NABHA POWER LIMITED Power to People - CIIGBCgreenbusinesscentre.com/energyaward2017presentations/Power/Nabha... · Global Benchmarks* 7 Nabha Power Limited – Power to People Source:

NABHA POWER LIMITED Power to People

18th National Award for Excellence in Energy Management 2017

30th August – 1st September 2017, CII-Hyderabad

2 x 700 MW Super Critical Thermal Power Plant

NABHA POWER LIMITED

1

Nabha Power Limited – Power to People 2 8/31/2017

COMPANY PROFILE • PROJECT & KEY FEATURES

BENCHMARKING • >660 MW FY17 PERFORMANCE

• ENERGY BENCHMARKING

ASSESSMENT

• STATUS OF SEC OF NPL FOR LAST 3 YEARS (Y-O-Y)

• OBJECTIVES, MONITORING & REPORTING

• STRATEGY FOR SEC REDUCTION

ENCON PROJECTS

• ENCON FY 14-15

• ENCON FY 15-16

• ENCON FY 16-17

INNOVATION • CATEGORY A INNOVATION

• CATEGORY B INNOVATION

SUSTAINABILITY

• GREEN PROJECTS

• BEST PRACTICES

• CERTIFICATIONS

• AWARDS

AGENDA


Bidding

9th Oct 2009

LOI

18th Nov 2009

PPA

18 Jan 2010

FSA Signing 15

Sep 2013

Unit-1 COD

1 Feb 2014

Unit-2 COD

10 July 2014

Project Developed by Larsen & Toubro Ltd – India’s largest

and most reputed infrastructure company under Case-2 of

Tariff based Bidding

25 Years Power Purchase Agreement (PPA) signed in January 2010 with Punjab State Power Corporation Limited (PSPCL).

Long term FSA with SECL for 20 years.

Environment friendly supercritical technology.

All major equipment manufactured indigenously through technology tie-up or JV’s

Best in class heat rate.

Turbine Heat rate(design-1849): 2084 Kcal/KWh (Gross)

Boiler ƞ-88.7%

NPL AT A GLANCE

2*700MW INDIGENOUS PROJECT

Station Availability: FY 14-15: 84.18 % FY 15-16: 91.79 % FY 16-17: 93.06 %

• Zero Liquid Discharge • 100% Fly Ash utilisation • Water Consumption less than 2.5

cum/MWh

Nabha Power Limited – Power to People 4

COMPANY PROFILE

BENCHMARKING

ASSESSMENT & MONITORING

ENCON PROJECTS

INNOVATION

SUSTAINABILITY

8/31/2017


ENERGY BENCHMARKING* (National & Global)

PARAMETERS ELECTRICAL SEC

(%)

THERMAL SEC

GROSS HEAT RATE (Kcal/KWh) PLANT

SEC (Specific Energy

Consumption) of the Unit 5.18% 2207 NPL, Rajpura

Competitor 1

(National) 7.7 % - 8.5% 2050 - 2142 CGPL, Mundra#

Competitor 2

(National) 5.0 % - 5.5 % 2151 - 2247 Adani Power, Tiroda

SEC (Specific Energy

Consumption) of the Unit

(Global)

4.5% 1870 Yuhuan Power, China

* Note: Data is indicative in nature # Coastal Gujarat Power Limited (Tata Mundra, Unit Size: 800 MW)

Roadmap to achieve national/global SEC

Reduction of APC through completion of projects considered under ENCON 2017-2018. Identification of energy saving area/equipment under ISO 50001:2011

Arresting of high energy drain valves passing Unit major overhaul to plug heat rate losses in BTG island Absorption of new technology/methodology to reduce part load heat rate losses

