJECTS IMPLEMENTED

Energy Saving Projects

Savings Investment Payback Months Million

(Rs.) Million

(Rs.)

SBU-2 Unit-1 (300MW) Capital overhaul of Turbine 29.4 8.7 4

Installation of Energy efficient fan blades in CT fans of SBU-1 (2X130 MW)

0.3 3.2 114

Installation of Spacer Coupling between Motor & Fan eliminating Voith coupling in SBU-2, Unit-1 of ID fan motors (2 nos.)

6.3 4.1 8

Installation of Variable Frequency drive ( VFD) in SBU-2, Unit-2 ID fan motors (2 nos).

9.4 19.3 25

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ENERGY SAVING PROJECTS IMPLEMENTED

Energy Saving Projects

Savings Investment Payback

Million (Rs.)

Million (Rs.)

Months

Installation of Variable frequency drives (VFD) in SBU-2, Unit-1 ID fan motors (2 nos.)

27.8 12.0 5

Installation of Variable frequency drives (VFD) in SBU-2, Unit-2 CEP

14.1 4.0 3

Installation of Energy efficient fan blades in 2 nos. of CT fans in SBU-2 & 2 nos. of CT Fans in SBU-I

0.9 1.1 18

Installation of a bypass chute to transfer coal from conveyor CJ 9C1 to 10C1 eliminating operation of Coal conveyor CJ 9RC1

0.5 0.7 17

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PROJECTS

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PROJECT -1- REPLACEMENT OF HYDRAULIC COUPLING WITH SPACER COUPLING

Induced draft fans (ID Fan) in the plant are carrying out a function of discharging flue gases

to atmosphere by consuming power 1430 kWh ( Rated-2240 Kwh)at full load.

The motor runs at 745 RPM whereas fan spins at around 550 RPM at full load through

hydraulic coupling operating the scoop in the range of about 55%.

REPLACEMENT OF HYDRAULIC COUPLING WITH SPACER COUPLING

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After installation/commissioning of VFD the process forced to maintain scoop around 63% with motor speed limited to 620 RPM ( saving of 200 Kwh/fan).

The limitation of scoop to maintain the speed is basically to ensure proper lubrication to all the bearings of hydraulic coupling which has limited saving potential.

Fixed & slip losses of Hydraulic coupling

REPLACEMENT OF HYDRAULIC COUPLING WITH SPACER COUPLING

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To overcome the scoop limitation and losses in the hydraulic coupling and utilize the advantage of VFD, opted for replacement of ID Fan hydraulic coupling with spacer coupling.

REPLACEMENT OF HYDRAULIC COUPLING WITH SPACER COUPLING

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Site conditions & risk analysis done

Detailed sizing calculation has been done for

spacer coupling

Calculation of Saving

The energy savings achieved at full load operation is as follows:

ID fan energy saving - 200 kWhr (for two fan )

Total - 200 KWhr

Monitory benefits and payback period were calculated and are as follows:

Investment made for replacing the hydraulic coupling with spacer coupling Rs 23 Lacs

Net monetary savings - (per annum / unit of 300MW)

(Considering Rs 3.0 / Kwh)

Recurring YOY savings - Rs. 27.8 Lacs

Payback period - 10 months.

Eliminating hydraulic coupling and related maintenance expenses.

Heat load on Auxiliary cooling water has also reduced

Implemented in one of 130 MW unit & observed resonance while rising speed. Same

is successfully solved by incorporating design changes in coordination with OEM.

REPLACEMENT OF HYDRAULIC COUPLING WITH SPACER COUPLING

REPLACEMENT OF HYDRAULIC COUPLING WITH SPACER COUPLING

S.NO Unit Implemented Project Savings

1 SBU-1 Unit-1

Installation of Spacer Coupling in ID fan 150 Kwh

2 SBU2 Unit-1

Installation of Spacer Coupling in ID fan 200 Kwh

3 SBU-2 Unit-2

Installation of Spacer Coupling in ID fan 200 Kwh

Total 550 Kwh

S.NO Unit Implemented Project Savings

1 SBU-1 Unit-2

Installation of VFD & Spacer Coupling in ID fan

150 Kwh

Implemented Projects

Proposed future projects

PROJECT -2- ENERGY EFFICIENT BLADES FOR COOLING TOWER FANS

REPLACEMENT OF CT FAN’S BLADE WITH OF ENERGY EFFICIENT FAN BLADES

Induced-draft cooling towers are used to remove the heat absorbed in the circulating cooling water systems. Induced-draft cooling towers will have 10 & 12 fans per each unit of 130 MW & 300 MW respectively to drive atmospheric air through CT fills there by cooling incoming hot water from condenser. Design power consumption of each fan for 300 MW unit with FRP Blades is 75 Kw Actual Consumption of each fan for with FRP Blades is 69 Kw

REPLACEMENT OF CT FAN’S BLADE WITH OF ENERGY EFFICIENT FAN BLADES

It is proposed to change existing FRP blades with hallow FRP Blades of aerodynamic design. In One unit , Blades are replaced with hallow FRP Blades on trail basis. Air flow being main parameter for cooling tower fan , air velocities are measured in both the transverse & air flow was estimated. It is observed that a saving of 29 Kwh / fan with out impacting air flow. Based on results , Power saving observed per fan 29 Kwh & same replicated in remaining fans.

