(Thermal Power Stations) GMR Warora Energy Limited (GWEL)...Reliance VIPL Butibori Dhariwal Power Station Sharing of Best practices & incorporating the learnings through Participation

1

21st National Award for Excellence in Energy Management - 2020

(Thermal Power Stations)

GMR Warora Energy Limited (GWEL)(A 2X300 MW Thermal Power Plant )

Team Member Details:

1. Mr. Mreenal Sharma -Manager

2. Mr. Edwin Williams S - Associate Manager

3. Ms. Pratiksha K Sharma - Manager

2

21st National Award for Excellence in Energy Management - 2020

(Thermal Power Stations)

Presentation Flow :

1. GWEL - At a Glance

2. Energy Management Policy

3. Energy Consumption Over-view

4. Reduction in Sp. Energy Consumption

5. Benchmarking of Energy Consumption

6. Energy Saving projects implemented in FY 2017-18, FY 2018-19 & FY 2019-20

7. Innovative Projects implemented in FY 2019-20

8. Utilization of Renewable Energy

9. Utilization of Waste

10. GHG Inventorization

11. Environment Management-Water

12. Best Practices – Non Energy Efficiency

13. Green Supply Chain Management at GWEL

14. Team work, Employee Involvement & Monitoring

15. Implementation of ISO 50001 at GWEL

16. Long Term Vision on Energy Efficiency

17. Awards & Accolades

18. Learnings from CII/Other Award Program

19. Major Achievement

3

1.1 GMR Group –Values & Beliefs

1. GWEL – At a Glance

Vision

“GMR Group will be an institution in

perpetuity that will build

entrepreneurial organization making a

difference to society through creation

of value.”

Mission

“By 2020, GMR Energy wants to be the most

profitable and one of the leading Integrated

Energy Companies in India and derive value by

• Diversifying strategically across Energy

value chain

• Being a preferred employer

• Being socially responsible”

1.2 Plant Synopsis & Technical Schematic

GWEL Plant Synopsis Technical Schematic

*DNH PPA of 200 MW got Expired on 30.06.2020

4

1. GWEL – At a Glance

1.3 Certificates:

GWEL Follows

“Auditable System Based Approach”

Driven by

Plan

Do

Check

Act

Approach

Deployement

Learning

Integration

5

2. GWEL – Energy Management Policy

2.1 Energy Policy-GWEL:

GWEL is committed to be the Most Energy Efficient and Integrated Energy Utility in the world

Efficient

Management

and usage of

Energy

Adoption of

Best Practices

& Continual

Upgradation

Training &

Knowledge

sharing to raise

awareness

Setting of Energy

Objectives &

Targets

Internal & External

Energy Audits &

Improvement

Initiatives

Compliance with

all legal

requirements

6

3. Energy Consumption Overview

3.1 Plant Performance – FY-19-20

2 x 300 MWCapacity

4138.79 MusGeneration

78.53 %Plant Load Factor

90.65 %Availability

97.77 %Deemed Availability

2322 Kcal/KwhGross Heat Rate

8.23 %Auxiliary Power Consumption

0.14 %DM Water Consumption

2.34 m3/MWhRaw Water

Consumption

0.13 ml/KWhSpecific Oil

Consumption

7

4.1 Year-wise Reduction in Specific Energy Consumption

4. Reduction in Specific Energy Consumption

9.2

8.6

8.2

8.2 8.2

80.1

82.0

86.8

83.4

86.6

76

78

80

82

84

86

88

7.6

8.0

8.4

8.8

9.2

9.6

2015-16 2016-17 2017-18 2018-19 2019-20

Auxiliary Power Consumption - %

APC-% Loading Factor-%

23

26

23

08

22

98

23

21

23

24

80.1

82.0

86.8

83.4

86.6

76

78

80

82

84

86

88

2280

2300

2320

2340

2015-16 2016-17 2017-18 2018-19 2019-20

Gross Heat Rate - (kCal / kWh of Gen)

Gross Heat Rate - (kCal / kWh) Loading Factor-%

*Improvement w.r.t Baseline Year FY 2015-16

99

98

98 99

98

95

86 8289

91

0

20

40

60

80

100

2015-16 2016-17 2017-18 2018-19 2019-20

Plant Availability- (%)

Deemed Availability-% Availability-%

KPI%

Improvement*Reason for Deviation

Heat Rate 0.1 %

1. Machine aging impact as U1

COH deferred from past 2

years & conducted in Aug-

19. Achieved Heat Rate

improvement of 47 Kcal/Kwh

& APC improvement of 0.5%

2. U2 COH also deferred from

last year, same planned in

Dec-2020

3. Heat Rate & APC effected

because of parameter

deviation due to frequent

schedule revisions

4. GCV Deterioration

APC 10.5 %

8


5.1 Benchmarking Strategies

Design Performance

PG Test Results

Interdepartmental Benchmarking

Performance after Modification

Past Best Achieved

Benchmarking with Thermal Power Stations

of Similar Capacity & Technology

International benchmarking with strategic Investor –

Tenaga

Site Visits to Similar capacity plants in the

region like

Reliance VIPL Butibori

Dhariwal Power Station

Sharing of Best practices & incorporating the learnings through

Participation in various Forums like Paper

presentations, Awards, Workshops etc

Adoption of World Class Best Practices by Cross-

Sector benchmarking like with our Airport Businesses - Best

Maintenance Practices for HVAC

Internal

Benchmarking

External

Benchmarking

GWEL uses Benchmarking tool to discover best performance being achieved

Within company

With competitor &

With entirely different industry also.

This information is then used to identify

Opportunities for Improvement

9

95.7

99.2

98.3

97.8

99.2

97.8

93.0

90.6

92.8 91.5 85.4 91.7 86.8 94.8

85.9 82.1 88.890.6

2014-15 2015-16 2016-17 2017-18 2018-19 2019-20

Availability–%

Deemed Availability Target Actual Availability

5.2 Internal Benchmarking of Key Performance Indicators (KPI’s)

68.8

76.2

70.5

71.3

74.1

78

.5

86.4 85.1

85.3

85.7 85.2 85.9

2014-15 2015-16 2016-17 2017-18 2018-19 2019-20

Plant Load Factor–%

Actual Availability Target

9.3

9.2

8.6

8.2

3

8.2

8.2

9.1 8.7 8.5 8.5

8.0 8.0

2014-15 2015-16 2016-17 2017-18 2018-19 2019-20

Auxiliary Power Consumption–%

Actual Availability Target

2340

2325

2306

2297

2320

2323

2342

2327 2325

2300

2295 2305

2014-15 2015-16 2016-17 2017-18 2018-19 2019-20

Heat Rate–Kcal/Kwh

Actual Heat Rate Target

2.1

5

0.3

3

0.2

7

0.1

3

0.1

3

0.1

0

0.1

3

2.50

0.89 0.59

0.34 0.36 0.11 0.07

2013-14 2014-15 2015-16 2016-17 2017-18 2018-19 2019-20

SOC–ml/Kwh

SOC Target

2.3

0.5

0.4

0.2

0.2

0.1

0.1

3.0

1.0

0.5 0.4 0.2 0.2 0.2

2013-14 2014-15 2015-16 2016-17 2017-18 2018-19 2019-20

DM Make-up–%

DM Water-% Target

Low Availability & PLF is on account of Coal Shortage & Customer Curtailment. However, GWEL has maintained Machine Availability of 98 % Increase in Heat Rate is on account of Machine Aging & Low Loading factor due to Coal Shortage, Customer Curtailment. 41% of the Time PLF

was less than 80%. U-1 COH done in Aug-2019 & achieved 47 Kcal/Kwh of Heat Rate & 0.18% of APC improvement. U2 COH Planned in Dec-20 Increase in SOC is due to COH; U-2 COH Planned in Dec-2020


