18th National Award for Excellence in Energy Management-2017
JSW Energy Limited, Toranagallu
2x130 MW + 2x300 MW
30th Aug-1st Sep, 2017 CII, Hyderabad
1
VIJAYANAGAR PLANT
860 MW
RATNAGIRI PLANT
1200 MW
BARMER PLANT 1080 MW
HYDRO POWER PLANT
1391 MW
JSW ENERGY POWER GENERATION BUSINESS IN INDIA
The existing operational capacity of 4,531 MW with a vision to achieve 10,000 MW by 2020
2
JSW ENERGY VIJAYANAGAR JOURNEY TOWARDS…
EXCELLENCE..
Jindal Tractebel Power Company Ltd. formation
SBU1 U2 & SBU1 U1 - 2x130 MW Power Plant - COD Mar, 1994
Jan & Aug, 2000
April & Sept, 2005
CPP1 - 100 MW & CPP2- 130 MW Power Plant – COD (O&M Services)
May, 2006
Incorporation of JSW Energy (Vijayanagar) Ltd. as a subsidiary
SBU2 U1 & SBU2 U2 - 2x300 MW Power Plant - COD
July & Sept, 2009
CPP3 & CPP4 – 2X300 MW - COD ( O&M Services)
Mar, 2011 & 2012
3
July, 2017
400 kV Ballari Pooling Station
JSW ENERGY, VIJAYANAGAR PROCESS
BUSINESS UNIT CAPACITY, (MW) FUEL MAKE
SBU-I 2 X 130 MW IMPORTED COAL + WASTE GAS BHEL
SBU-II 2 X 300 MW IMPORTED COAL SEC,CHINA 4
AWARDS & ACCOLADES
5
6
Silver Award by The Royal Society for the Prevention of Accidents - 2016.
AWARDS & ACCOLADES
CSR Impact Award - 2016
Best Livelihoods Initiative for Watershed Programs
CBIP Award - 2016
Best Performing Utility in Thermal Power Sector
CII Award - 2015
Excellence in Energy Management
IPPAI Power Award - 2016
Installation of Spacer Coupling at ID Fans Innovation
Shrishti Good Green Governance Award - 2016
8
AWARDS & ACCOLADES
Golden Peacock Award - 2016
Environment Management Award
8
CII-ITC Sustainability Award - 2015
Corporate Excellence
AWARDS & ACCOLADES
The Five Leaves Award - 2015
Centre for Science & Environment Green Rating
Project Rated 2nd Best in Environment Performance
ENERGY CONSERVATION PROJECTS
9
ENERGY CONSERVATION FOR LAST THREE YEARS
Year of Implementation
No. of Encon
Annual Electrical Savings achieved
Annual thermal savings
Total Annual Savings
Invest. Made Payback
months Million Units
Rs Million
Tons of Fuel
Rs Million
Rs Million
Rs Million
2016-2017 8 4.5 13.4 - - 13.4 23 Within 2 year
2015-2016 12 4.4 14.0 5950 41.0 56.0 48 Within year
2014-2015 4 5.6 28.1 2238 15.2 43.3 18 Within year
Total 24 14.5 55.5 8188 56.2 112.7 89 Within year
10
POWER SAVING WITHOUT INVESTMENT
Energy Saving Projects Saving
Instrument air compressor Power consumption by changing load set point
100 Kwh
BFP recirculation valve passing arrested by servicing 219 Kwh
Reduction in fly ash unburnt by improving mill
performance & tuning combustion at SBU2 Units 7116 T/year
Ash Water pump stoppage by changing source of water
supply to Cooling pond pump which is common for all
units
10000 Units / Year
S No Description Saving (KWH) /
Unit
1 Second BFP Stopping 3130
2 Second CWP Stopping 1434
3 PA Header Pressure Optimization 206
4 Seal Air Fan IGV Throttling 10
5 Ash Conveying Optimization 35
6 6.6KV Bus Voltage Optimization
POWER SAVING WITHOUT INVESTMENT
During Part Load Operation (300 MW Unit)
ENERGY SAVING PROJECTS IMPLEMENTED
Energy Saving Projects Savings Investment
Payback Months Million
(Rs.) Million
(Rs.)
Installation of variable frequency drives (VFD) & Spacer Coupling between Motor & Fan eliminating Voith coupling in SBU-1, Unit-1ID fan motors (2 nos.)
2.9 2.3 10
Installation of Spacer Coupling between Motor & Fan eliminating Voith coupling in SBU-2, Unit-2 of ID fan motors (2 nos.)
2.8 2.3 10
Installation of Energy efficient fan blades in CT fans of SBU2 300 MW Unit.
3.6 3.0 10
Installation of variable frequency drives (VFD) in SBU-1, Unit-1 PA fan motors (2 nos.)