S.NO Unit Implemented Project Savings

1 SBU-2 Unit-1 Installation of Energy Efficient Blades in CT fans

290 Kwh

2 SBU-1 Unit-1 &2 Installation of Energy Efficient Blades in CT fans

70 Kwh

REPLACEMENT OF CT FAN’S BLADE WITH OF ENERGY EFFICIENT FAN BLADES

Implemented Projects

S.NO Unit Implemented Project Savings

1 SBU-2 Unit-2 Installation of Energy Efficient Blades in CT fans

290 Kwh

Proposed Future Projects

SPECIFIC ENERGY CONSUMPTION

PLANT PERFORMANCE HIGHLIGHTS

JSWEL, Vijayanagar conquest National Awards for Meritorious Performance since 2006-07

Continual improvement in Auxiliary Power Consumption on Y-O-Y basis. APC for FY17 is 7.83 %.

Continual improvement on sustenance & improvement in Station Heat Rate.

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PLANT SEC – 860 MW(2X130 + 2X300)

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Sustained APC even at Lower

PLF

SPECIFIC ENERGY CONSUMPTION

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SPECIFIC ENERGY CONSUMPTION

Under PAT Cycle-I, Specific Energy consumption for SBU-1 & SBU-2 are detailed as below.

Unit Notified SEC

Target Achieved SEC

No. of Escerts issued

Kcal/Kwh Kcal/Kwh No. SBU-1 2503 2422.74 16710 SBU-2 2420 2416.53 730

Total 17440

COMPARISION WITH OUR PEERS

FINANCIAL YEAR 2016 - 2017

PARAMETERS JSWEL (SBU-I)

2 X 130 MW JSWEL (SBU-II)

2 X 300 MW Adani, Mundra

(330MW)

Heat Rate 2293 2318 2289

APC (%) 7.23 8.21 8.59

PLF (%) 75.3 51.38 73.36

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ROAD MAP TO ACHIEVE BENCH MARK

Fuel Strategy with Optimal Coal Blend with respect to international Coal Price Movement & Forex Variations.

Firing of Domestic Coal to be competitive in Market

Sustaining the plant performance and producing substantial environmental benefits by utilising waste gas from steel plant.

Exploring the usage of waste gas firing or other methods during start up to reduce Sp. Oil consumption.

Effective utilisation of resources cross functional knowledge sharing at flexible operating loads.

Business Planning with life cycle management approach

Learning & Development initiatives for Skill up-gradation & Capacity Development.

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30%

31%

32%

33%

34%

35%

36%

37%

38%

39%

INDIA AUSTRALIA CHINA US JSWEL,TORANAGALLU

32.8% 33.3%

35.7% 35.8%

38.0%

ENERGY EFFICIENCY %

COMPARISON WITH GLOBAL NORMS

Source:Heat On Power ,GRP Rating,Centre for science and Environment-Feb 2015 34

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GHG INVENTORISATION

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Operational Measures

• Low Specific Water consumption (2.0 cum/ Mwh) , below the CEA guidelines .

• Use of imported low Ash, low Sulphur coal.

• Use of steel plant waste gas.

• 100 % Fly ash utilization.

Environment Management Initiatives

• Reed bed based STP over conventional or domestic effluent treatment and use for plantation

• RO based effluent recycling plant to re-use and balance effluent for ore beneficiation unit at steel plant.

• Rain water harvesting for water utilization

• Closed Coal Conveying System to mitigate fugitive emission.

• Use of low NOx burners to minimize formation of NOx

• Electro chlorination system for SBU-II and SBU-I

ENVIRONMENT & CARBON EMISSION REDUCTION PROJECTS

CARBON EMISSION REDUCTION

With a mission to reduce GHG emissions from 0.9 kg/kwh to minimum levels, waste gas firing system project is executed in 2X130MW since from inception. With this we have reduced CO2 emissions in SBU-1 well below the stipulated norms from year on year basis.