10

5.3 External Benchmarking with Competitors of Similar Capacity & Technology (FY 2019-20)


GWEL achieved the Best Heat Rate, SOC & DM make-up %

95.35

97.7

93.7494.99

91.33

97.80

RPGDhariwal

RelianceRosa

JSWRatnagiri

LancoKorba

DTPSDahanu

GWEL

Availability-%

64.157.3

74.6566.04

76.22 78.53

RPGDhariwal

RelianceRosa

JSWRatnagiri

LancoKorba

DTPSDahanu

GWEL

Plant Load Factor-%

7.91 8.05 8.37 8.409.58

8.23

RPGDhariwal

RelianceRosa

JSWRatnagiri

LancoKorba

DTPSDahanu

GWEL

Auxiliary Power Consumption-%

2353 23442368

2427

2323

RPGDhariwal

RelianceRosa

JSWRatnagiri

LancoKorba

GWEL

Heat Rate-Kcal/Kwh

0.18

0.11

0.14 0.15 0.14 0.13

RPGDhariwal

RelianceRosa

JSWRatnagiri

LancoKorba

DTPSDahanu

GWEL

Specific Oil Consumption-ml/Kwh

0.380.31

0.56

0.270.31

0.14

RPGDhariwal

RelianceRosa

JSWRatnagiri

LancoKorba

DTPSDahanu

GWEL

DM Make-Up-%

11

Plan Do

Act Check

Adoption of New Technologies

Renewable Energy Projects

Energy Conservation projects implementation

Green Supply Chain Management

Evaluation of Energy Performance

Internal & External Energy Audits

Evaluation of Vendors / Suppliers

Benchmarking of Performances

Energy Objectives & Targets

Separate budget for Energy Conservation

Participation in Various Forums & Awards

Training & Knowledge Sharing

Best Operation & Maintenance Practices

Energy Conservation projects for Stakeholders

& CSR

Sustenance Monitoring

Approach

5. Energy Benchmarking

5.4 National & Global Benchmark : Short-Term/Long-Term Target

National Benchmark Global Benchmark

Aux power consumption of the unit % 8.11 % (Dahanu) 7.50% ( TNB Janamanjung)

Gross heat rate (Kcal/kWh) 2273 2280

GWEL achieved Lowest(Best Achieved)

Heat Rate of 2282 Kcal/Kwh & APC of 7.53% at 100% PLF

&

APC-7.16% in Winter & 7.53% in Summer

5.5 Roadmap to achieve National / Global Benchmark : Approach

12

S.No Project Description Status Target Date Annual Expected Benefit

1Installation of Vibro Feeder in Second Stream Conveyor-BCN-2A

Under Finalization Stage November-2020 221.29 Million Kcal

2Installation of 5 MW Floating Solar Plant at Reservoir

Technical Vetting Under Progress December-2020 21.60 Million kWh

3 Unit-2 COH Planned in Dec-2020 COH planned in Dec-20 December-20201.86 Million kWh

92045 Million Kcal

4Six Sigma project taken for Reduction in Start-up Oil consumption by 20% by adopting various operational strategies & new technologies

Under Progress November-2020 454.18 Million Kcal

5Utilisation of fluidized air for hopper instead of hopper heater in ESP

Project Under Study December-2020 3.24 Million kWh

6

Cooling Tower Performance Improvement Programme (Existing Cooling Tower Drift eliminator & Fill replacement, CW line modification etc)

2 Cells Completed,2 Under Progress,PO Placed for 4 more

December-2020 35045 Million Kcal

7

AHP fly ash silo existing 3 no. Conventional HORN antenna type radar level transmitter to be replaced by new DROP antenna radar level transmitter

Procurement Under Progress October-2020 0.131 Million kWh

8Intelligent flow controller (IFC) installation in Compressed Air System.

Procurement Under Progress November-2020 0.23 Million kWh

9CFD Analysis of Flue gas duct-Economiser outlet to APH Inlet

Planned in COH in FY-20-21 December-2020 0.60 Million kWh

10Application of Anti-erosion Coating in ID fan 2A and 2B Impeller

Planned in COH in FY-20-21 December-2020 0.90 Million kWh

11Cooling tower fan motor to gearbox metallic shaft to be changed with carbon fiber shaft

Vendor Exploring Under Progress January-2020 1.05 Million kWh

12 VFD installation for Induced draft Fans Planned in COH in FY-20-21 December-2020 3.56 Million kWh

Total Expected Benefits : Electrical Energy : 33.17 Million kWh Thermal Energy : 127225 Million KCal

5.6 Future Plans towards Energy Conservation – FY-20-21

5. Energy Benchmarking – Action Plan

13

6.1 Energy Conservation Projects implemented in last 3 FY’s

6. Summary of Energy Saving Projects

Financial Year

No. of

Projects

Implemented

Savings Achieved Expenditure

DoneElectricity Coal Oil

Lakh kWh MT Kl Lakh

FY 2017-18 18 133.88 9142 102 264

FY 2018-19 20 230.94 1168 165 31*

FY 2019-20 22 237.84 53752 41 862

Total 60 602.65 64062 308 1157

* Investment done in Previous FY

14

6a. Energy Saving projects implemented in FY 2017-18

S.No. Title of ProjectAnnual Electrical

Saving (kWh)

Annual Thermal Saving

Total Annual Savings

(Rs million)

Investment Made

(Rs million)

Payback (Months)

1Reduction in Start up/Shut down Cycle Time through implementation of various measures.

0 101.64 kl 4.228 0.00 0.0

2 Heat rate improvement programme from 2308 to <2300 kCal/kWh. 0 9142 MT 30.727 0.705 0.3

3Power factor improvement at all Balance of plant loads by installing capacitor banks (Installed in Stacker LT MCC bus section and Bunker MCC).

