national award for excellence in energy management,2016 .... gmr-warora_cii ppt from...optimize the...

1

National Award For Excellence in Energy Management,2016

Power Sector -CII

GMR Warora Energy Limited.(GWEL)

(A 2X300 MW Thermal Power Plant )

GMR Group –Values & BeliefsVision:

GMR Group will be an institution in perpetuity that will build entrepreneurial organizations making a difference to society through creation of value.

Humility:We value intellectual modesty and dislike

false pride & arrogance

Entrepreneurship:We seek opportunities they

are everywhere

Team Work & Relationship:Going beyond the

individual encouraging boundary less

Respect for Individual:

We treat others with dignity , sensitivity

and honor

Learning:Nurturing active

curiosity to question, share and improve

Deliver the Promise:We value a deep sense of responsibility & self discipline to meet &

surpass on commitment made.

Social Responsibility:Anticipating & meeting relevant and emerging

needs of society

GWEL – At a Glance

S.No Features Details

1 Plant capacity 600 MW

2 Configuration 2 X 300 MW

3 Unit-1 Commercial Operation Date( COD) April 2013

4 Unit-2 Commercial Operation Date(COD) September 2013

5 Coal requirement (per unit) 1.33 MTPA @ 85% PLF

6 Gross Calorific value 3,300 kcal/kg

7 Sulphur content 0.3 to 0.5%

8 Ash content in coal 33 to 38%

9 Ash generation @ 85% PLF 0.51 MTPA (per unit)

10 Stack Single stack Twin Flue chimney of 275m height

11 Water requirement and allocation 50 MLD

2

ISO Certifications:

GWEL- At a Glance

FY Wise Station Performance:

40%

60%

80%

100%

120%

2013-14 2014-15 2015-16

Availability – FY Wise

AOP Actual

4538.92 4472.91

2000.00

3000.00

4000.00

5000.00

2013-14 2014-15 2015-16

Generation in Mu’s – FY Wise

AOP Actual

40.00%

60.00%

80.00%

100.00%

2013-14 2014-15 2015-16

Plant Load Factor – FY Wise

AOP Actual

7.00%

8.00%

9.00%

10.00%

11.00%

2013-14 2014-15 2015-16

APC– FY Wise

AOP Actual

0

0.5

1

1.5

2

2.5

2013-14 2014-15 2015-16

SOC– FY Wise

AOP Actual

0.00

0.20

0.40

0.60

0.80

1.00

2013-14 2014-15 2015-16

SCC– FY Wise

AOP Actual

0.00%

1.00%

2.00%

3.00%

4.00%

2013-14 2014-15 2015-16

DM Make Up– FY Wise

AOP Actual

2300

2350

2400

2013-14 2014-15 2015-16

Heat Rate– FY Wise

AOP Actual

193159

288

80

180

280

380

2013-14 2014-15 2015-16

SIPs– FY Wise

SIPs

National Award For Excellence in Energy Management,2016 Power Sector

3

GWEL – Absolute Savings & Investments Made

FY Energy Savings (Lakh Kwh)

Fuel Savings ( Ton/year)

Financial Benefits(Millions)

Investments made(Millions)

2013-14 74.82 41128 138.19 11.7

2014-15 276.62 45323 210.6 31.81

2015-16 330.43 49518 239.17 6.12

74.82

276.62

330.43

60120180240300360420

2013-14 2014-15 2015-16

Lakh

KW

H

Cumulative Energy Savings

41128

4532349518

40000

42000

44000

46000

48000

50000

2013-14 2014-15 2015-16

Cumulative Fuel Savings

138.19

210.6

239.17

050

100150200250300

2013-14 2014-15 2015-16

Cumulative Financial Benefits


GWEL – Awareness Creation among Employees

Employee Engagement in Energy Conservation Activities Ø Employee Awareness Training

Ø Internal training conducted by Energy Management Cell.

Ø Involving Employees in

§ Energy Conservation Weeks.

§ Energy Quiz.