8/31/2017

S. No Name of IPP OEM TG/BLR Size APC % SHRKcal/Kwh PLF %

1 Nabha Power Ltd, Rajpura L&T MHI/L&TMHI 2 X 700 5.0 % - 5.5 % 2084 - 2178 77

2 CGPL(Tata Mundra), Gujarat Toshiba/Doosan 5 X 800 7.7 % - 8.5% 2050 - 2142 76

3 Adani Power, Tiroda SEC/SEC 5 X 660 5.0 % - 5.5 % 2151 - 2247 60

4 NTPC (Sipat), Stage-1 LMZ/Doosan 3 X 660 6.0 % - 6.5 % 2206 - 2306 90

5 Reliance Power, Sasan SEC/SEC 6 X 660 6.0 % - 6.5 % 2178 - 2276 85

PLANT PERFORMANCE COMPARISON*

6 Nabha Power Limited – Power to People

*Source: Order in Case of 2012/2014

8/31/2017

Global Benchmarks*

7 Nabha Power Limited – Power to People

Source: Siemens, SST-6000 steam turbine for future

coal-based thermal plants, 2011.

*Source: Powermag USA.

NAME MW MS

Pressure (KSC)

SH/RH TEMPERATURE

(DEG.C)

DESIGN THERMAL

EFFICIENCY OEM

HEKINAN UNIT # 3, JAPAN*

700 245 538/593 47.4% MHPS, JAPAN

HESSLER PLANT, GERMANY*

720 280 578/600 47.6% ALSTOM, UK

KAWAGOE UNIT #1 & #2, JAPAN*

700 316 566/566/566 48.4% TOSHIBA, JAPAN

NABHA POWER LIMITED RAJPURA UNIT #1 & #2

700 245 563/593 41.3% MHPS, JAPAN

8/31/2017

Best APC achieved @ Full Load

4.8%


COMPANY PROFILE

BENCHMARKING


ENCON PROJECTS

INNOVATION

SUSTAINABILITY

8/31/2017

NABHA POWER LIMITED – POWER TO PEOPLE 9

2365.74 2360.94

2321.3

2431

2381

2329

54.11%

62.64%

76.99%

40.00%

55.00%

70.00%

85.00%

100.00%

2260.0

2310.0

2360.0

2410.0

2460.0

14-15 15-16 16-17

PLF %

HEAT R

AT

E (

kcal/

kw

h)

Target SHR*(kcal/kwhr)

Actual SHR(kcal/kwhr)

PLF

SPECIFIC ENERGY CONSUMPTION (Kcal/KWh): NHR Y-O-Y

*Target SHR (Kcal/KWh) has been derived in consideration with PPA Heat rate of 2268 Kcal/KWh at full load

Unit #1 AOH;

November 2015

(22 days)

Unit #2 AOH;

March 2016

(19 days)

Unit #1 AOH November 2016

(33 days)

Unit #2 AOH April 2017

(31 days)

Generator Thread Out

Attending of duct leakages & RAPH seal replacement.

High energy drains attended (Unit #1: 38, Unit #2: 59)

GHR improvement: (Unit #1: 14 Kcal/kwh, Unit #2: 16 Kcal/Kwh)

LP Turbine Overhaul

High energy drains attended (Unit #1: 128, Unit #2: 141)

Insulation replacement in Boiler, MS/HRH/CRH piping, Feedwater Heaters

GHR improvement: (Unit #1: 30 Kcal/kwh, Unit #2: 34 Kcal/kwh)

8/31/2017


Obje

cti

ves

Maximizing station availability >94.1% by reduction in outages

Minimize the gap between target heat rate and actual heat rate

Improving plant efficiency by plugging the energy losses in the system

To upgrade with latest technology for Energy Conservation & Sustainability

Perf

orm

ance M

onit

ori

ng Monitoring of Plant

availability, Forced Outage analysis

Heat Rate Monitoring (target vs actual),PADO-is used as tool for monitoring (Design Vs Actual)

APC deviation against standard curve developed based on 3 years of operations

Temperature & thermography mapping of drains and insulation

Report

ing

Monthly Energy Efficiency Review Report (Efficiency linked with commercial losses)

NHR deviation report circulation

Daily MIS circulation

Defect reporting through service request

Forced outage committee meeting: review and deviation reporting through trip report