537506 1.613 0.00 0.0

4 Air Handling Unit power optimization in ESP control room. 13500 0.041 0.00 0.05 Optimization of ESP Power through Power Saver Mode 5873499 17.620 0.00 0.06 Further optimization of CW Pump running hours 3334915 10.005 0.00 0.07 Further optimization of CT Fan running hours 332507 0.998 0.00 0.08 Optimization of CEP output through VFD* 323499 0.970 0.00 0.09 Optimization of LDO Pump output through VFD* 3848 0.012 0.00 0.0

10 Optimization of Mill Seal Air Fan output of U-I & II through VFD 57237 0.172 0.27 18.9

11 Optimization of Hotwell M/U Pump output through VFD* 6966 0.021 0.00 0.012 Optimization of MGF Feed Pump output through VFD* 8399 0.025 0.00 0.0

13 Optimization of BA Conditioning Pump through VFD * 62972 0.189 0.00 0.0

14 Plant wide LED installation (Phase-I & II) 141255 0.424 24.84 703.4

15 Optimization of ACW Pump running hours 837056 2.511 0.00 0.0

16 Optimization of ECP Pumps output through VFD * 61221 0.184 0.00 0.0

17 Optimization of Raw Water Pumps output through VFD * 437708 1.313 0.00 0.0

18

Reduction in Auxiliary Power Consumption due to Loading factor improvement, Heat rate improvement, Energy deviation analysis (EnMS), Optimization of excess air, Attending ESP, APH & duct leakages and other miscellaneous steps.

1355612 4.067 0.63 1.9

Total 133876999142 MT

102 Kl75.12 26.45


6a. EnCon Projects of FY 2017-18

15

S.No Title of ProjectAnnual

Electrical Saving (kWh)



(Rs million)

Investment Made

(Rs million)

Payback (Months)

1 Make up of Cooling Tower fore-bay by gravity and Minimization of Pump Operation 257180 0.772 0.51 8.0

2 Replacement of Existing conventional light with LED’s throughout plant-Phase-II* 1720357 5.161 1.86 4.3

3 Degassifier water usage through gravity to CT forebay 106537 0.320 0.26 9.64 Installation of VFD in AHP CCW Pump 82832.28 0.248 0.27 12.8

5Installation of roof transparent sheet at AHP compressor house for daytime illumination

4380 0.013 0.02 13.7

6 Single Engine operation of Locomotives 37.05 Kl 2.698 0.00 0.0

7Running of 1 no. of Air washer pump with 100% discharge open instead of 2 pumps with 50% discharge open

120888 0.363 0.00 0.0

8 Energy Saving opportunity in Mill-F LOP 87768 0.263 0.00 0.09 Condensate dumping from LP Heater-4 for reduction in blow down hours 511 MT 1.897 0.03 0.2

10 CW blowdown line connection from CW return line 657 MT 2.438 0.03 0.111 Utility Pump Operation Optimization 11548 0.035 0.00 0.0

12FD fan servomechanism operating fork link modification for better control over blade pitch.

86052 0.258 0.02 0.9

13 Installation of Motion Sensor in Washrooms 1051 0.003 0.002 7.614 Oil Consumption Optimization by improving operational philosophy 107 Kl 5.590 0.00 0.015 CHP Operational Optimization 381400 1.144 0.00 0.016 Optimization of CW/ACW Pump & CT Fan running hours 5886583 17.660 0.00 0.017 Optimization of Pump & Fan output through VFD* 2562600 7.688 0.00 0.018 Optimization of ESP Power through Power Saver Mode 10423162 31.269 0.00 0.019 Reduction in Diesel Consumption in CHP by adopting best operating practices 21 Kl 1.494 0.00 0.0

20

Capacitor bank installation in1. AHP LT MCC section-A & B 2. DM plant MCC section-A3. CHP LT MCC bus section-A & B 4. Bunker LT MCC bus section-A5. Stacker LT MCC bus section 6. WT LT MCC bus section-A & B

1361214 4.084 0.10 0.3

Total 230935521168 MT

165 Kl83.398 3.09


6b. Energy Saving projects implemented in FY 2018-19

6b. EnCon Projects of FY 2018-19

16

6c. EnCon Projects of FY 2019-20

6c. Energy Saving projects implemented in FY 2019-20

S.No Title of ProjectAnnual

Electrical Saving (kWh)



(Rs million)

Investment Made

(Rs million)

Payback (Months)

1 Reduction in Windage losses by Improvement in H2 Purity 929097.60 2.787 0.020 0.1

2Energy Conservation by Use of Rain Water Harvested from WTP area building roof tops as Cooling Water Makeup in CW Fore bay

3846.31 0.017 0.033 22.9

3 Reduction in Diesel Consumption by installation of Vibro-feeder in Truck Hopper 27 Kl 1.969 1.86 11.34 Auto Closure of Valves during Black-out to avoid Diaphragm Rupture 14 Kl 0.716 0.00 0.05 Improvement in Yard losses by 51 Kcal by adopting best operational strategies 37175 129.168 0.500 0.0

6Fan Power Consumption Optimization by attending Flue gas duct Leakages & Fan Impellar Coating

2065562.92 6.197 10.76 20.8

7 Heat Rate Improvement Through CT Fills Replacement & Condenser Cleaning 3505 Tonn 12.177 16.06 15.88 Heat Rate Improvement by Turbine Overhauling 6659 Tonn 23.136 40.71 21.1

9Boiler Efficiency improvement by attending duct leakages, Valves Servicing, Coal Mill Orifice adjustment

6413 Tonn 22.284 16.13 8.7

10Stopping of Ferric Chloride dosing pump by providing Ferric Chloride Tank By-pass discharge line for gravity dosing

5390.00 0.016 0.002 1.5

11 Alternate Street Lights in Service after 11 PM inside PTS 8820 0.026 0.02 6.812 Auto Operation of Lamps in CW pump house 876 0.003 0.004 18.313 CSU Screw Conveyor Bypass Modification Work 2409 0.007 0.01 8.314 Installation of Advanced Drift Eliminator in Cooling Tower 8900 0.040 0.09 28.015 Transparent sheet cladding in RO-DM Plant & Bunker floor to reduce lighting load 10950 0.033 0.03 11.0

16Replacement of Conventional exhaust fans with energy efficient exhaust fans at washrooms

4555 0.014 0.0208 18

17 To provide CT make up by gravity without CT make up pump pumping* 416268 1.249 0.00 0.0

18Replacement of Existing conventional lightings with LED’s throughout the plant-Phase-II*

3225190 9.676 0.00 0.0

19 Degassifier water usage through gravity to CT forebay* 140770 0.422 0.00 0.020 Optimization of CW/ACW Pump & CT Fan running hours 4177098 12.531 0.00 0.021 Optimization of Pump & Fan output through VFD* 2472930 7.419 0.00 0.022 Optimization of ESP Power through Power Saver Mode 10311368 30.934 0.00 0.0