§ Idea Factory – a portal for encouraging new ideas.

§ Reward Recognition for best ideas & CIPs by Group Chairman.

§ Sector Level O&M meet for discussing various best practices followed for energy conservation.

§ Knowledge Management chat session across all sectors of GMR group.

§ Knowledge Management Portal –a discussion forum across the group about best practices.

§ Knowledge sharing with School Children and Ladies club.

Ø Placing Display Boards to create awareness among employees & contractors in each work area regarding Energy

Conservation.

Ø Circulate information regarding new projects, new initiatives, audits to every employee through GMR intranet.

Ø Dedicated portals for Idea Factory, Knowledge sharing, Energy management.

Ø Participating in Energy efficiency Summit by CII,EU Summit, NTPC conference on best O&M practices etc.


4

GWEL – Electrical Energy Saving Projects (2014-15)

S.No. Title of Project YearAnnual

Electrical Saving (kWh)

Annual Electrical

Cost Saving (Rs million)

Total Annual Savings (Rs

million)

Investment Made (Rs million)

Payback (Months)

1 Improve the performance of PA-2B fan 2014-15 683280 1.71 1.71 0.00 0

2 Improvement of FAD by supply cool air in AHP air compressor building 2014-15 40000 0.10 0.10 0.15 18

3 Optimise coal mill of Unit 1 2014-15 0.03 0.03 0.10 40

4Improve the performance of the chiller by cleaning the evaporator and condenser 2014-15 6132 0.02 0.02 0.00 0

5 Switching OFF the under loaded transformers in MLDBs’ 2014-15 37200 0.09 0.09 0.00 0

6 Reducing the single phase voltage level to <220V at all lighting feeders. 2014-15 260600 0.65 0.65 0.00 0

7 Replace old River water pump-1 with same specification as pump-2 2014-15 96800 0.24 0.24 0 0.00

Total1124012 2.84 2.84 0.25 8.3





Annual Electrical


Total Annual

Savings (Rsmillion)


Payback (Months)

8 Replacement of 250 W Conventional street lights with 90 W LED lamps. 2014-15 31939 0.08 0.08 0.61 91

9 Replacement of 56W building Luminaries with 36 W LED lamps 2014-15 213197 2.3 2.3 7.5 3.27

10Installation of CEP VFD

2014-15 24076086.02

6.02 23.00 46

11CHP Operation- Optimisation

2014-15 305200.76

0.76 0 0

13 Reliability Improvement of Plant Electrical System 2014-15 6000000 18 18 0 0

14 Reliability improvement in Operating System by reducing no of trips by 50%. 2014-15 9000000 27.5 27.5 0 0

15 Improve the effectiveness of ESP Deashing system 2014-15 180000 0.45 0.01 0.45 0

16 AHP Operation-Optimisation 2014-15 920000 2.3 2.3 0 0

Total18783264 57.41 57.41 31.56 17.53


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GWEL – Thermal Energy Saving Projects (2014-15)

GWEL – Thermal Energy Saving Projects (2015-16)

(2014-15)

S.No. Title of Project Year

Annual Electrical

Saving (kWh)

Annual Electrica

l Cost Saving

(Rsmillion)

Annual Thermal Saving

(Ton/year)

Annual Thermal Saving

(Rsmillion)

Total Annual Savings

(Rs million)


Payback (Months

)

01 Conversion of HFO System to LDO-U#01 2014-15 195609 0.49 4195 12.11 12.6 0 0

Total195609 0.49 4195 12.11 12.6 0 0





Annual Electrical


Total Annual

Savings (Rsmillion)

Investment Made (Rsmillion)

Payback (Months)