OBJECTIVES, MONITORING & REPORTING

8/31/2017


REPORTING FORMAT & IMPLEMENTATION METHODOLOGY

Initiation of Idea

Modification Note

Proposal to ENCON team in monthly

review meeting for feasibility study

Yes/

No

Implementation

Yes

No

ENERGY METER OF HT DRIVES

MASTER DPR DATA EXTRACTED FROM

DPR FOR ENERGY

CONSUMPTION REPORT

MAIL FOR

MONTHLY MIS

Improvement

Monitoring

8/31/2017

8.1, 13%

8.0, 13%

8.2, 13%

7.7, 12% 3.4, 5% 3.5, 6%

3.0, 5% 1.4, 2%

0.2, 0%

0.3, 0%

19.8, 31%

Other, 24.7, 38%

ENERGY CONSUMED IN JULY (MWH)

U#1 CW PUMP

U#1 FANS

U#2 CW PUMP

U#2 FANS

U#1 MILLS

U#2 MILLS

Plant AHP

Plant CHP

U#1 AIR

COMPRESOR

U#2 AIR

COMPRESSOR

Plant

MISCELLANEOUS*


COMPANY PROFILE

BENCHMARKING


ENCON PROJECTS INNOVATION

SUSTAINABILITY

8/31/2017

Nabha Power Limited – Power to People

ENCON PROJECTS UNDERTAKEN (FY 14-15)

13

Sl No. Project

Annual Electrical Saving

Annual Thermal Saving

Investment

(INR Million)

Payback

(Months) (MWH) (INR

Million) (Tonnes)

(INR

Million)

1

Optimisation of PA header

pressure set point from 943 to

860 mmWC resulted in

reduction of PA Fan current

197 0.55 Nil Nil Nil Nil

2

Optimisation of HVAC cooling

system operation during

favourable ambient conditions

(1.2 MW for 150 days, OCT 2014

- MAR 2015)


Total 4517 12.65 Nil Nil Nil Nil

8/31/2017



14

Sl No. Project



Investment

(INR Million)

Payback

(Months) (MWH) (INR

Million) (Tonnes)

(INR

Million)

1

Stopping of one nos. of CW pumps

during winter season (November to

March) by utilising interconnection

lines. System Design: 2 x 50%


2

APC reduction in Fan currents (Pro-

active initiative to identify the air

ingress and leakage points in Air & Flue

Gas ducting through soap bubble test

and arresting the same by welding all

the joints)

1858 5.02 Nil Nil 2.05 8

3

Complete Switchover from HFO to LDO

(LDO is less viscous and doesn’t require

steam source for heating)

Nil Nil 15107 80.23 3.75 Nil

8/31/2017



15

Sl No. Project



Investment

(INR Million)

Payback

(Months) (MWH) (INR

Million) (Tonnes)

(INR

Million)

4

Optimization of cycle make-up by

arresting the high energy drain valve

passing (Minimizing system losses)

Nil Nil 15466 79.96 1.5 0

5

Optimization of Unit Cold Start-up

Operation (Optimization of coal firing

and unit cold start-up turbine rolling

pressure)

Nil Nil 1339

(oil) 62.2 Nil Nil

Total 17230 46.52 30573 222.40 7.3 8

8/31/2017



16

Sl No. Project



Investment

(INR Million)

Payback

(Months) (MWH) (INR Million) (Tonnes) (INR

Million)

1 Improvements in Ash Handling

Plant 4234 11.431 NIL NIL 1.828 2

2 Improvements in Coal Handling

Plant 384 1.037 NIL NIL NIL NIL

3 Replacement and servicing of

high energy drains NIL NIL 4083 20.99 11.586 7

4

Provision of interconnection

line between Service water

header and ESP/BBD water

header

640 1.728 NIL NIL 0.003 NIL

8/31/2017



17

Sl No. Project



Investment

(INR Million)

Payback

(Months) (MWH) (INR Million) (Tonnes) (INR

Million)

5

Optimization of CEP Minimum

re-circulation flow during part

loading

990 2.674 NIL NIL NIL NIL

6

Tap position optimization of all

lightning transformers in plant


7

Hotwell make-up pump

switched off by using vacuum

drag line


8

Lube oil and hydraulic oil

pumps of standby mills in

standby and stop condition

during part load condition


Total 7563 20.42 4083 20.99 13.417 9

8/31/2017


FUTURE ENCON PROJECTS PLANNED (FY 17-18 onwards)

18

Sl No. Project Planned Investment (Cr.)