23784029.9953752 Ton

41 Kl260.82 86.23* Investment done in Previous FY

17

6.2 Absolute savings achieved & Investment made:

225.9

359.8

590.7

828.6

0100200300400500600700800900

2016-17 2017-18 2018-19 2019-20

Energy Savings (Lakh kWh/year)

15691

24833

26001

79753

10000

30000

50000

70000

90000

2016-17 2017-18 2018-19 2019-20

Coal Savings(MT/year)

1349

2101 2934

5539

0

1000

2000

3000

4000

5000

6000

2016-17 2017-18 2018-19 2019-20

Financial Benefits(Lakh Rs/year)

84

349

380

1242

0

500

1000

1500

2016-17 2017-18 2018-19 2019-20

Investment made(Lakh Rs/year)

Cumulative Benefits Achieved

***All savings are w.r.t Baseline Year FY 2015-16. Absolute Savings considered for FY-19-20

***All savings achieved audited by Management Assurance Group (MAG) Audit.

FYEnergy Savings

(Lakh kWh/year)

Coal

Savings

(Ton/year)

Oil Savings

(kl/year)

Financial Benefits

(Lakh Rs./year)

Investment

made-Year wise

(Lakh Rs./year)

2016-17 225.90 15691 403 1349 84

2017-18 359.78 24833 505 2101 264

2018-19 590.72 26001 670 2934 31

2019-20 828.56 79753 711 5539 862

Cumulative 828.56 79753 711 5539 1242

6. Summary of Energy Saving Projects-Benefits

18

7.1 : Make up of Cooling Tower fore-bay through gravity and Minimization of Pump Operation

Replicability : YES

7. Key Project implemented in FY 2018-19

Results Achieved: Reduction in APC as shown below

Project Trigger: Through Quarterly Internal Energy Audit

Implementation:

Earlier, 2 out of 3 pumps used to run for 16-20 Hrs per day to cater CT make-up

requirement by taking suction from RGSF sump & discharge to CT fore-bay

Now, Separate line laid from existing RGSF bed outlet channel to CT make-up

pump discharge header.

This line is providing make-up water through Gravitational Head without

Pumping & giving huge saving in terms of energy consumption by pump

Reduction in Running Hours of Pump by 50% achieved.

0

500

1000

1500

2000

2500

3000CT Make-Up Pump Power Consumption

Description

CT M/u Pump Running-Considering 2 Pumps

RunningSavings

Daily Run Hours

Energy Consumption

Hrs Mwh %

Before Gravity Make up

38.43 2.11

After Gravity Make up

17.75 0.98

Savings/Day 20.68 1.14 53.81%

Project Implemented

System Modification

19

7a : Reduction in Auxiliary Power & Diesel Consumption by Installation of Vibro-feeder in Belt Conveyor

Replicability : YES


Solution Implementation:

Vibration Feeding technology with controlled feeding rate was explored to mitigate

the problem of high diesel consumption, Partial loading & belt wear.

Vibro-feeder with Rack & Pinion Gate arrangement (RPG) was installed at BCN-2B

Truck hopper which eliminated Poclain usage by directly pushing coal through

dozer & RPG helped in even loading of belt by controlled feeding.

New & Innovative approach with high risk & high cost involvement for coarse duty

material handling & is First time implemented for CHP Conveyor belt at National Level

by GWEL.

300

600

Before After

Improvement in Belt Coal Feeding Rate-TPH

15.4311.63

3.8

Before After Saving

Reduction in Diesel Consumption-Ltr / 100 MT Coal Crushed

10965282648

27004

FY-18-19 FY-19-20 Saving

Reduction in Diesel Consumption-Ltr

Impact :

Reduction in Diesel Consumption by 25%

Belt Loading improved from 300 to 600 TPH & wear & tear reduced

Problem Description:

Alternate coal arranged from nearby mines due to severe coal shortage & same was

transported through truck to plant & stored in truck hopper yard & then moved to truck

hopper for loading conveyor belt with help of dozer & poclain.

This led to increase in diesel & Energy consumption due to frequent handling of

coal through Dozer & Poclain & partial loading of conveyor belt due to inconsistent

feeding through truck hopper leading to coal spillage, belt running out & reducing life

of Conveyor.

Vibro Feeder

SOP for Vibro Feeder

20

7b : Reduction in Auxiliary Power Consumption by reducing Turbine Cooling Time

Replicability : YES



Annual overhaul is essential activity for plant up-keepment & consumes energy while

turbine on barring gear & during maintenance.

AOH is planned activity of approx. 25 days, out of which 10 days is taken for Turbine

Natural Cooling before the temperature of turbine components (FSMT) reaches at

level that allows maintenance work to begin and stop all turbine auxiliaries.

This high cooling time leads to increase in unit downtime & running auxiliaries

of turbine contributes to power consumption.


The process was first analyzed in Numerical Simulations for various cooling conditions

for mitigating any risk of stress

On load Cooling - Turbine is fed with live steam at lower pressure & temperature

under “sliding conditions” to decrease temperature of its components during on load.

Off Load Cooling - This cooling process starts immediately after shut down by

maintaining partial vacuum in turbine and continued until temperature of components

reaches the desirable level.

Very fine Cooling adjustments are required for avoiding any parameter deviation.

Modification done at site for turbine cooling.

GWEL is first plant to implement this cooling procedure for SEC machine in India

Joint protocol signed with SEC (OEM) for SOP developed by GWEL.

Impact :

Electrical Energy Saving - 36535.5 KWh

Revenue generation by Increase in Unit Availability - Rs. 6.4 Crs

SOP was shared with peer plants and achieved desired results

160 53

Turbine Cooling Time Reduction-Hrs

Before After

Numerical Simulations

Modification

OEM Joint Protocol

21

7c : Reduction in Generator Windage losses by Improvement in H2 Purity

Replicability : YES


Impact :

Generator Windage losses improved by 57 KW

Improved purity from 95% to 98% which is best in SEC supplied unit in India


At GWEL, design hydrogen purity is 99% but same not achieved since

commissioning & maintaining at around 95%. This is an inherent issue in all

Chinese supplied machine in India.

Less Hydrogen purity contributes to Energy losses & same is a disastrous Safety

threat as well


Adopted Six Sigma methodology blended with Strategical tools for improving

Hydrogen purity

I-MR chart - To identify when the process goes out of control and also to indicate

where to focus for source of assignable cause

Normality test - To check data consistency

Kano Model – Identification of CTQ

Fish Bone & Cause & Effect Matrix – Identification of probable causes &

Recommended action.

Total 5 number of improvement initiatives has been implemented

263.86

56.93

206.93

Before Reduction After

Windage Losses Reduction-Kwh

98.2

95.7 96.595.2 95.1

GWEL RosaPower

Dhariwal JSWRatnagiri

ReliancePower

Hydrogen Purity Comparison with Peers-%

9598

Before After

Hydrogen Purity Improvement-%

22

8. Use of Renewable Energy / ENCON measures

8.1 : Renewable Energy Projects at GWEL

(150 nos.) on TG Building, Ware House, CW Pump House,

AHP Compressor House by replacing motor operated fans.