1 Replacement of Turbo ventilator fans with Wind ventilator fans in Turbine Building

2015-16 1051000 2.62 2.62 0.25 1

2Installation of VFD in seal air fans

2015-16 438000 1.10 1.10 0.54 6

3 Installation of VFD in Service Water Pumps 2015-16 148920 0.37 0.37 0 0

4 Installation of VFD in Hot well Make Up pumps. 2015-16 146000 0.37 0.37 0.18 8

5CFD Analysis for Flue Gas Ducts in U#02 ESP

2015-16 595984 1.5 4.2 1.5 4

6 Interconnection of U#02 ESP Pass-A line ( hopper A8 to A14) with Pass-B header line 2015-16 547500 1.37 1.37 0.2 2

7Enabling Power saver Mode for Mill Reject Handling System(MRHS)

2015-16 105339 0.26 0.26 0.00 0

Total3032743 7.59 7.59 2.6 3


6




Annual Electrical Cost

Saving (Rs million)

Total Annual

Savings (Rsmillion)


Payback (Months)

8 Extension of ECO & APH discharge line to Fly ash silo 2015-16 1000000 2.5 2.5 0.3 8

9 Replacement of Turbo ventilator fans with Wind ventilator fans in Ware house

2015-16 260000 0.65 0.65 0.5 1

10 Replacement of Turbo ventilator fans with Wind ventilator fans in CW pump house.

2015-16 240000 0.6 0.6 0.45 1

11 Optimize the pressure of compressed optimize the pressure of compressed air(BTG)

2015-16 424000 1.06 1.06 0 0

12Optimize the lighting voltage

2015-16 106000 0.32 0.32 0 0

13Optimize the operation of HFO & LDO pumps

2015-16 100000 0.3 0.3 2.2 7

14Direct Bunkering of coal rake

2015-16 100375 0.25 0.25 0 0

Total2230375 5.68 5.68 3.45 2.42


GWEL – Energy Saving Projects

S.No. Title of Project YearEstimated Annual Electrical Savings

(kWh)

Estimated Annual Thermal Savings

(Ton/year)

1 VFD installation for Raw water pump 2016-17 567210

2 Complete stoppage of H2SO4 Dosing pumps & provision of dosing the acids through gravity. 2016-17 3285

3 Replacement of MIV of Raw water pump recirculation line with Auto operated valve through PLC for optimum running of pump 2016-17 328500

4 Shifting of outdoor units of package AC of Admin Bldg. from roof top to ground floor to reduce the load. 2016-17 21024

5 Providing Hydro Pneumatic arrangement in Fire Water System to reduce Auxiliary power consumption. 2016-17 832200

6 Install VFD for AHU’s and operates base on return air temperature 2016-17 84000

7 Installing thermostat controller and VFD for cooling tower fans to operate at reduced speed 2016-17 81200

Total 1917419


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GWEL – Energy Saving Projects

S.No. Title of Project YearEstimated Annual Electrical Savings

(kWh)

Estimated Annual Thermal Savings

(Ton/year)

8 Interconnection of U#01 ESP Pass-A line ( hopper A8 to A14) with Pass-B header line 2016-17 547500

9 CFD Analysis for Flue Gas Ducts in U#01 ESP 2016-17 595984

10 Solar Panel Roof Top for Colony 2016-17

11 TAC Air Flow Measurement 2016-17

12 Recycling of RO-2 reject to UF storage tank 2016-17 4041

13 CHP 90kW motor connection with Energy Management System2016-17

14 AHP 90kW motor connection with Energy Management System2016-17

Total 1147525


GWEL –Use of Renewable Energy SourcesGWEL has committed to amplify its usage of renewable Energy Sources. Projects Implemented:1. Use of Wind operated Turbo ventilated Cooling fans on TG Building, Ware House & CW Pump House by replacing motor operated fans resulted in a saving of 15.51 Lakh Kwh of energy.2. Use of battery operated vehicle inside the plant premises which reduce the fuel consumption. 3. Green Belt development through drip irrigation.

Projects Under Implementation:1. Installation of solar panels on the turbine roof which is utilized for lighting the entire TG building.2. Use of dimmers in lighting circuits.3. Solar lamps across Boundary wall and raw water reservoir.4. Solar water heaters for Township.


