Nava Bharat Ventures Limited Power Plant (Orissa)

Kharagprasad, Near Meramandali Rly. Station, Dist. Dhenkanal Unit Profile Nava Bharat Ventures Limited Bharat Ventures Limited ( formerly Nava Bharat Ferro Alloys Limited) is a Rs 6 billion, diversified company committed to excellence. The company’s corporate headquarters is in Hyderabad (India) and manufacturing units are located in the States of Andhra Pradesh and Orissa. The company’s units have ISO 9001 and 14001 certifications for the Quality and Environmental Management Systems adopted and follow 5-S for work place excellence. The business activities of the company comprise power generation, manufacture & marketing of bulk ferro alloys, manufacture and marketing of crystal sugar and by-products like extra neutral alcohol and infrastructure projects. The company operates two coal based thermal power plants - one at Paloncha in Andhra Pradesh and another at Kharagprasad near Angul in Orissa. These power plants supply power to the grid/licensed power trading companies in addition to meeting the entire requirement of power for the company’s ferro alloy plants at the same premises. As the production of ferro alloys is power intensive, it is imperative for the power plants to generate reliable power at low cost. The Company’s Power Plant in Orissa (“the Unit”) was commissioned with an installed capacity of 30 MW in 2003. A new unit of 64MW capacity is being set up at the same location, making the total capacity after expansion as 94MW. To achieve economy in operation and maintenance, the total O&M of the power plant is handled through contracts with a core group of O&M executives on permanent roles of the unit. The core group has the principal responsibility to maintain quality in O&M practices, make continuous efforts to bring down operational and energy costs incurred for power generation. Energy conservation is thus an essential responsibility of each member of the core group of the unit. Process Flow Chart

Energy Consumption Ever since the Unit was commissioned in 2003, constant efforts were made for reducing energy consumption and improving process efficiency. By implementing various energy conservation projects the Unit achieved a consistent decrease in the Specific Electrical and Thermal Energy Consumption in the process of generation of power as tabulated below:

Description Unit 2003-2004 2004-2005 2005-2006 Annual Electricity Generation

Lakhs kWH 451.3852 1726.262 2182.18

Total Electricity Consumption for Generation.

Lakhs kWH 42.5542 150.544 178.595

Specific Energy consumption – Electrical.

kWH/KWH generated

0.0943 0.0872 0.0818

Total Thermal (Fuel) consumption / annum.

MkCals 144942.408 535017.41 667954.658

Specific Energy consumption – Thermal (Fuel)

kcal / kWH generated

3204.66 3094.19 3059.28

Electricity Thermal (Fuel) Year Consumption (KWh/ KWh generated)

% reduction over year 2003-2004.

Consumption (KCal/ KWh generated)

% reduction over year 2003-2004

2003-2004 0.0943 3204.66 2004-2005 0.0872 7.53 3094.19 3.45 2005-2006 0.0818 13.26 3059.28 5.54

Energy Conservation Commitment, Policy & Set up As already stated, Nava Bharat Ventures Limited, Power Plant in Orissa considers energy conservation as its major objective to achieve cost effective power generation. In this process, the core group of Plant Supervisors adopt a day to day approach through observations & discussions within the group and also with the O&M contractors to get into every possible area where energy saving can be achieved and then discuss to evaluate each and every suggestion in the regard. After evolving an action plan, the proposal is sent to the Managing Director for his approval to go ahead with necessary budgetary support for the energy conservation projects. Through continued training, both by in-house and outside professionals in the field, a work culture is created which supports knowledge enrichment of the group to effectively work as a team and take up the energy conservation measures. Exchanges in the areas of such work between various units of the Company also have given a tremendous strength & support for energy conservation with a competitive spirit within the Company. The environmental & safety aspects are closely studied and monitored in carrying out project works for energy conservation. Top Management takes keen interest in the progress and outcome of these projects and renders all the support required through continuous interactions & monitoring. The Unit has adopted ‘5-S’ for work place excellence which also contributes to energy conservation through improved methods of operations. The Unit has adopted SAP R/3 system. The FI&CO module helps every one involved to have access to costs in a transparent manner which enables employees to identify areas suitable for energy conservation efforts. The company’s philosophy of conserving natural resources, and, reducing, reusing and recycling of wastes generated, gives constant impetus to energy conservation in the Unit. Energy Conservation Achievements Ever since the Unit was commissioned in December 2003 various steps have been taken for implementation of Energy Conservation measures as a result of which the % auxiliary consumption in powercame down from 9.43% in 2003-04 to 8.18% in 2005-06 giving a total saving of Rs.42.66 lakhs for an investment of Rs.34.34 lakhs. The following are the Energy Saving measures taken. A) ELECTRICAL SAVINGS ( 350days operation ): 1. Cooling water pumps with Variable Frequency Drive:

Before installation:

Two C.W. pumps were operating with total motor capacity of 500kW. Motor capacity = 500kW

Power consumption per annum = 42 lakh kWh Operating cost = Rs.105 lakhs / annum

After installation: C.W pumps with VFD are now operating with a motor capacity of 200kW each.