Solar water heater of capacity 1000 LPD installed

at Associate employee township.

Solar Water Heater in Permanent Township

installed for 150 Families

Translucent sheet cladding in CHP belt conveyors,

Compressor House, RO-DM to reduce lighting load

Pipe light in Stores & Warehouse.

Wind operated Cooling

Fans

Solar Water Heater for

Associates

Solar Water Heater for

Township

Translucent sheet

cladding

Pipe-lighting

Renewable

Energy

Utilization

Roof Top Rainwater

Harvesting

Roof Top Rain Water Harvesting from all buildings.

Rainwater HarvestingDeep Aquifer Recharge by Rainwater Harvesting in

Plant & Colony

23

8. Use of Renewable Energy / ENCON measures

8.2 : Savings achieved through Onsite Renewable Energy Projects

2015-16 2016-17 2017-18 2018-19 2019-20No. of Project

Implemented2 1 1 3 3

Total Capacity - MW 1Total Power Savings

Lakh KWh80.70

% Share 0.20Cumulative Savings

(Rs Lakh)16.93 25.63 38.76 68.20 242.09

RPO Obligation Nil

8.3 : Renewable Energy Projects under Implementation at GWEL

Key Highlights:

05 MW Internal Grid connected Floating Solar Installation on Plant reservoir

Contract Finalization completed, project execution by Nov-2020

Payment through POS (Pay out of Savings) Scheme to ESCO.

Electricity generated to be fed as internal APC throughout the plant.

24

9. Environment Management-Ash Utilization

9.1 : Utilization of Ash Generated

Distribution of Areas of Ash Utilization

Sr No. Particulars UoM 2017-18 2018-19 2019-20

1Ash Utilized in manufacturing of cement/ concrete others similar products

% 83% 68% 53%

2 Ash Utilized in Fly Ash Bricks % 6% 0% 14%

3 Ash Utilized in Mine Filling % 0% 9% 2%

4 Ash Utilized for Road Pavements % 3% 4% 26%

5Ash Utilized in Brick Manufacturing ( from Bottom Ash)

% 8% 13% 4%

6 Ash Utilized in Bottom Ash Mine Filling % 0% 4% 0%

7Ash Utilized Bottom Ash for Road Pavements

% 0% 2% 0%

8 Expenditure on Ash Utilization (annual)INR

(Lakhs)0.25 0 828

Ash Utilization at GWEL is 100% of the Total Ash Generated

66

87

104109 106

2015-16 2016-17 2017-18 2018-19 2019-20

Year-wise Ash Utilization - %

7.60 8.43 8.82

4.86 4.54 3.82

2017-18 2018-19 2019-20

Ash Generated Vs Ash Stock-Lakh MT

Ash Generated Ash Stock

1010

80

Ash Handling Method

Wet Semi Dry Dry

10-%- Through Slurry Pumps

80%-Through Bulkers

10%-Through Ash Conditioners & Dumpers

Utilization of Ash at GWEL

25

9. Utilization of Waste

9.2 : Utilization of Waste Water for Low End Applications

Application of RO-DM Plant waste water in AHP for

Makeup water to ash slurry pump & flushing water pump

Floor Cleaning in AHP & Boiler Area

B.A. Dust conditioner pump water tank filling

Bulker washing spray system

Cleaning of pipe racks

Water sprinkling arrangement at Ash Pond

Fountain at FA silo area

Application of RO-DM Plant waste water in CHP for

Sprinkling in Coal Yard

Dust Suppression System

Application of CW Blowdown water as

Make-up for Firefighting system

Other downstream requirements after ERS

Application of Domestic waste water for

Development of Green belt

Application of Waste Water in AHP

Application of Waste Water in CHP

Application of Domestic Waste Water for Greenbelt

9.3 : Utilization of Organic waste for Manure production in Plant & Colony

All the organic waste generated at Plant & Colony is used for

the production of manure through Bio composter.

The manure generated is utilized for vegetables and fruit

bearing plants planted inside plant premises & in Colony.

26

10. Environment Management-Emission

10.1 GHG Inventorisation

GMR Sustainability Report

Every year GMR group publishes its sustainability report for public.

It is available on the following link: Scope-1 Emission

https://www.gmrgroup.in/energy/

Best Practices for Maintaining Emission Level within Norm

Current Control: GWEL is having Low Nox Burner installed since design stage

with Nox value within norms limit

GWEL is having 100% Ash Utilization

Coal Blending through Automated Software to minimize

emission & maximize efficiency. PM within norms limit

Real time Ash monitoring system installed

Transportation of ash through jumbo bags by train mode

Future Control: FGD Implementation by 2021- Contract finalization

completed, Project Execution will start from Nov-2020

5 MW Floating Solar Installation- Contract finalization

completed, Project Execution by- Nov-2020

AAC (Aerated Autoclave Concrete ) block manufacturing unit

installation for further enhancement of Ash Utilization

727 739 7341200

2017-18 2018-19 2019-20

SOx Emissions-mg/Nm3

276 265 264300

2017-18 2018-19 2020-21

NOx Emissions-mg/Nm3

46 45 4550

2017-18 2018-19 2020-21

Particulate Matter-mg/Nm3909 918 919

2017-18 2018-19 2020-21

CO2 Emission-Ton/KW

10.2 PAT Cycle-II Compliance

PAT Cycle-II - Energy Consumption Target & Actual - Registration No.-TPP0149MH

Energy Consumption & Production for

Baseline Year 2014-15

Target Net Heat Rate for

Assessment Year 2018-19

Actual Net Heat Rate Achieved for

Assessment Year 2018-19

Net Heat Rate

(Kcal/Kwh)

Net Product Output

(Million Units)Net Heat Rate (Kcal/Kwh)

2581.52 3277.35 2554.62 2524.24

Operating Station NHR achieved with Normalization in FY 2018-19 : 2524.24 kCal/kWh

Number of Escerts to Sell : 9956 Price of Escerts to sell : Rs. 1 Crores

https://www.gmrgroup.in/energy/

27

11. Environment Management

11.1 Specific Water Consumption

3.82.4 2.3 2.4 2.2 2.3

3.5

2.21

FY 2014-15 FY 2015-16 FY 2016-17 FY 2017-18* FY 2018-19 FY 2019-20

Specific Water Consumption (m3/MWh)

Specific Water Consumption CPCB Limit

0.50.37

0.19 0.15 0.12 0.14

FY 2014-15 FY 2015-16 FY 2016-17 FY 2017-18 FY 2018-19 FY 2019-20

DM Water Consumption (%)

GWEL is a Zero Liquid Discharge Plant

Zero Liquid Discharge Scheme

S

N

o

Waste

Generation

Area

Generation PointCollection

PointTreatment Process

Application of treated

waterPhoto

1Pre-

Treatment

Plant

PT & ERS clarifier

Sludge

Handling

System

Sludge pit- Sludge Thickener-

Centrifuge Feed tank-

Centrifuge- Sludge Transfer point

Water recycled to

Reservoir

Solid Sludge separated

disposed to Ash dykeRGSF Back washSupernatant

tankPhysical Settlement of impurities

2RO-DM

Plant

RO & UF Reject/

MGF Backwash/ DM

Regeneration waste

Effluent

Collection

(EC) Pit

Acid and Alkali treatment

scheme for Neutralization

Ash handling plant

Coal handling plant

3

Circulating

Water

System

Cooling Tower

Blowdown

CW

Blowdown

tank & Dead

Storage for

Fire Water

System

Effluent recovery system (ERS),

wherein water is passed through

Clarifier- MGF- UF- RO system

Fire Fighting System

make up

Stored in ERS Clarified

water storage tank for

downstream

applications

4Domestic

Waste

Various domestic

waste generation

points

Collection

sump of STP

Collection sump- Collection

chamber- FBR (Fluidized Bed

Reactor)- Tube settler- Clarifier

storage tank- Filter Press

Green belt development

and landscaping

28

11. Environment Management

11.2 Best Practices in Water Management

Dedicated Water SCADA for Water

consumption accounting &

balancing.

32 Flowmeters installed plantwide

Key Benefits :

Area-wise Water consumption &

cost accounting

Specific water consumption

Monitoring

Identification of Water Wastage

Automated Reports

Real Time Dashboard & Trend

Alarm for increase in Water

Consumption above base value

WaterSaving-317314 m3

At Plant:

Deep Aquifer Recharge:

Plant-wide storm water drains

connected to Rain water

harvesting pond.

Annual Rain Water

Harvesting of 8.6 Lac m3.

Rooftop Rain Water Harvesting:

Rain water harvesting from

building roof tops & used as

cooling tower makeup .

Fresh Water Saving of

13140.46 m3/Annum

At Colony:

Water collection from Building

Rooftop & drains for Deep Aquifer

Recharge

External Water Audit by CII Triveni

Water Institute.

Plant overall water balance

Opportunities for Water

Conservation

8 Nos. of recommendations given &

all implemented resulted in

significant water saving

Internal Audit:- Through CIPs -

Continual Improvement Plan

Every year CIPs being taken

through Cross-functional team for

internal assessment of water

resources & conservation by

internal audits,

Water Saving of 1.94 Lac m3 has

been achieved through CIPs

Awareness on Scientific

Watershed Management for

improving water condition in

draught areas

RO Water ATM installed in 14

Villages for providing Safe

drinking water in fluoride zone

Check Dams construction

Pond deepening at nearby

villages

2 Nos. KT Weir restored

More than 285 acre land

brought under irrigation

Water SCADA Rain Water Harvesting Water Audit Water-Beyond the Fence

29

12. Best Practices in Plant-Non Energy Efficiency

12.1 Best Practices – Non-Energy Efficiency

Biodiversity

Friendly Habitat for

Floras & Faunas

Afforestation

Green GWEL

Flexibility

Sale of 10 MW of

Power saved through

APC in Market

Asset Management

GWEL is Certified with

Asset Management

System

Digitisation-

”Digital GWEL”

Project SARATHI –

Digital Platform for

Becoming Paperless

Regulatory Market

with Fixed tariff

Sustenance by

Agility & Innovation

First Plant to

Materialize this

Opportunity for

Revenue Generation

Revenue Generation

– 7.58 Crs

27 Process Digitized

with PDCA approach

Digital Logbook

Near Miss, Incidents

IMS Internal Audits

Waste Management

Vehicle Gate Pass

Agency Gate Pass

Agency Evaluation

HIRA ….. ETC

Increase in no. of

various bird species like

Indian pond heron,

Indian roller, etc

Various varieties of fruit

bearing & forest species

plants like Danima,

Eycaliptus, Golichowli,

Conocorophous,

Jamun, Amla etc

41% of the total

Plant area is

covered under

Green Belt against

norm of 33%

Total 200250 No. of

Plants has been

planted in plant area.

Plantation has been

done in nearby

villages under CSR

activity.

AMS Helped in

Performance & Cost

improvements

Management of risk

Enhanced stakeholder

confidence

AMS implementation by

Asset System Manual

AMS Procedures

Work Instructions and

Manuals

Identification of

Significant Assets by

Asset Risk register

30

12. Best Practices in Plant-Non Energy Efficiency

12.1 Best Practices – Non-Energy Efficiency

Nirmal Jeevan

InitiativeSocial Responsibility

Power Sale

Optimization Model

Reliability Centered

Maintenance

Online Monitoring

System for Ash &

Density

Data analysis tool to

generate innovative

solutions to Cope

with dynamic &

regulated scenario

for correct decision

making for

profitability

improvement

1. Online Ash & Moisture

Content Analyzer –

Provides instantaneous,

continuous, on-belt

measurement of Ash

and Moisture in coal

2. Online Ash Density

Meter - for Continuous

Online monitoring of

water content to

optimized on water

consumption

Employees Wellbeing is

of Paramount

Importance

Various Wellbeing

Initiatives being taken

Fun Run

Kausalika

Tournaments

Celebrations

Open Air Movie

Outbound Trainings

Yoga & Mindfulness

Heath Awareness

Infrastructure support to

Govt Schools

Kid Smart Centers

Transportation Facility

for students

Health Clinics & Camps

Construction of

Iindividual Sanitory

Lavoratory

Vocational Training

Center

Tailoring centers for

women

Farmers Training

Community Libraries

Drain Construction

Best in class Maintenance

Methodologies adopted for

100% reliability

Vibration Analysis

Lube Oil Analysis - Wear

Debris, NAS, TAN

Infrared Thermography

Dissolved Gas Analysis

Motor Current Signature

Analysis

At GWEL we follow Six

Sigma based approach

for Chronic issues.

WellnessBeyond The Fence-

CSRResearch

Maintenance &

ReliabilityNew Technology

Education

Health Hygiene & Sanitation

Empowerment & Livelihood

Community Development

31

13.1 Initiatives taken in Supply Chain to Reduce Energy Consumption

SN Projects Implemented at GWEL End

1Evaluation Format for Significant Energy consuming

equipment's/ Auxiliaries for vendors.

2

Procurement of Energy Efficient, free of hazardous

materials , repairable and made of modular

components and highly recyclable electronics.

3Identification of local suppliers/ vendors for improved

logistics.

4Integration of energy efficiency with the procurement

process and policy.