8

GWEL – Web based Portal for Creating Awareness

Knowledge management Portal in GMR intranet EnMS (ISO 50001) web page in GMR intranet

Idea Factory Portal in GMR intranet Drop Box for EC Ideas, Slogans


Awards & Recognition :


9

GWEL – Rewards & Recognition for Energy Conservation Program.

Reward recognition for Best CIPs by Group Chairman

Reward recognition for participants in Energy QuizEnergy Conservation pledge by Employees


GWEL – Management of Energy Conservation Program

Process of Energy Conservation program comprises of

• Identification

• Implementation

• Monitoring.

Identification:

• Identification of program through Audits(Internal or

External).

• Brain Storming on operation philosophy

and Optimization.

• Root Cause Analysis & CA PA for deviations.

• Notification in the SAP- Z5 category for

approval of MR & Head-O&M.

• System Improvement Plan(SIP) documented the

standard format for approval.

• SIP discussed & reviewed in SIP review meeting

headed by Head- O&M for approval in SAP for

implementation.


10

GWEL – Management of Energy Conservation ProgramImplementation:

• After approval from Head- O&M , Plan to be executed by user

department.

• After Completion ,the raised notification to be closed along with

submission of Implementation & completion documents of SIP.

Monitoring:

• The status of identified program monitored on daily/

weekly/monthly basis through generation of MIS.

• Additional resource allocation if required for Pending SIP.

• Total Energy Conservation Plans

implemented through SIPs -36 Nos.

SIP Summary

SAP Z5 Notification


GWEL – Setting Energy Objectives & Targets

GWEL has adopted PDCA(Plan – Do- Check- Act) cycle for

its Energy management System.

Ø Formulation of objectives & targets for different functions

and level based on Annual Operation Plan of the plant.

Ø Energy Policy at core.

Ø Monitoring the performance against defined targets.

Ø Deviation considered as a non conformity.

Ø Closure of Non Conformity through RCA, CAPA in the

form of improvement program.

Ø Notification in Z5 category(in SAP) for Improvement program

approved by Energy management cell.

Ø Improvement programs reviewed monthly in monthly

operational review meeting.

Ø Energy Conservation targets part of departmental objectives and

targets and individual KRI & KPIs.


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GWEL –Setting Energy Objectives & Targets

DateSr. No.

Objectives Derived From Policy Startegic Objective Performance Indicator Unit FY Target YTD Target Monthly Target Monthly Status YTD Status

Pl ant Avai l abi l ity %Unpl anned outage %PLF %% Loa di ng Factor %

Mi ni mi se No of Tri ps/1000Hrs Tri p/1000 Runni ng hrs <2 Mi ni mi se AuX Power Aux powe r Consumpti on %

Spe cifi c oi l Consumpti on ml/KWhSpe cifi c Die sel Consumpti on Lit/ton CH

Mi ni mi se O&M Cost O&M cost Lac/MWDM Water consumpti on %CBD Hours Hr's

Opti mi ze he at rate Gros s Heat ra te Kcal/ KwhCustomer Sati s fa cti on Custome r sati s faction a fte r 6 month of operation No's

IMS i mpl ementa ti on proce ss- Surve il ance Audi t No'sNo of CIPs No'sSystem Improve me nt Pl ans No'sSafety Improve ment p la ns No'sEne rgy cons ervation p la ns No's

2

Provi de and ma inta in sa fe and he al thy work p l ace by a dopti ng be st and a ppropri ate operational practi ces

IMIP for Qual i ty, Environmental , Occupational Hea lth and Safety & Ene rgy Performance.

GMR Energy Limited GMR WARORA ENERGY LIMITED-2X 300 MW

GWEL Objectives and Target FY 2015-16Format- F1

1

Del iver rel ia bl e a nd qua li ty productsand s ervices to al l custome rs atcompe ti ti ve costs , wi th focus oncustome r care –thereby cre ati ngsuperior val ue for a ll s takehol ders .