2.8 9.3 40
13
ENERGY SAVING PROJECTS IMPLEMENTED
Energy Saving Projects
Savings Investment Payback Months Million
(Rs.) Million
(Rs.)
SBU-2 Unit-1 (300MW) Capital overhaul of Turbine 29.4 8.7 4
Installation of Energy efficient fan blades in CT fans of SBU-1 (2X130 MW)
0.3 3.2 114
Installation of Spacer Coupling between Motor & Fan eliminating Voith coupling in SBU-2, Unit-1 of ID fan motors (2 nos.)
6.3 4.1 8
Installation of Variable Frequency drive ( VFD) in SBU-2, Unit-2 ID fan motors (2 nos).
9.4 19.3 25
14
ENERGY SAVING PROJECTS IMPLEMENTED
Energy Saving Projects
Savings Investment Payback
Million (Rs.)
Million (Rs.)
Months
Installation of Variable frequency drives (VFD) in SBU-2, Unit-1 ID fan motors (2 nos.)
27.8 12.0 5
Installation of Variable frequency drives (VFD) in SBU-2, Unit-2 CEP
14.1 4.0 3
Installation of Energy efficient fan blades in 2 nos. of CT fans in SBU-2 & 2 nos. of CT Fans in SBU-I
0.9 1.1 18
Installation of a bypass chute to transfer coal from conveyor CJ 9C1 to 10C1 eliminating operation of Coal conveyor CJ 9RC1
0.5 0.7 17
15
PROJECTS
16
PROJECT -1- REPLACEMENT OF HYDRAULIC COUPLING WITH SPACER COUPLING
Induced draft fans (ID Fan) in the plant are carrying out a function of discharging flue gases
to atmosphere by consuming power 1430 kWh ( Rated-2240 Kwh)at full load.
The motor runs at 745 RPM whereas fan spins at around 550 RPM at full load through
hydraulic coupling operating the scoop in the range of about 55%.
REPLACEMENT OF HYDRAULIC COUPLING WITH SPACER COUPLING
18
After installation/commissioning of VFD the process forced to maintain scoop around 63% with motor speed limited to 620 RPM ( saving of 200 Kwh/fan).
The limitation of scoop to maintain the speed is basically to ensure proper lubrication to all the bearings of hydraulic coupling which has limited saving potential.
Fixed & slip losses of Hydraulic coupling
REPLACEMENT OF HYDRAULIC COUPLING WITH SPACER COUPLING
19
To overcome the scoop limitation and losses in the hydraulic coupling and utilize the advantage of VFD, opted for replacement of ID Fan hydraulic coupling with spacer coupling.
REPLACEMENT OF HYDRAULIC COUPLING WITH SPACER COUPLING
20
Site conditions & risk analysis done
Detailed sizing calculation has been done for
spacer coupling
Calculation of Saving
The energy savings achieved at full load operation is as follows:
ID fan energy saving - 200 kWhr (for two fan )
Total - 200 KWhr
Monitory benefits and payback period were calculated and are as follows:
Investment made for replacing the hydraulic coupling with spacer coupling Rs 23 Lacs
Net monetary savings - (per annum / unit of 300MW)
(Considering Rs 3.0 / Kwh)
Recurring YOY savings - Rs. 27.8 Lacs
Payback period - 10 months.
Eliminating hydraulic coupling and related maintenance expenses.
Heat load on Auxiliary cooling water has also reduced
Implemented in one of 130 MW unit & observed resonance while rising speed. Same
is successfully solved by incorporating design changes in coordination with OEM.
REPLACEMENT OF HYDRAULIC COUPLING WITH SPACER COUPLING
REPLACEMENT OF HYDRAULIC COUPLING WITH SPACER COUPLING
S.NO Unit Implemented Project Savings
1 SBU-1 Unit-1
Installation of Spacer Coupling in ID fan 150 Kwh
2 SBU2 Unit-1
Installation of Spacer Coupling in ID fan 200 Kwh
3 SBU-2 Unit-2
Installation of Spacer Coupling in ID fan 200 Kwh
Total 550 Kwh
S.NO Unit Implemented Project Savings
1 SBU-1 Unit-2
Installation of VFD & Spacer Coupling in ID fan
150 Kwh
Implemented Projects
Proposed future projects
PROJECT -2- ENERGY EFFICIENT BLADES FOR COOLING TOWER FANS
REPLACEMENT OF CT FAN’S BLADE WITH OF ENERGY EFFICIENT FAN BLADES
Induced-draft cooling towers are used to remove the heat absorbed in the circulating cooling water systems. Induced-draft cooling towers will have 10 & 12 fans per each unit of 130 MW & 300 MW respectively to drive atmospheric air through CT fills there by cooling incoming hot water from condenser. Design power consumption of each fan for 300 MW unit with FRP Blades is 75 Kw Actual Consumption of each fan for with FRP Blades is 69 Kw
REPLACEMENT OF CT FAN’S BLADE WITH OF ENERGY EFFICIENT FAN BLADES
It is proposed to change existing FRP blades with hallow FRP Blades of aerodynamic design. In One unit , Blades are replaced with hallow FRP Blades on trail basis. Air flow being main parameter for cooling tower fan , air velocities are measured in both the transverse & air flow was estimated. It is observed that a saving of 29 Kwh / fan with out impacting air flow. Based on results , Power saving observed per fan 29 Kwh & same replicated in remaining fans.
