TALWANDI SABO POWER LTD.tpp2018.missionenergy.org/presentations/TSPL.pdf · Unit Start up/ shutdown with TDBFP instead of MDBFP VFD installation in Raw water pump & VT pumps Turbine

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TALWANDI SABO POWER LTD.

Energizing Punjab’s Growth

“Partnering Punjab towards power self sufficiency”

Largest Power Generator in Punjab

one vision . one vedanta . 2

TSPL at a Glance

TSPL is a case 2 bid 1980 MW

Thermal Power Plant

TSPL is wholly owned

Subsidiary of Vedanta Limited

ISO 9001:2008; ISO14001:2004;

ISO 50001, ISO 39001

& OHSAS

18001:2007 certified

company.

3*660MW Coal Fired

Supercritical Technology

Based thermal Power Units.


Eco-friendly Super Critical Technology to conserve natural resources and reduce emissions

Zero liquid discharge system ensuring recovery & re-use of treated wastewater

Hybrid ESP with Bag Filters to limit particulate emissions in air < 50 mg/Nm3

275 M tall flue stacks with monitoring stations to reduce ground level pollution/concentrations

Concentrated form of ash disposal (HCSD) to HDPE lined Ash Dyke, saving ground water contamination

Natural Draft Cooling Tower (NDCT) to reduce Auxiliary Power Consumption

DM plant with RO system to reduce chemical consumption and hence contamination

Salient Features


TSPL Journey- Major Milestones

Talwandi Sabo Power Limited

Sep 2008 Power

Purchase Agreement

Sep 2013 Fuel

Supply Agreement

Nov 2013

Railway Connectivity

July 2014 U2

Commercial Operation

Nov 2015 U3


Aug 2016 U1


Sep 2016 Station


Mar 2018Performance

Guarantee Test

www.Vedantalimited.com

Health, Safety & Environment

Zero Harm Zero Waste Zero Discharge

one vision . one vedanta .

Fatal free operation for 3 years

1388 Accident (Fatal) Free Man Days (Till March’18)

4069 Man Days of Safety Training imparted

Lowest ever Auxiliary Power Consumption (APC) -7.61 %

Lowest ever Specific water consumption-1.97 L/Kwh

Highest ever fly Ash Utilization-73%

HSE highlights-2017-18


Worker Safety-Implementation of Personal LOTO System

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Improved Productivity

Easy Traceability

Enhanced Accountability

Effective Visual

Solutions

Standardize System

one vision . one vedanta . 8Talwandi Sabo Power Limited

People Safety First and Always

Deployment and propagation of 8 life saving rules/ 5 golden safety rules to ensure people safety


TSPL Performance


Journey towards Excellence -TSPL Performance at Glance

10Talwandi Sabo Power Limited

2304

22702265

2240

2250

2260

2270

2280

2290

2300

2310

FY 15-16 FY 16-17 FY 17-18

SHR Trend SHR Reduction Initiatives Combustion optimization through air flow optimization

and usage of washed coal.

Optimization of PA header Pressure to reduce unburnt carbon loss

Reduction in yard losses through effective coal yard management

Condenser tube cleaning during shutdown to improve Vacuum

Helium leak detection test to improve condenser vacuum

Insulation Mapping to reduce radiation losses

High Energy Drain Mapping

Optimizing Mill outlet temperatures


Reduction in Auxiliary Power Consumption


10.12%

8.90%

8.57%

7.61%

5.00%

7.00%

9.00%

11.00%

FY 14-15 FY 15-16 FY 16-17 FY 17-18

APC TrendFinancial Year Energy Savings

(in Mus)FY 15-16 15.23

FY 16-17 48.65

FY 17-18 79.63

APC Reduction Initiatives

APC Reduction Initiatives

Single CW pump/Vacuum pump operation at part load and in winters.

Unit Start up/ shutdown with TDBFP instead of MDBFP

VFD installation in Raw water pump & VT pumps

Turbine lube oil cooling line modification

Optimization of compressors energy consumption through comprehensive air leakage drive.

Optimization of Ash Handling Plant auxiliaries running hours through improved ash utilization.

Replacement of CFL/FTL with high efficient LED’s

3 Mill operation at part load


Reduction in Specific Water Consumption


2.5 L/Kwh(FY 15-16)

2.1 L/Kwh (FY 16-17)

1.97 L/Kwh (FY 17-18)

Initiatives to Reduce Water Consumption

• Recycle and reuse of treated wastewater through zero discharge system

• Maintaining COC > 5

• HCSD System for Slurry Disposal

• Minimizing leakages from hydrant posts

• Periodic Water Audits from third party

• Minimizing passing of valves


Spare Part Management - Reducing Non coal Cost


Group % of Total Items Priority for equipment Control

Vital ~15-20% High• Tight Control• Accurate Records• Frequent Reviews

Essential ~30-35% Medium• Normal Control• Good Records• Regular Attention

Desirable ~50% Low

• Simplest Control• Make Sure of enough

Qty.• Simple Records

100 % Availability of Insurance Spares Quality Assurance of Refurbished Spares

Equipment spare consumption history from SAP SMI/NMI Tracking

Spare Parts Management


Coal Yard Management

FIFO method for reclamation

Periodic Thermography of coal Yard

Effective control through regular yard mapping

Stacking layer by layer with compaction

Stacking in small heaps with trapezoidal shape

Stacking of coal through windrow method

Spraying chemicals to eliminate hot spots


5.24% (FY 14-15)

32.78% (FY 16-17)

72.8%(FY 17-18)

Journey towards 100% Ash Utilization

24.56% (FY 15-16)

“ Runners Up Award” in the category of “Research & Excellence Category” in Fly Ash Utilization by “Mission Energy” at New Delhi in Feb’18.