1 HIP turbine major overhaul in both the units.

Unit #1 (Nov – Dec 2018); Unit #2 (Apr- May 2019) 12

2 Phase – 1: 200 KW roof top solar panel installation to further reduce auxiliary

power consumption of the plant. Phase – 2 : 200 KW (2019-20) 3

3 Implementation of VFD in CEP for energy conservation during part load operation

in both units phase wise. 3

4 Use of natural lighting for MPHB roof lighting by provision of transparent poly-

carbonate sheet 0.080

5 Stopping of one no. of Instrument Air (IA) compressor in Ash Handling Plant by introducing an air receiver tank

0.015

6 Introduction of topping desuperheater and modification of LP Bypass warm-up

drain in both unit phase wise 20

7 Coating of internals of CW, CCW, ACW pumps and associated piping 1

Total 39.095

8/31/2017


NPL Energy Conservation Journey (FY15 – FY17 cumulative)

19

12.65

281.57

322.98

0. 7.3 17.

30573 34656 4517.5

176747.2 184310.3

0.

50000.

100000.

150000.

200000.

0.

87.5

175.

262.5

350.

FY 15 FY 16 FY 17

SAVINGS (INR Million) INVESTMENT (INR Million) COAL (MT) MWHR

8/31/2017


COMPANY PROFILE

BENCHMARKING


ENCON PROJECTS

INNOVATION SUSTAINABILITY

8/31/2017


INNOVATION AT NPL

CATEGORY B : New concept (risks taken/self driven/beyond OEM)

TITLE OF THE PROJECT: Implementation of modified cage in HP Heater #6, #7 & #8 cascading normal drain

DESCRIPTION: Due to severe cyclic operation of units, frequent choking was observed in HP Heaters #6, #7 & #8 normal

drain control valve cages. On an average monthly 7 to 8 times cages cleaning was required, which was leading to

frequent outages of HP heaters consequently deteriorating the heat rate.

ACTION TAKEN: Modified cages installed in one unit as pilot project to eradicate the frequent choking problem with an

increase in 38% total opening, decrease in opening of HP heater #6, #7 drain by 16% and 4% respectively.

OBSERVATIONS: With an investment of 10.2 lacs the problem of repeated heater outage for drain cleaning was resolved.

The pilot project has proved to be successful and same has been implemented in the other unit and the issue of the

heat rate deterioration on account of cage choking was eliminated.

HPH-06 Old Cage HPH-06 Modified Cage HPH-07 Modified Cage HPH-07 Old cage HPH-08 modified cage HPH-08 Old cage

8/31/2017


INNOVATION AT NPL

CATEGORY A : (Known concept with unique application)

TITLE OF THE PROJECT: ESP BBD pump switched off by providing interconnection with service water line

DESCRIPTION: ESP/APH/BBD pumps each of 150 KW (2W + 1S)

• Washing of Electrostatic Precipitator (Shutdown)

• Washing of Air Preheater (Shutdown)

• Quench the hot drains in Boiler Blow Down Tank (Daily operation).

SHUTDOWN: No vibration symptoms and optimum design operation

NORMAL OPERATION: Shut-off pressure operation with high vibration causing repeated failure

8/31/2017


ROOT CAUSE: Temperature Control Valve (TCV) provided for

quenching purpose was open in the range of 10-20%, creating

severe back-pressure on pump. Issue couldn’t be resolved through

RC as it is designed for 30% as per standard design.