S.NO Unit Implemented Project Savings
1 SBU-2 Unit-1 Installation of Energy Efficient Blades in CT fans
290 Kwh
2 SBU-1 Unit-1 &2 Installation of Energy Efficient Blades in CT fans
70 Kwh
REPLACEMENT OF CT FAN’S BLADE WITH OF ENERGY EFFICIENT FAN BLADES
Implemented Projects
S.NO Unit Implemented Project Savings
1 SBU-2 Unit-2 Installation of Energy Efficient Blades in CT fans
290 Kwh
Proposed Future Projects
SPECIFIC ENERGY CONSUMPTION
PLANT PERFORMANCE HIGHLIGHTS
JSWEL, Vijayanagar conquest National Awards for Meritorious Performance since 2006-07
Continual improvement in Auxiliary Power Consumption on Y-O-Y basis. APC for FY17 is 7.83 %.
Continual improvement on sustenance & improvement in Station Heat Rate.
28
PLANT SEC – 860 MW(2X130 + 2X300)
29
Sustained APC even at Lower
PLF
SPECIFIC ENERGY CONSUMPTION
30
SPECIFIC ENERGY CONSUMPTION
Under PAT Cycle-I, Specific Energy consumption for SBU-1 & SBU-2 are detailed as below.
Unit Notified SEC
Target Achieved SEC
No. of Escerts issued
Kcal/Kwh Kcal/Kwh No. SBU-1 2503 2422.74 16710 SBU-2 2420 2416.53 730
Total 17440
COMPARISION WITH OUR PEERS
FINANCIAL YEAR 2016 - 2017
PARAMETERS JSWEL (SBU-I)
2 X 130 MW JSWEL (SBU-II)
2 X 300 MW Adani, Mundra
(330MW)
Heat Rate 2293 2318 2289
APC (%) 7.23 8.21 8.59
PLF (%) 75.3 51.38 73.36
32
ROAD MAP TO ACHIEVE BENCH MARK
Fuel Strategy with Optimal Coal Blend with respect to international Coal Price Movement & Forex Variations.
Firing of Domestic Coal to be competitive in Market
Sustaining the plant performance and producing substantial environmental benefits by utilising waste gas from steel plant.
Exploring the usage of waste gas firing or other methods during start up to reduce Sp. Oil consumption.
Effective utilisation of resources cross functional knowledge sharing at flexible operating loads.
Business Planning with life cycle management approach
Learning & Development initiatives for Skill up-gradation & Capacity Development.
33
30%
31%
32%
33%
34%
35%
36%
37%
38%
39%
INDIA AUSTRALIA CHINA US JSWEL,TORANAGALLU
32.8% 33.3%
35.7% 35.8%
38.0%
ENERGY EFFICIENCY %
COMPARISON WITH GLOBAL NORMS
Source:Heat On Power ,GRP Rating,Centre for science and Environment-Feb 2015 34
35
GHG INVENTORISATION
36
Operational Measures
• Low Specific Water consumption (2.0 cum/ Mwh) , below the CEA guidelines .
• Use of imported low Ash, low Sulphur coal.
• Use of steel plant waste gas.
• 100 % Fly ash utilization.
Environment Management Initiatives
• Reed bed based STP over conventional or domestic effluent treatment and use for plantation
• RO based effluent recycling plant to re-use and balance effluent for ore beneficiation unit at steel plant.
• Rain water harvesting for water utilization
• Closed Coal Conveying System to mitigate fugitive emission.
• Use of low NOx burners to minimize formation of NOx
• Electro chlorination system for SBU-II and SBU-I
ENVIRONMENT & CARBON EMISSION REDUCTION PROJECTS
CARBON EMISSION REDUCTION
With a mission to reduce GHG emissions from 0.9 kg/kwh to minimum levels, waste gas firing system project is executed in 2X130MW since from inception. With this we have reduced CO2 emissions in SBU-1 well below the stipulated norms from year on year basis.