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Greening Efforts:

Green cover of about 62 acre outside the plant premises Total tree planted - 23,000 Nos. in plant area

and 1 Lac trees outside the plant area till date

Survival Rate of plants are 91%

Extensive Plantation undertaken at

Township

Ash Pond area

Near by hills

Labor colony

Plantation at Hill Area

Plantation at Labor colony 38

ENVIRONMENT

EMPLOYEE INVOLVEMENT

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• Energy Conservation Week celebrated in the month

of December 2016. Awareness created among

Employee & family by organizing competitions &

rewarding the best.

• E-portal developed for capturing Employee

suggestions.

EMPLOYEE INVOLVEMENT

• To capture innovative ideas, a portal is developed

under Digitization initiative which will enable each

employee to put forth their innovative ideas.

• Integrated DCS with intranet through OSI PI tool &

EMS to monitor Auxiliary power consumption,

plant critical parameters & deviations

EMPLOYEE INVOLVEMENT

ENERGY MANAGEMENT SYSTEM AT JSW,VIJAYANAGAR

Certified for ISO 9001,14001, OSHAS 18001 and ISO 50001:2011

Energy policy established

Structured Energy Management Cell

Identify, Evaluate and Analyze Energy use & Consumption ( Coal, Oil, electricity ,

Water)

Periodic Energy Audit as per CEA Guidelines

Daily energy deviation reporting

Total 25 Energy auditors

E LAN (EMS) System for Energy Consumption Monitoring.

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Sl No Monitoring and Review Chaired by Participants Frequency Benefits

1

Daily Monitoring of Generation( Aux consumption, parameters deviation ,sp oil consumption, make up water cons etc),Environment, safety

Head of Plant Section In

charges,SCE and HOD's

Daily

Solutions for deviation in Heat rate ,APC, Sp oil Cons, make up water cons etc, Solutions for Environment and safety issues.

2 MOPR (Monthly operation performance review)

Head of Plant Section In

charges,SCE and HOD's

Monthly

Monthly Performance review includes plant performance, Efficiency Gap analysis and Correction. Inventory and consumption pattern.

3 Performance Optimization Group (POG)

Head of Plant POG (cross functional

team), HOD,s Monthly

Water conservation, Heat rate reduction, APC reduction, condenser vacuum improvement, Combustion optimization.

4 Internal Audit of IMS ISO 9001,14001 and ISO 50001:2011

MR,Trained Internal

Auditors,HOD

Auditors and Auditees,HOD’

s Half yearly

Monitoring Documentation ,SOP and Management programmes of plant improvements.

ENERGY REPORTING & MONITORING

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ENERGY MONITORING

Time Synchronization of all the meter and Server through EMS software.

Available plant network is being utilized for the metering system.

Meters data is collected in redundant servers for computing & calculation.

Infinite Web clients developed for viewing & analyzing of data.

Automatic report generation with emailing facility is developed to eliminate

manual intervention

Monitoring real time parameters individual equipment wise

Trending & customizable dashboards are additional advantage.

EMS - UNIQUE FEATURES

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EMS DASH BOARDS

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Installation of VFD & Spacer coupling

SBU2 U1 & U2 Installation and commissioning Mill reject pneumatic conveying system SBU1 Boiler - Replacement of Existing IFM Igniter system with High Energy Arc ignitor (HEA)

Energy Management System installation for better monitoring and tracking of energy consumption

APH - Installation of additional baskets to yield reduction of 2°C in the temperature of exit flue gas

S . No Unit En Con Power Saving

1 SBU1 Unit1, ID Fan VFD & Spacer Coupling 150 Kwh

2 SBU1 Unit-1 PA fan VFD 146 Kwh

3 SBU2 Unit-1 ID fan VFD & Spacer Coupling 600 Kwh

4 SBU2 Unit2 ID Fan VFD & Spacer Coupling 600 Kwh

REPLICATION OF BEST PRACTICES & TECHNOLOGY ABSORPTION

SBU1 Unit1 DCS Renovation & Modernization from old Bailey System to ABB

ESP Spike Electrodes replaced with spiral Electrodes

N2 Blanketing of EH oil system

ABT system up gradation for better monitoring & tracking of DSM

REPLICATION OF BEST PRACTICES & TECHNOLOGY ABSORPTION

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Indigenization of Mill Gear box spares for reducing the maintenance cost Up gradation of 130 MW & 300 MW AVR with ABB Make Unitrol

Up gradation of SBU1 GRPs with numerical relays DCS panel 24 VDC field power supply wiring redundancy scheme for more reliability

Installation of LHSC Cables for Fire monitoring at BCN 2A/2B/3A/3B conveyors

SBU1 U2 Up gradation of Electro Hydraulic Turbine Control System (EHTC) Implementation of SPS scheme on 220kv lines for protecting & isolating the complex

during sustained/ uncleared faults

REPLICATION OF BEST PRACTICES & TECHNOLOGY ABSORPTION

Thank You

“Excellence is a journey not a destination” R.Peddanna

Kumar Ivaturi 50