ACTION TAKEN: Alternate source of water supply from service

water which had margin was utilized through interconnection

between the discharge header of both the pumps (Service water

and ESP BBD pumps)

BENEFITS: This, out of the box modification resulted in stopping

of the ESP/BBD pump. It thereby resulted in an energy saving as

well as preventing the breakdown of ESP BBD pumps during normal

operation. SAVING : 6400000 KWH, INR 1.728 MILLION p.a.


INNOVATION AT NPL

CATEGORY B : New concept (risks taken/self driven/beyond OEM)

TITLE OF THE PROJECT: Use of one no. of crusher and vibrating grizzly feeder for washed Indian coal

against earlier philosophy of two no. of crushers and VGFs

DESCRIPTION: One no. crusher and One no. VGF of both stream taken into operation instead of two nos.

each . Use of one no. of crusher and vibrating grizzly feeder for washed Indian coal against earlier

philosophy of two no. of crushers and VGFs.

ROOT CAUSE: The deck plate of VGF had one solid stretch (2310 mm x 600 mm) which was directly below

the chute area and was obstructing the free flow of coal mass in forward movement causing severe

chokage thus loading had to be frequently reduced for smooth operation.


ACTION TAKEN: By modification in the perforating deck plate of

VGF (2310 mm x 600 mm with 70 mm dia. holes) the loading of

crusher was raised from 1100 TPH to 1500 TPH. This helped in

stopping of one stream of VGF and crusher.

BENEFITS: This, out of the box modification resulted in improving

the crusher loading and also stopping on stream of VGF & Crusher

with washed coal in operation. SAVING : 384070 KWH, INR 1.037

MILLION p.a.

RISK INVOLVED: The problem was addressed to OEM but they

couldn't come up with suitable solution. An in-house RCA was

carried out and the modification was done which was self-driven

and didn't involve OEM support. With risk element involved, the

modification was done as a pilot project and it was successful.

SO

LID

DECK P

LATE

(2310 M

M X

600 M

M)

BEFORE MODIFICATION

AFTER MODIFICATION


COMPANY PROFILE

BENCHMARKING


ENCON PROJECTS

INNOVATION

SUSTAINABILITY

COAL YARD MANAGEMENT

Wind shield barrier erection on three sides to avoid direct

air impact on inclined portion (12 m x 600 m)

Compact stacking of received coal in stock yard, water

sprinkling on condition basis

Homogenous coal blending in stock yard.

100% Use of Auto Coal Sampler for sample Collection

Zero outage due to CHP downtime

20 September 2016 27 28 8/31/2017 Nabha Power Limited – Power to People

28

Rooftop Solar PV panel of 5 KWp installed for lighting of CHP building

Use of solar heater of 4.8 KWp for water heating in Field hostel

Proposed another 200KWp roof top solar planned for lighting of:

DM plant building: 130 KWp

Clarified and fire water pump house: 30 KWp

Field Hostel: 40KWp

Proposed use of Sky lighting in main plant TG building for lighting during day hours

Clean Sources of Energy at NPL

8/31/2017 Nabha Power Limited – Power to People

GHG EMISSION DATA: (as per GHG Protocol)

FY Generation (MU) Scope-1

CO2e Emission (MT)

Scope-2

CO2e Emission (MT) Source Considered

2014-15 5727.29 4343269.17 7067.57 Scope-1 : Coal + LDO

Scope-2 : Start-up

Power

2015-16 7703.31 6042853.12 2396.92

2016-17 9441.75 7165538.49 227.09

FY Specific CO2 emission % Reduction in emission intensity since

baseline year study

2014-15 863931 Baseline Year

2015-16 851676 1.41 %

2016-17 837632 3.04 %

% Reduction in emission intensity since baseline year study = {Specific CO2 emission (Baseline Year) - Specific CO2 emission (Year in

consideration)}/ Specific CO2 emission (Baseline Year) %

Scope-3 emission is not applicable to us.