Motor capacity = 400kW Power consumption per annum = 33.6 lakh kWh

Operating cost = Rs.84.0 lakhs / annum

Savings per annum = Rs. 21,00,000/- 2. New energy efficient packaged instrumentation air compressor

Before installation

The old compressor was operating always in loading & unloading conditions.

After installation The new compressor was operating during loading & getting off during unloading condition Energy saved = 210000 units / annum Savings per annum = Rs. 5,25,000/- 3. FRP blades in place of GRP blades in 3 nos of cooling tower fans

Before installation The old GRP fans were operating with 47-48kW loads on each fan.

After installation The new FRP Fans are operating with 33-35kW loads on each fan

Energy saved = 315000units / annum

Savings per annum = Rs. 7,87,500/- 4. Replacement of smaller capacity ash vessel with higher capacity ash vessel

Before Installation With small size vessel ash conveyance was almost continuous.

After installation With larger vessel size now, ash conveyance is being done in intervals for a higher quantity conveyance at a time. This has reduced the compressor running hours. About 300-units/day of energy is saved. Energy saved = 105000 units / annum Savings per annum = Rs. 2,62,500/- 5. Installation of Capacitor bank at intake well for raw water pump drives

Before installation

Power Factor penalty of Rs. 45,000/- was paid to CESCO in 2004-05. After installation Power factor penalty is nil in 2005-06 Savings per annum = Rs. 45,000/- 6. Installation of booster pump in ACW system

Before installation The VFDs of CW pumps were kept at min. 8

86% in order to 5-

maintain water pressure down stream of ACW. After installation

The VFDs of CW pumps are kept as low as 81% in winter & in low load condition.

Energy saved per day = 100 units (approx.). Savings per annum:100 x 350 x Rs.2.50 = Rs. 87,500/- 7. Optimization of station lighting Before All station lights were glowing. After 25nos of SV lamps were removed without affecting the area illumination.

Energy saved per day = 20 kWh Savings per annum = 20 x 365 x Rs.2.50 = Rs.18,250/- (Please see Write up on pages 8 & 9)

B) THERMAL SAVINGS 1. By providing steam traps in the Main Steam line drains Before installation

Approximately 4MT of steam per day was constantly drained.

After installation The above steam was saved & 1 MT of coal/day is also saved. Savings per annum = Rs. 4,20,000/- C) PROCESS CHANGES 1. Maintaining steady load in the Unit. Before

Approximately 5MT/day of DM water was drained through continuous blow down in order to maintain phosphate level in the Drum water.

After The above water was saved & 0.5 MT of coal/day also saved.

Savings per annum = Rs.3,15,000/- ENERGY CONSERVATION PLANS AND TARGETS

Anticipated savings in Approx. investment (Rs.lakhs)

Project Commencement & Completion year

Energy Value Rs. LakhsEnergy Conservation Measures (Planned)

(specify units)

Year 2006-2007

Replacing Boiler Bed Evaporator tubes with

riffle tubes & increasing riser size

from 100NB to 150NB to overcome tube

thinning in evaporator during part loads and to gain efficiency in heat utilisation by

reducing heat input through reducing coal

firing to boiler. 11000MKcal/yr 30.00 16.00 2006 - 2007

Replacing V-belt drives with Flat-belt drives for coal crusher-3nos and compressors-5nos. 1.82 Lakh kWh/yr 4.60 5.20 2006 - 2007

Replacing existing 55kW CT fan motors (3nos) with 37.5kW motors 1.03 lakh kWh/yr 2.60 2.75 2006 - 2007

Year 2007 - 2008

Installation of vapour absorption system for air conditioning of the plant 1.72 lakh kWh/yr 4.30 10.00 2007-2008

Replacing 1 No. energy inefficient air compressor (9000 CFM) with energy efficient compressor 0.56 lakh kWh/yr 1.36 6.40 2007-2008

ENVIRONMENT & SAFETY Environment The Unit has engaged an agency authorized by the State Pollution Control Board, Orissa for regular monitoring of the system. As a further measure of control, parameters like chimney emissions are continuously recorded in the DCS system of the Unit and checked and corrective actions taken whenever required. The water effluent generated by the Unit is continuously checked, neutralized and re-used within the Works, leading to Zero Discharge of liquid effluent. The requirements stipulated in the applicable environmental legislations are strictly adhered to, ensuring ecological balance in and around the premises of the Unit. Safety The Unit strongly believes in safety as a work practice. Regular inspection is carried out by the Unit’s Safety Officer to rule out any unsafe practices or work spots. The technique of 5-S is practised in all areas of the Unit for work place excellence. As a result of these measures, the Unit achieved a record of Zero Accidents for the last three years.

BRIEF WRITE UP ON MAJOR ENERGY CONSERVATION PROJECTS EXECUTED BY NAVA BHARAT VENTURES LIMITED IN 2005-2006

1. Introduction of FRP Blades in Cooling Tower :

The original 3 Nos. of CT Fans were of GRP blades. With this each CT Fan was consuming 47-48 kW of power. As CT fans are in continuous running drives it was thought to replace one no. CT Fan with FRP Blade in the year 2004-05 to see the effect of this on energy saving. Encouraged by the result of the energy saving of 12 kW, it was decided to replace the balance 2 Nos. of CT fans with FRP blades. Before replacement with FRP fan these two nos. of fans were consuming 2 x 48 x 24 kWh = 2304 kWh per day. After introducing FRP fans the power consumption came down to 1700 kWh per day in these two fans. The cost of energy saved worked out to Rs.1550/- per day. Total saving in 2005-06 is more than Rs.5.2 Lakhs. Cost of installation of 2 FRP fans was Rs.5.1 lakhs & the pay back was achieved in less than a year. The impact of this has been reflected in the reduction of auxiliary power consumption.

2. Installation of Capacitor Bank in Raw Water Pump House:

The raw water pump house is located away from main plant & it is powered from utility source. In the year, 2004-05 on account of running of this pump a P.F. penalty of Rs.0.45 lakhs was paid to the utility over and above the cost of energy procured. It was analysed that the low P.F. was due to the utility voltage always remaining low & it was decided to install a capacitor bank as a remedy. The capacitor bank was installed at a cost of Rs.0.11 lakhs & as a result the P.F. penalty in 2005-06 was nil.

3. Introduction of Higher Size Ash Vessel at Economizer :

The ash vessel installed at the economizer had a capacity to handle 1300 kg per hour of ash. With this, the ash accumulated in economizer zone was to be evacuated continuously round the clock. As a result the 90kW compressor was running non-stop & was consuming 1,500 units of power per day. Yet there were frequent chockings in the ash conveying lines resulting in boiler load reduction. The problem was analysed & it was decided to increase the hopper capacity from 7 M3 to 14 M3 & replace the ash vessel with a 4000 kg per hour capacity vessel. With this, the ash conveyance was reduced to 12 hrs. – 14 hrs., resulting in saving of 300 units per boiler per day & 600 units per day for both the boilers. The investment cost for replacement of vessels for both the boilers was Rs.1.22 lakhs & the cost of saving was of Rs.2.62 lakhs. The pay back was achieved in less than 6 months.

4. Installation of Booster Pump:

ACW Pumps are used for cooling of compressors. To achieve the desired pressure in the cooling water line VFDs of CWS are kept minimum at 86% (as the ACW suction is from CW discharge ) irrespective of TG load. Sometimes even the compressors were tripping on ‘Low ACW header pressure’. The problem was analysed & it was decided to install a booster pump down stream of ACW discharge line in order to boost up the water pressure near compressor. After installation of the booster pump it was observed that the CW Pump VFDs are operated as low as 81% during “Climatic & Low Load Condition”. The energy saving was achieved worked out to 35000 units per year. The investment cost of the booster pump is Rs.69,000/- & the savings amounted to Rs.87,500/-. The pay back was achieved in less than a year.

5. Power Plant Station Lighting :

The different stations in Power Plant such as Boilers, ESPs, TG Hall etc. were having bright illumination. Feedbacks were taken from the field operators. Based on this feedback, it was felt that some reduction in illumination level was possible in these areas. Accordingly, it was decided to conduct a survey on illumination level at different periods of time. Lux measurements were taken at different points of the above areas and based on this, it was decided to eliminate 25 Nos. of Sodium Vapour Lamps (each of 70W). After this reduction in no of luminaries, it was observed that working level illumination was maintained without sacrificing comfort level of working in these areas. The investment cost for this was NIL whereas the savings were Rs.18,250/-.

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