5 Refurbishment of spares

6Energy Management System and Water Management

system

7 Condition Monitoring of Equipment's

8Recycling of Waste generated within the Plant &

Colony

9

Companies vision for Green Supply Chain

Management communication to Suppliers through

policy

13. Green Supply Chain Management at GWEL

GWEL is committed to be the “Most Energy Efficient Unit” along-with “Minimizing Carbon Foot Print” in

all direct/indirect processes by adopting “Green Supply Chain Management”

Projects Implemented at Suppliers End

Sr No.Projects Implemented by

GWEL for SuppliersBenefits Achieved to Suppliers

1 Eco-Friendly Packaging SystemMinimization of impact of Supply Chain on

Environment

2Supplier Evaluation Program &

Feedback for Improvement

Awareness on Safety, Energy & Environment

leading to resource conservation & reduction

in carbon foot print

3 Training & Awareness Program

• Efficient Resource Management

• Energy conservation measures at their

premises

4

Encouragement for adopting

EnMS-ISO 50001 & Purchase

preferred from ISO 50001 supplier

Suppliers are adopting ISO-50001 & has

helped to improve efficiency and reduced

production cost

5

Energy Efficiency Audits for

Supplier-Implementation of

Equipment Performance

Evaluation Format

• Helped Potential vendors to gain

competitive advantage over competitors

• Market Opportunities for Potential Vendors

6Encouragement & Support for

Green Logistics

Reduction in transportation cost & carbon foot

print

7Sharing of Energy Conservation

opportunities with Vendors

Energy Conservation projects implementation

by Vendors thus reduction in carbon foot-print

Total Investment Made- 2 Lacs

32

Centralized Energy Management System

Real Time Comparison of HT & LT Equipment’s Auxiliary Power

consumption in EMS system for both Units, BOP, AHP & CHP

Auto Reports Generation for Energy Consumption on Daily/

Monthly and FY basis

Trending for better Analysis of Energy Consumption

System Upgraded for

Availability of Plant-wide Equipment's with Rating >75KW

Availability of Alarm, Auto SMS & Mail Facility

14.1 Monitoring of Energy Consumption


Energy Measurement Process & Validation:

Electrical Energy(KWh) Thermal Energy- Coal Thermal Energy- LDO Thermal Energy- HSD

Installing Energy Meters and

Monitoring online through

EMS

Accuracy Class of Energy

meters : 0.5

Calibration Schedule in form

of SAP notification.

As Fired Coal Weighment

through Coal Feeders.

Coal feeder Integrator recorded

in DCS.

Accuracy Class : +/- 0.2%

Calibration Schedule in form of

SAP notification.

LDO tank oil level & the

difference of the tank level

with respect the calibration

charts is monitored.

LDO tank oil level Transmitters

are calibrated on regular basis

HSD tank oil level & the

difference of the tank level

with respect to calibration

chart is monitored.

HSD tank oil levels are

Monitored on regular basis

33

14.2 Daily MIS Reports for Monitoring of Energy Consumption

Daily Energy Deviation Report Daily APC Break up Report

Daily Heat Rate Report

Daily & Monthly Plant Performance Report

Equipment Performance Test

Daily Water Consumption Monitoring Report


Dashboards for Sustenance Monitoring

Daily Parameter Excursion Report Cooling Tower Performance Test

34

14.3 Trainings & Workshops related to Energy Conservation

Internal & External Trainings and Workshops related to Energy Conservation

Sr.No Program Name & details Organized By

1 Six Sigma Training to All Employees for Structured Methodology of Energy Efficiency Optimization M/s KPMG

2 Workshop on Opportunities for Energy Saving in Thermal Power Plant M/s NPC

3 Workshop on Energy Audit Process for effective Energy auditing M/s NPC

4 Understanding the best practices of Energy Management System M/s EU India

5 CII Energy Efficiency Summit M/s CII

6 National Boiler Work Shop M/s NPC-Visakhapatnam

7 O&M conference on best practices by NTPC M/s NTPC

8 Overview of PAT Scheme: Achievements & prospects M/s BEE

9 Regional Workshop on PAT Scheme M/s BEE

10 Strategies & Best Practices on Energy Efficiency, Conservation & Management for Sustainability” by CII M/s CII Nagpur

11 Workshop on "Advanced Training Program on Energy Efficiency" by CII M/s CII Hyderabad

12 Workshop on "RCM & Streamlining the Maintenance Processes for Better Productivity & Energy Efficiency" by CII M/s CII Nagpur

13 Workshop on Induced Draft Cooling Tower Performance Enhancement In-house

14 In-house Workshop on Plant Performance Monitoring-(Boiler Efficiency, Heat Rate, Cooling Tower, Pump, Fans) In-house

15 Knowledge Sharing Session on "Operational SOP for Auxiliary Power Consumption Reduction at GWEL" In-house

16 Training on Energy Management System (ISO 50001) & Energy Conservation awareness for all stakeholders In-house

17 In-house Workshop on Learning from Failures in Thermal Power Plants In-house

18 In-house Workshop on Learning from COH in Thermal Power Plants In-house


35

14.4 GWEL – Celebration of Energy Conservation Week

Display of Energy Conservation Posters

EC Training for GWEL Employees and Associate employees

EC Programme for Children of nearby village schools

Competitions based on EC for Employees, Associates, family members etc

EC programme for family members

Felicitation of Winners

14.5 GWEL –Training & Awareness to Associates

14.6 GWEL – Web based Portals for Creating Awareness

EnMS (ISO 50001) Web Portal in GMR intranet EnMS (ISO 50001) web page in GMR intranetKnowledge Management Portal in Intranet


36

14.7 Involvement of Employees in Energy Conservation

Formation of Energy Management Cell under ISO-50001.

Objectives of EMC :

Monitoring of Specific Energy Consumption

Energy Audit (Internal & External) Recommendation

implementation status review

Discussion on Energy Conservation Projects

Identification of New Energy Conservation Initiatives

Members of EMC : Plant Head (Chairperson), O&M Head, Head

of EMC, EMC members (Energy Managers & Auditors)

Total Energy Managers- 21 Energy Auditors- 18

Appointment of Energy Leaders

Appointed throughout the plant & township

Monitoring of Energy consumption in their area

Reporting of Energy (Electrical, Thermal, Air, Water

wastage)

Identification of energy saving opportunities.

Monthly Localized Energy Audits through Checklist

Total 23 Energy leaders appointed.

EMC MOM

Monthly Energy Leader Checklist


37

14.8 Projects implemented through Kaizen ( Workers and Supervisor level)

At Supervisor Level At Workmen Level

Stopping of Ferric Chloride dosing pump by providing

Ferric Chloride Tank By-pass discharge line for gravity

dosing

Auto Operation of Lamps in CW pump house by Day-

Night Sensor

CSU Screw Conveyor Bypass Modification Work for

stopping Motor

Installation of roof transparent sheet at RO-DM for

daytime illumination

Replacement of Conventional exhaust fans with energy

efficient exhaust fans at washrooms.