37
Greening Efforts:
Green cover of about 62 acre outside the plant premises Total tree planted - 23,000 Nos. in plant area
and 1 Lac trees outside the plant area till date
Survival Rate of plants are 91%
Extensive Plantation undertaken at
Township
Ash Pond area
Near by hills
Labor colony
Plantation at Hill Area
Plantation at Labor colony 38
ENVIRONMENT
EMPLOYEE INVOLVEMENT
39
• Energy Conservation Week celebrated in the month
of December 2016. Awareness created among
Employee & family by organizing competitions &
rewarding the best.
• E-portal developed for capturing Employee
suggestions.
EMPLOYEE INVOLVEMENT
• To capture innovative ideas, a portal is developed
under Digitization initiative which will enable each
employee to put forth their innovative ideas.
• Integrated DCS with intranet through OSI PI tool &
EMS to monitor Auxiliary power consumption,
plant critical parameters & deviations
EMPLOYEE INVOLVEMENT
ENERGY MANAGEMENT SYSTEM AT JSW,VIJAYANAGAR
Certified for ISO 9001,14001, OSHAS 18001 and ISO 50001:2011
Energy policy established
Structured Energy Management Cell
Identify, Evaluate and Analyze Energy use & Consumption ( Coal, Oil, electricity ,
Water)
Periodic Energy Audit as per CEA Guidelines
Daily energy deviation reporting
Total 25 Energy auditors
E LAN (EMS) System for Energy Consumption Monitoring.
42
Sl No Monitoring and Review Chaired by Participants Frequency Benefits
1
Daily Monitoring of Generation( Aux consumption, parameters deviation ,sp oil consumption, make up water cons etc),Environment, safety
Head of Plant Section In
charges,SCE and HOD's
Daily
Solutions for deviation in Heat rate ,APC, Sp oil Cons, make up water cons etc, Solutions for Environment and safety issues.
2 MOPR (Monthly operation performance review)
Head of Plant Section In
charges,SCE and HOD's
Monthly
Monthly Performance review includes plant performance, Efficiency Gap analysis and Correction. Inventory and consumption pattern.
3 Performance Optimization Group (POG)
Head of Plant POG (cross functional
team), HOD,s Monthly
Water conservation, Heat rate reduction, APC reduction, condenser vacuum improvement, Combustion optimization.
4 Internal Audit of IMS ISO 9001,14001 and ISO 50001:2011
MR,Trained Internal
Auditors,HOD
Auditors and Auditees,HOD’
s Half yearly
Monitoring Documentation ,SOP and Management programmes of plant improvements.
ENERGY REPORTING & MONITORING
43
ENERGY MONITORING
Time Synchronization of all the meter and Server through EMS software.
Available plant network is being utilized for the metering system.
Meters data is collected in redundant servers for computing & calculation.
Infinite Web clients developed for viewing & analyzing of data.
Automatic report generation with emailing facility is developed to eliminate
manual intervention
Monitoring real time parameters individual equipment wise
Trending & customizable dashboards are additional advantage.
EMS - UNIQUE FEATURES
45
EMS DASH BOARDS
46
47
Installation of VFD & Spacer coupling
SBU2 U1 & U2 Installation and commissioning Mill reject pneumatic conveying system SBU1 Boiler - Replacement of Existing IFM Igniter system with High Energy Arc ignitor (HEA)
Energy Management System installation for better monitoring and tracking of energy consumption
APH - Installation of additional baskets to yield reduction of 2°C in the temperature of exit flue gas
S . No Unit En Con Power Saving
1 SBU1 Unit1, ID Fan VFD & Spacer Coupling 150 Kwh
2 SBU1 Unit-1 PA fan VFD 146 Kwh
3 SBU2 Unit-1 ID fan VFD & Spacer Coupling 600 Kwh
4 SBU2 Unit2 ID Fan VFD & Spacer Coupling 600 Kwh
REPLICATION OF BEST PRACTICES & TECHNOLOGY ABSORPTION
SBU1 Unit1 DCS Renovation & Modernization from old Bailey System to ABB
ESP Spike Electrodes replaced with spiral Electrodes
N2 Blanketing of EH oil system
ABT system up gradation for better monitoring & tracking of DSM
REPLICATION OF BEST PRACTICES & TECHNOLOGY ABSORPTION
49
Indigenization of Mill Gear box spares for reducing the maintenance cost Up gradation of 130 MW & 300 MW AVR with ABB Make Unitrol
Up gradation of SBU1 GRPs with numerical relays DCS panel 24 VDC field power supply wiring redundancy scheme for more reliability
Installation of LHSC Cables for Fire monitoring at BCN 2A/2B/3A/3B conveyors
SBU1 U2 Up gradation of Electro Hydraulic Turbine Control System (EHTC) Implementation of SPS scheme on 220kv lines for protecting & isolating the complex
during sustained/ uncleared faults
REPLICATION OF BEST PRACTICES & TECHNOLOGY ABSORPTION
Thank You
“Excellence is a journey not a destination” R.Peddanna
Kumar Ivaturi 50