Achieved 100 % Ash Utilization in H2 for FY 17-18


Fly Ash Utilization Initiatives

Pond Ash Utilization in Road Projects

Reclamation of low lying areas with Fly Ash

Successful usage of fly ash usage in clay bricks having 15%

& 20% proportion.


In-house Innovation


Developed economical in-house road sweeping machine to control fugitive dust emissions inco-ordination with Punjab Pollution Control Board.

Cost of the project: 3.0 lakhs

Received Certificate of appreciation from Chairman PPCB


Key Positions

Sub-Contractor

Systems & Process

Process Quality

Quarterly Appraisal

SME

QA-QC

Hiring of key positions by the Business Partner in consultation with TSPL through joint panel

Review of all sub-contractors as proposed by business partner before finalization.

All the SOPs and SMPs duly approved by TSPL before commencement at site.

Quality Assurance Plan (QAP) in place to ensure quality and stretch asset life.

Periodic competency assessment on random basis for employees of business partner.

SME (Subject Matter Expert) group formulation to Capture, Enrich and DisseminateKnowledge and ideas among different plants and implement best practices.

Strong Quality Assurance and Quality Control (QAQC) system developed with business partnerand implemented

O & M Outsourcing Management


Best O & M Practices Management


Daily Morning Concall

Daily Plant Review Meeting

Weekly business partner Review

Fortnightly Outage management Review

Monthly Operation/Maintenance Review

Periodic Audits

Annual Business plan formulation


Power Digitalization-The need of the HourPartnering with Siemens AG for Power business diagnostic & analytics center

Design & Objectives

Develop IT enabled platform for Diagnostics & Analytics of Plant Performance

Enable Real time automated alerts with guidance for plant operational performance

Improved Reliability through Advance Pattern Recognition technology

Plant Performance improvement through diagnostic based Combustion Optimization Techniques

Deliverables

Smart best in class Dash Boards for key management with KPI trackers

SHR improvement by 0.5%

Reliability improvement - Forced outage reduction by 0.5%

Automatic MIS and performance Report generation

Instantaneous Alert Management with SMS facility



Power Digitalization- Making India Digital


Real Time Monitoring from remote Online Dashboards accessible from remote


CCTV Monitoring


CCTV Cameras

A organized user oriented CCTV Monitoring A well-organized user oriented CCTV Monitoring and Surveillance System with 159 installed

cameras

• 24x7 monitoring and recording of unmanned operational area.

• Cost effective method for monitoring large sites.

• Real time video recording and network transmission with multiple user connectivity at a single time.

• Effective event handling and professional visual alarm verification.


Current State

Internal benchmark(2 years)

World Class( 5 years)

Establish Center of Excellence to drive performance and efficiency maximization initiatives, to reduce outages, optimizeCost, Improve Quality to become Best in class

Vision

Objective Roadmap

Forced Outages Zero

Scheduled Outages

Overhauling Duration to be reduced to 18 days (Without Compromising in Quality & Quantity)

Ash Utilization 100%

Benchmarking Figures PLF, Availability, APC, SCCand SOC.

Centre of Excellence (COE)


Asset Optimization Framework


Asset optimization (AO) aids to standardize operational and maintenance practices with a robust approach & methodology based on world class manufacturing and maintenance work practices

Leadership & Organization

• Strategic planning• Customer Focus• Organizational

sustainability• Gemba Walk

Core Modules

• Reliability Centred Maintenance

• Spare Parts Management• Process Optimization• Asset life Cycle

Digitalization & Skill Development

• Knowledge Management• Continuous Improvement

Projects• Contractor Management

Components


Fostering Renewable Energy

25

30 Kwp Solar Rooftop panel installed in Hostel and made operational in July’17.


Guinness World Record-Making Punjab Greener


World Record by engaging stakeholders to increase green cover of Mansa from 0.27% to 0.31%


“Coming together is a beginning. Keeping together is progress. Working together is success”

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Total Ownership Drive - Swachh Bharat Abhiyan at TSPL

Talwandi Sabo Power Limited

A weekly Campaign drive at TSPL that aims to improved housekeeping of plant areas

Participation of Workers, Villages & Locals

Directly driven by Top Management

QMS ISO 9001 EMS ISO 14001 OHSAS 18001

EnMS ISO 50001 NABL Accreditation QCFI Member

Certifications


Awards @ TSPL

Greentech Safety Gold Award in 2016,2017

Shrishti Good Green Governance Award in 2016,2017 &2018

Talwandi Sabo Power Limited 29

• Greentech CSR Silver Award in

2015

• Rashtra Vibhushan Silver Award

in 2015

• 9th India Power Award in 2016

• “ Runners Up Award” in Fly Ash

Utilization by “Mission Energy”


Quality Circle Team

Two Silver Medals in Quality Circle chapter Convention

Excellent & Distinguish award at

National Level

Quality Circle Teams working for improvement projects

Talwandi Sabo Power Limited 30

Gold Award in Lean Quality Concepts organized by QCFI


Thank You

Documents

TALWANDI SABO POWER LTD.tpp2018.missionenergy.org/presentations/TSPL.pdf · Unit Start up/ shutdown with TDBFP instead of MDBFP VFD installation in Raw water pump & VT pumps Turbine