Utilization of EC Pit water for floor cleaning instead of

fresh water

Saving of power consumption in PTS by modification of

Connection to keep Alternate Street Lights in Service

after 11 PM inside PTS

Reduction in Auxiliary Power Consumption in

Compressor House by identifying and attending air

leakages.

14.9 Expenditure towards EnCon Projects

• - Implementation of few projects of FY 2016-17 was already started in FY 2015-16. Budget of these projects is considered in FY 2015-16.

• - Implementation of LED projects of FY 2018-19 was already started in FY 2017-18. Budget of this projects is considered in FY 2017-18

321.85 324.61

84.27

264.45

30.87

862.30

2014-15 2015-16 2016-17* 2017-18 2018-19* 2019-20

Expenditure towards EnCon Projects – In lakhs

% Investment on Turnover in FY 2019-20 : 0.47%


38

14.10 Major Area of Concern in Energy Efficiency & Reliability

One out of 3 PPA which was contributing to 37% of Station export capacity got expired in June-20 which has significantly affect performance in terms of Efficiency & Profitability due to absence of new market opportunity

PPA Expiry

Plant PLF is getting affected due to Coal Quality & Quantity Constraint & same is affecting station Performance

Coal Issue

Impact of Machine aging on Plant Performance

Machine Aging

FGD installation will result in increase in plant Auxiliary Power Consumption

Increase in APC due to FGD

Fund availability major constraint for Technological Upgradation

Fund Availability

Increase in worldwide Renewable Energy portfolio is necessity for tackling Climate change issues but same may affect Plant PLF which will effect performance

Increase in Renewable Energy Portfolio


39

15.1 Implementation of ISO 50001


Setting Clear Energy Objectives & Targets

Formation of Energy Management Cell

Monitoring-Measurement-Analysis of Significant energy

use & consumption by Equipment’s/

Processes

Generation of Daily Energy Deviation

Generation of Non-Conformities

Corrective and Preventive Actions

Internal & External Energy Audits

Management of Energy Conservation

Programmes

Reviews at various levels and frequencies

Sustenance of Results

Integration of Energy Conservation to GWEL Objectives & Targets Monitoring through Daily Energy Deviation Report & Deviation

Closure by CAPA Closure Mechanism

40

15.2 GWEL – Management of Energy Conservation Program

SAP Z5 Notification for Implementation of Energy

Conservation Project

Identification

• Identification through Internal/ External Audits, RCA or CAPA for

Energy deviations etc.

•Energy Conservation Plan(EC Plan) raising & Approval

•Notification in SAP- Z5 category for approval of MA & Head-O&M

Implementation

•EC Plan Implementation Plan is Reviewed & Approved by

Steering committee headed by Plant Head

Completion

•Post Completion of EC Plan, Completion along with

Benefits will be certified by the Steering committee

Effectiveness

•Actual savings achieved to be furnished against expected

after 1 month of project completion.

•Status of EC plans will be monitored on Weekly/ Monthly

reviews.


Total 160 Energy Conservation SIP’s implemented in last 6 FY’s. Digitalization-Journey of Project Implementation

Identification Implementation Completion Effectiveness

41

16. Long Term Vision on EE

16.1 Long Term Target of Energy Efficiency

GWEL is committed to become the Most Energy Efficient Utility in the World

Our vision is to make use of all form of energy resources most efficiently, minimize the impact of our operationson Environment & conserve the Scarce Natural Resources

For that at GWEL we follow following Practices

Setting of Energy Objectives & Targets

Efficient Management and Usage of Energy

Adoption of Best Practices & Innovative Technologies

Internal & External Energy Audits & implementation of Improvement measures

Compliance with all legal requirements

Training & Knowledge sharing to raise awareness

Technological Upgradation

• Flexibility of inclusion ofNew Technologies inExisting System

Financial Support

• Availability of Pay Outof Saving Facility foradoption of NewTechnologies

Supplier Engagement

• Active Involvement ofSuppliers in GWELsGreen Supply ChainManagement

Challenges- Most Energy Efficient Utility

42

17. Awards & Accolades

BEE-National Energy Conservation Award-2017 CII National Award for Excellence in Energy Management-2018 & 2019

13th State Level Award for Excellence in Energy Conservation & Management by MEDA for the year 2018

IMC Ramkrishna Bajaj National Quality Award2017

Global Performance Excellence Award 2018-World Class BSC 5 Star 2019Sword of Honour 2019

Best Boiler Award 2019

Quality Circle Award

43

18. Learnings from CII/Other Award Program

To learn about the best practices adopted from best performing companies.

Facilitate adoption of similar projects at our unit, leading to enormous saving viz.

Intelligent Flow Controller

Airtron AC Energy Saver

An Opportunity to interact & network with individuals and companies of repute for further strengthening

Energy Efficiency System

Information about Latest market trends & innovative products for Energy Efficiency .

To identify strengths and opportunities to excel, based on a comprehensive and rigorous assessment by

experts.

18. Learning from CII/Other Award Program

44

19. Major Achievements

19. Completion of Capital Over-hauling in Record 37 Days

COH is an essential activity for Equipment up-keepment & usually carried once in 5 year or as per running condition

As per industry-wide practice, complete Over-haul activity for a Chinese unit takes approx. 45 days from Unit Shutdown to Sync

This contributes to approx. 12% of availability loss & hence major loss of revenue

From Past few years, GWEL was already facing availability & revenue loss due to Coal Shortage, hence it was essential to

maximize our availability as COH was also due for Performance improvement

Hence, GWEL took this as a Challenge to reduce COH timing without compromising to equipment maintenance

Cross Functional Team was formed & detailed study was carried out for identification of OFIs

Action Plan Result

Critical path for major time

consuming activities

Four major time consuming activities

identified

Previous overhaul repetitive jobs 2 Repetitive Jobs Identified

Activities which can be eliminated 1 Activity identified for Elimination

Parallel activities 3 Activities identified for Paralleling

New maintenance practices 3 New Maintenance Practices

identified

Other Plant site visits during their

overhauling

Best Practices from other plant

Turbine Cooling Time Reduction-

Major time consuming activity

Reduction by 4.2 Days by On-load &

Off-load cooling methodology- First

time for any Chinese unit

U-1 COH Completed in Record 37 days with

Zero Safety incidence

100% Completion of Planned Activities

Achieved Desired Result

Unit Heat Rate Improvement-47 Kcal/Kwh

APC Improvement – 0.2%

45

Team Member Details:

1. Mr. Mreenal Sharma -Manager - 8390903673 [email protected]

2. Mr. Edwin Williams S -Associate Manager - 8390903673 [email protected]

3. Ms. Pratiksha K Sharma -Manager - 8380098446 [email protected]

Documents

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