Procurement of goods at NPL is done as per energy efficiency criteria.

Note: Supercritical technology is an Environment friendly technology and therefore with higher loading of the machine the

specific CO2 emission reduces

29 8/31/2017 Nabha Power Limited – Power to People

QMS ISO 9001:2015

Nabha Power Limited – Power to People 8/31/2017 30

EMS ISO 14001:2004 OHSAS 18001:2007 EnMS 50001:2011 NABL ISO 17025

AWARDS:

❖ BEE National Energy Conservation Award 2016 in thermal power plant category >100 MW from MOP, Gov. of India

❖ IPPAI 2016, first runner up in best thermal power generator category

❖ Bronze award in “Coal Power Project of the Year” & “Independent Power Producer of the year” at Asian Power-2016

❖ Environment Excellence Award-2016 Clean Generator of the year –Coal from Mission Energy

❖ Greentech Environment Award-2017 – Gold Award in Thermal Power Plant


NPL has planted 2,30,000 trees in and around the vicinity of the plant.

Thank You


DAMAGE IN SEAT & PLUG BLUE MATCH CHECKING IN SEAT & PLUG

Agency that executed the project (with complete address and email):

1) EFCO Maschinenbau India Pvt. Ltd. Address: 55/A, Annaram Village, Jinaram Mandal. Medak, Andhra Pradesh – 502313 Email:

[email protected]

mailto:[email protected]




ENERGY CONSERVATION MEASURES IN ASH HANDLING PLANT

Action Taken:

• Duct hopper to buffer hopper line re-routed resulting in

reduced line length from 69 to 29 m.

• Reduction in number of bends from 6 no. to 2 no.

• Hopper fluidizing line rerouting done to provide

improve fluidizing air to ash in ESP hoppers.

• Use of additional Knife Gate Valve in downstream of air

intake valve for improving vacuum of ash conveying

line.

Poking of hoppers reduced to Zero

All hoppers evacuation possible Three times a

day

System idle time of Seven hours/day

achieved

Housekeeping levels improved

Specific Power consumption reduced from 24.8 KWH/T –

16.76 KWH/T

Benefits: AHP Specific Power Consumption Source: NPL operations record; AHP energy meters


24.85 24.63

24.38 22.57

21.08 17.42 17.40 17.38

17.35

17.32 17.11

16.76

0

5

10

15

20

25

30

Mar-16 Jul-16 Oct-16 Jan-17

SPC (

kw

hr/

MT)

Specific Power Consumption in AHP (kwhr/ MT of Ash)

ENERGY CONSERVATION MEASURES IN COAL HANDLING PLANT Action Taken:

• Improving the belt utilization factor by increasing the loading of conveyor belt from 1800 – 2200 TPH during coal

reclaiming process

• By-passing of Vibrating Grizzly Feeder (VGF) and Crushers for imported coal.

• Use of one no. of crusher and vibrating grizzly feeder for washed Indian coal against earlier philosophy of

two no. of crusher and VGF.

Benefits:

• Reduction in over-crushing and fine generation in imported coal.

• Crusher Loading improved from

1100 TPH to 1500 TPH (design-1600 TPH)

• Aux. power savings by stopping of

one VGF (37 KW), Crusher (372 KW) and other auxiliary (15 KW).

Source: CHP operations record


1.71

2.3

1.6 1.6

1.42 1.4 1.3

1.35 1.3

1.25

1.4 1.4 1.32

1.42 1.31

1.45

1.

1.2

1.4

1.6

1.8

2.

2.2

2.4

2.6

2.8

3.

Sep-1

5

Dec-1

5

Apr-

16

Jul-

16

Oct-

16

Jan-1

7

May-1

7

Specific Power Consumption in CHP (KWh/MT of Coal)

Documents

NABHA POWER LIMITED Power to People - CIIGBCgreenbusinesscentre.com/energyaward2017presentations/Power/Nabha... · Global Benchmarks* 7 Nabha Power Limited – Power to People Source: