18th National Award For Excellence In Energy Management-2017

CAPTIVE POWER PLANT (9x135 MW)

VEDANTA LIMITED, JHARSUGUDA

GROUP PHILOSOPHY

Entrepreneurship

Innovation

Excellence

Integrity

Respect

Trust

Care

Core Purpose “Vedanta is a globally diversified

natural resources company with low

cost operations. We empower our

people to drive excellence and

innovation to create value for our

stakeholders. We demonstrate world-

class standards of governance, safety,

sustainability & social responsibility”

PLANT PROCESS

IMPLEMENTATION OF MANAGEMENT SYSTEMS

• Quality management ISO 9001:2008

• Environment management ISO 14001:2004

• Energy management ISO 50001:2011

• Asset Management ISO 55001:2014

• Occupational Health and safety management

OHSAS 18001:2007

• Par-Excellence by QCFI 5S

Installation of CAAQMS for continuous air quality monitoring

Biomedical Deep burial

pit

High Concentration

Slurry Disposal

(HCSD) -1st In Odisha

Co –Combustion

of Anode Butt in CPP with

due permission from CPCB

Real Time Data

Acquisition system

Weather monitoring station with solar panels

ENVIRONMENTAL PROJECTS

CARBON FOOT PRINT ACTIVITIES

Year Scope 1 emissions

CO2e (MT) Scope 2 emissions

CO2e (MT) Scope 3 emissions

CO2e (MT) CO2e MT Mitigation*

2013 - 14 9760105 2484 102634 9865223 Baseline Year

2014 - 15 9986049 27,134 117,702 9986193

2015 - 16 10568356 8,403 321,478 10568685

2016 - 17 15098803 45942 399815 15544560

2017 - 18 5% reduction 5% reduction 5% reduction 5% reduction

Efforts towards GHG emission reduction: Adoption of new technology. Stepping in towards renewable energy sources. Creating awareness among employees and stakeholders. Reduction in no. of light vehicle by 50%. Vehicle with aging less than 3 years only allowed &

ensuring PUC certificate for every vehicle. Increasing the loadability in transportation to reduce carbon emission.

Source: AT Kearney Report

BENCHMARKING

1.90%

1.20%

3% 2.9%

0.00%

0.50%

1.00%

1.50%

2.00%

2.50%

3.00%

3.50%

Player 2International

Player 1National

Player 3 National

JSG 1215 Actual

Δ SHR value - JSG 1215 (% of Design SHR)

8% 9.08% 9.50% 9.68%

0%

2%

4%

6%

8%

10%

12%

Player 1International

Player 2National

Player 3 National

JSG 1215 Actual

APC Value - JSG 1215 (% of generation)

Unit : gms/Kwh

Design : 789

Units in

Commissioning

Stage

REDUCTION IN SEC

a) Commissioning of Ultra

filtration

b) Turbine Overhauling

c) Replacements of Turbine

Drain Valves

d) Operational Improvements

a) CT fills design modification

b) HFO to LDO gun conversion.

c) APH O/H, Soft Touch Seals Installation & Basket

design modification.

d) Turbine Seal Checking & Rectification

e) Condenser Cleaning

f) Operational Improvements

g) FGET temp reduction.

2730 2679 2463 2442 2418 2442 2421 2451 2400

2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 Target 17-18

STATION HEAT RATE (Kcal/kwhr) PG test Value : 2400

REDUCTION IN SEC

Benchmarking : 2.00

a) Zero Discharge.

b) Improvement of COC

c ) Recirculation of Ash-

pond Sedimentation water

d) Reduction in Steam

Leakages & Blow Downs

a) Commissioning of ETP-2 for

CT Blow-Down

b) Commissioning of Ultrafiltration for DM

c) Modification Compressor

Return Line

a)Reuse of Blow Downs in fire fighting

b) Installation of ETP-1 & 90% west

water reuse inside the plant.

C)Recycling of Ash pond retention

water.

2.76

2.45

2.11 2.14 2.20 2.19 2.16 2

2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 Target17-18

Specific Raw Water Consumption (m3/MWh)

Units in

Commissioning

Stage

REDUCTION IN SEC

a) Reduction of Forced Outage

b) Optimization of Cold Startup

c) Improved Operational Controls

a) Reduction of Forced Outages

b) Availability of Mills and Feeders

c) Installation of Air Blasters

d) Reduction in Bunker Choking

3.67

0.8

0.21 0.09 0.09 0.11 0.08 0.12 0.05

2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 Target 17-18

Specific oil consumption(ml/kwh)

a) BFP recirculation valve design

modification

b) CT Fans Blades design modification

c) Optimization of Compressor Running Hrs

d) CW pump Interconnection

e) Installation of Natural roof Ventilation

Fans

a) Replacement of Existing Dryers with

Energy efficient dryers

Units in

Commissioning

Stage

a) Installation of Additional

Compressors

a) Installation of New ID

fans

a) Truck Tripler

Commissioning

a) Ultra filtration

Commissioning

REDUCTION IN SEC

a) Energy Efficient

Motor installation.

a) Lighting

Modification.

a) CW interconnection.

b) APH seal

design modification

(4 no.s)

9.82% 10.14% 10.24% 9.84% 9.63% 9.66% 9.58% 9.81% 9.25%

0.00%

5.00%

10.00%

15.00%

2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 Target 17-18

APC PG test Value: 9.59%

Sl.No. Projects for FY 2014-15 Total Annual

Savings(Rs Million ) Investment Made

(Rs million)

1 APH Soft touch seal replacement for 5 unit 20.85 1.5

2 APH basket replacement in 1 unit 4.7 11.4

3 Operational optimization by maintaining Main steam pressure, Main steam temp etc.@ near design values

20.4 0

4 CT fan Blade Replacement & angle changing (5 fans) 1.9 1.7

5 CW pump impeller coating in 2 pumps 0.42 0.514

6 Condenser bullet cleaning in 4 units 6.53 0.76

7 APC reduction in Power transformer in all units 1.23 0

8 Increase in belt utilization in coal handling plant 1.85 0

9 Leakage arresting of clarifier storage tank 0.07 0

10 Reducing heat loss through condensate drain 2.22 0.03

11 Usage of portable hydro pump instead of BFP 0.18 0.85

Total 60.35 16.75

ENERGY SAVING PROJECTS

Sl.No. Projects for FY 2015-16 Total Annual Savings(Rs Million )

Investment Made (Rs million)

13 Cooling Tower fills design modification for one Unit 3.91 7.0

14 APH seal replacement(4 no.s) 4.05 0.6

15 Condenser chemical cleaning 1.3 0

16 CW interconnection 0.53 1.4

17 BFP recirculation valve design modification 1.77 1.4 18 Energy efficient driers 0.04 0

Total 11.6 10.4

ENERGY SAVING PROJECTS

Sl.No. Projects for FY 2016-17 Total Annual Savings(Rs Million )

Investment Made (Rs million)

19 Cooling Tower fills design modification 119.8 56.0

20 APH seal design modification(4 no.s) 3.7 0.6 21 CW pump interconnection 1.3 0

22 BFP recirculation valve design modification 0.7 1.4 23 HFO to LDO Gun replacement 1.8 1.4

24 Turbine overhauling 53.9 31.37 Total 181.2 89.77

Project Synopsis:

Turbine was running on high turbine rotor expansion. To maintain

Turbine Expansion within limits, turbine inlet temperatures are

reduced. Reduction in turbine inlet temperature has resulted in

increase in specific coal consumption.

High Turbine Differential Expansion in Unit#2 attributed to a

deviation in SCC by 6.28 g/kwh (18.83 Kcal/kwh)

Turbine LPDE Reduction

Actions Taken :

Unit #2 shut down taken .

Turbine Front bearing pedestal guide blocks inspection & correction to

increase the HIP Turbine Casing Expansion

Unit #2 2010 Before Project After Project

CE (mm) 20.1 17.1 20.05

LPDE (mm) 6.3 7.4 6.5

Benefits:

1. Turbine healthiness & Reliability has improved

2. Achieved Reduction in SCC by 6.28 gm/kwh which is financial

savings of Rs 1.07 Crores

DE(H)

DE (L)

LP T

GENERATOR

CE 1

CE 2

HP T IP T

INNOVATIVE PROJECT-1

Manufacturer recommends battery life of 5 years, at room temperature of 27 deg C.

Battery room temp. was above 33 deg C resulting in reduction Battery bank life .

Air flow coming from ECU duct was restricted due to Fire proof false ceiling & Continuously running Battery room exhaust fans.

ECU duct extension done for proper circulation of air. Battery room exhaust fan timer installed & Room Sealing Cost savings for 22 battery banks Rs 60,50,000

Cost savings of Exhaust fan Rs 287000

INNOVATIVE PROJECT-2

Replacement of CT fills has been done with new design incorporating following improvements.

Flute size change from 17 mm to 19mm to avoid choking in rain zone. Increase in total height from 1675mm to 1800mm to increase surface area. Total height is split in 4 layers for ease of handling and maintenance.

This leads to vacuum improvement of 1 kpa with a saving of 22 lacs /Unit/month.