Maxi mi ze Pla nt ava il ab il i ty

Maxi mi s i ng Loadi ng Factor

Mi ni mi se s peci fic oi l consumpti on

Mi ni mi se DM water consumpti on


GWEL –Monitoring Energy Objectives & Targets

GWEL believes KPI which are not measured cannot be monitored and improved. Hence GWEL has put

measurements system for Energy consumption across the plant.

Measurement Process:

Electrical energy(KWh) :

Installing Energy Meters and Monitoring online through EMS.

Ø Accuracy Class of Energy meters : <0.2

Ø Calibration frequency :1 year.

Ø Calibration Schedule in form of SAP notification.

Thermal Energy:

Incoming Coal Weighment integrated with SAP.

Ø Coal feeder Integrator recorded in DCS.

Ø Accuracy Class : +/- 0.2%

Ø Calibration Frequency: 2 Months.


12

GWEL –Benchmarking of Energy Conservation ProgramBenchmarking is done as

1. Internal Benchmarking

2. External Benchmarking.

Internal Benchmarking is based on PG tests, Design performance.

Generation of Daily Energy Deviation Report.

Ø A Baseline of Sp. Energy Consumption is set by using past 6 months data and reviewed.

Ø Setting of Operational & maintenance Control limit for effective monitoring.

Ø Any Deviation beyond OCL/MCL for 3 consecutive days leads to an NC product which should be complied by user dept. by producing CAPA.

Internal Benchmarking:


Benchmarking of Performance:

93% 93%91% 92%

95%

90%

92%

94%

96%

98%

100%

RelianceButibori

RelianceRoja

JSWRatnagiri

RelianceDahanu

GWEL

Availability

76%

67%

80%

91%

76%

65%70%75%80%85%90%95%

RelianceButibori

RelianceRoja

JSWRatnagiri

RelianceDahanu

GWEL

Plant Load Factor

8.90% 8.83% 8.91% 8.88%9.17%

6.00%

7.00%

8.00%

9.00%

10.00%

RelianceButibori

RelianceRoja

JSWRatnagiri

RelianceDahanu

GWEL

APC 2415

2384

2337

23072324

23002320234023602380240024202440

RelianceButibori

RelianceRoja

JSWRatnagiri

RelianceDahanu

GWEL

Heat Rate

0.13

0.24

0.15

0.13

0.27

0.05

0.10

0.15

0.20

0.25

0.30

RelianceButibori

RelianceRoja

JSWRatnagiri

RelianceDahanu

GWEL

SOC

0.490.42

0.320.37

0.20

0.30

0.40

0.50

0.60

RelianceButibori

RelianceRoja

JSWRatnagiri

RelianceDahanu

GWEL

DM Make Up


13

GWEL New Technologies – Installation of Dynamic Classifier in Coal Mill

GWEL is the first power plant in India to use this technology.

Reason for Implementation: • To Minimize Unburnt Carbon Losses by effective control.

• Unburnt carbon losses accounts to 2 % of boiler efficiency.

• Lesser the unburnt carbon greater the boiler efficiency.

• In efficiently operated plant,3.5% of unburnt carbon is present in

Bottom ash and 0.8 % in Fly Ash. This results in enormous heat loss.

About Dynamic Classifier:

• Unlike Conventional Static classifier, a dynamic classifier is a

VFD operated drive.

• Desired fineness is maintained with dynamic classifier.

• Better Control on Combustion efficiency by controlling speed

of Dynamic classifier.

Benefits :

• Percentage of Unburnt carbon reduced from 3.5 % to 1.0 %

in bottom Ash and from 0.8% to 0.4% in fly ash system.

• Reduction in Coal mill reject losses.

• Approximately 82.82x106 Million k.Cal each Year can be saved.

• Improved Fly ash quality which is one of the raw materials in

cement industry.

• 100% Fly ash Utilization & reduced stack emissions.


national award for excellence in energy management,2016 .... gmr-warora_cii ppt from...optimize the...

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