PROCESS IMPROVEMENT-1

BEFORE AFTER

Energy saving

21 kcal

AVR panel should be maintained within 28 Deg C for long life of components like Thyristor and PCB.

Existing ventilation system

Two AVR Panel Exhaust fan in Each Thyristor panel

One 3 Ton tower AC & two no of 1.5 Ton Split AC.

Installed duct for exhaust air removal from room, switching off 2 Split Acs & exhaust fans .

BELLOW Energy saving

143.27 KW

BEFORE AFTER

PROCESS IMPROVEMENT-2

PROCESS IMPROVEMENT-3

CT fan Motors & Seal Air Fan motors were running at partial load, as high capacity motor was installed.

2 CT fan Motors were replaced with 110 KW (down from 132 kW)

Energy saving of 6 kW/motor

2 Seal air fan motors were replaced with132 KW which was removed from CT fan motor instead of 160 KW motors

Energy saving of 8 kW/motor

Energy saving

14 kWhr

PROCESS IMPROVEMENT-4

BEFORE – 50 kWhr AFTER – 46 kWhr

Installation of Mechanical seal on Auxiliary cooling water pump

Installation of mechanical seal by

1. Replacing gland packing in auxiliary cooling water pump to ensure the better sealing

2. Reduce the auxiliary power consumption of 4 units by improving the friction between

stationary and rotary parts

Energy saving

4 KWhr

LP Turbine

PROCESS IMPROVEMENT-5

Condenser flood test:

It’s a proven method to detect the condenser tube leakages in unit overhauling / shut down maintenance .

For condenser flood test –channel support needs to be installed to avoid spring deflection due to overload of condenser filled with 5 meter height.

In order to improve the manpower productivity and lesser shut down time we developed a Height adjustable screw supports and has been installed for condenser flood test

Improvement in Operational Practices

Implementation of Asset Optimisation & war room concept

Development and Implementation of Innovative and Breakthrough Energy Efficiency Improvement Projects

Implementation of Six Sigma Projects,Quality circle, Autonomous maintenance & Kaizen Projects

Daily Monitoring of Specific Consumptions

Idea generation drive and implementing best out of it.

Energy Managment system ISO 50001 implemented in 2012 & re-certification done in the year of 2015.

FOCUS ON ENCON EFFORTS

Projects

RO Installation

Installation of VFD Drives

Addition of New CT Cells

Recommendation of energy Audit

Solar Lighting

Vapour Absorption Chiller

Energy efficient Motor replacement

Rain Water Harvesting

FUTURE ENCON PROJECTS

Integrated Energy Meters reports

MES

Energy Efficient Procurement

E-CER (Capex) Energy Impact Assessment

ENERGY REPORTING & IT ENABLEMENT

IT as a Strength

• CPP has been declared as “Par excellence” unit for 3-year back to back by QCFI.

• CPP achieved “Par Excellence” award for 5S performance and best presentation in National 5S conclave.

• Autonomous Maintenance: Total 10 Sub zones taken in CPP. 03 subzones are certified by QCFI (Score: >80%) in autonomous maintenance and qualified for level 2.

5S

• 54 QC teams are operational with 100% participation Including both direct & indirect employees.

• One of the CPP teams received gold award in CCQC 2016 and Excellence in LQC category in NCQC 2016. QC

• Wave-6 drive has started with 5 top priority projects worth Rs.9.41 crores with 50 employees.

• One of the CPP teams received gold award in CCQC 2016 & Par-Excellence in Six-Sigma category in NCQC 2016.

Six Sigma

• Total 121 Kaizen Projects completed in FY 2016-17.

• CPP received gold award in CCQC and Par Excellence in NCQC 2016.

• One of the CPP teams received gold award in CCQC 2016 and Excellence award in NCQC-2016 & one team received silver award in CCQC 2016.

Kaizen

BUSINESS EXCELLENCE

PEOPLE FOCUS In

stan

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eco

gnit

ion

Shabash Card

Au

dit

Sco

rin

g B

ased

Kaizen Rolling Trophy Fo

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L Em

plo

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Employee of the Month

Bas

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core

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Quality Circle Rolling Trophy

Awards/Recognition

Men

tori

ng

“V-Connect Program

Inte

ract

ion

“LSIP” Program

Enga

gem

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Proud parents

Lear

nin

g “WILP”

(BS,MS & MBA program) with bitt’s Pilani

Employee engagements

AWARDS & RECOGNITIONS

EXCELLENT ENERGY EFFICIENT UNIT – SINCE 2013

AWARDS & RECOGNITIONS

BUSINESS EXCELLENCE