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Total Present Operational Capacity : 4559 MW Power evacuation through 4 x 400 kV transmission line
Upcoming Capacity Addition : 1275 MW (Renewables)
2. Energy Consumption Overview – FY 2020-21
Station Gross Heat Rate (kCal/kWh) Station Aux Power Consumption (%)
2380 8.65
2368 8.59
8.50
2350 2346
8.45 8.41
2340 8.40
2329 8.35 8.33
2330
8.30
2320
8.25
2310 8.20
2300 8.15
2018-19 2019-20 2020-21 2018-19 2019-20 2020-21
75
• The major decrement in availability is due to planned • Lower demand from captive consumers as a result of
shutdown of units ( AOH ) prevailing market conditions resulted in lower plant load
factor
4. Information on Competitors & Benchmark
01 03 05
PLANT LOAD FACTOR AUX POWER CONSUMPTION SPECIFIC DM CONSUMPTION
• Increase in PLF by • Installation of VFD in
• Conversion of
augmentation of Primary Air Fans.
HFO to LDO
CPP power. • Installation of ESP smart
controller
• Installation of VFD in
LDO pumps
4. Major Encon Projects Planned for FY 21-22
Annual Annual
Total Annual Investment
Electrical Thermal Payback Status / Timelines
Savings Made
Sr No Title of project Savings Savings
kWh MT Rs million Rs million Months
5 Solarization of Raw Water (Nivali) Pump House 438000 0 3.07 9.10 36 March-22
Investments Savings
FY Number of Proposals
(INR million) (INR million)
Defective APH High pressure Installation of new Installation of HPH-6 after refurbishment of
baskets water jet cleaning basket tube bundle
of basket
5. Energy Saving Projects Implemented for FY 18-19
Annual Thermal Annual Total Annual
Investment
Sr No Title of Project Savings Electrical Savings
(INR million)
(MT of coal) Savings (kWh) (INR million)
5 Reducing PA fan loading by optimizing its header pressure - 4847040 16.29 Nil
2 Replacement of APH baskets for APH-B in Unit-1 1478 1116900 13.51 8.40 7
BEFORE AFTER
4 Elimination of HFO guns by replacement with LDO guns in Unit-1 1831 - 11.90 0.02 0.02
MIV SOV
Parting planes' surface
Damaged area of parting corrected & blue
plane matching done Tapping for LDO Modification
HPH parting plane rectification connection with MIV implemented
5. Energy Saving Projects Implemented for FY 20-21
Motor RPM
120 150
(μm)
Graph-1
• After VFD installation CEP power optimization done from from 932kWh to 90
75 100
1230
636kWh by reducing motor speed. And also CEP discharge pressure 50
1290 1250 1240 1212
reduced from 3.2Mpa to 2.2MPa.(The predicted APC reduction after VFD 1180 0
13:00 13:15 13:30 13:45
installation was 550 KWH). Time
Motor speed(RPM) Motor NDE Vibration (μm)
• At full load (315 MW) below 2.2MPa discharge pressure vibration in motor
Speed Vs Power consumption
NDE bearing observed higher than the alarm value (i.e. 80um). 570
Motor RPM
1260 400
Graph-2
restricted as Motor NDE vibration going higher side as shown in Graph-1. 1240 300
1220 200
• However reduction of power consumption with respect to speed shown in
1200 100
1290 1250 1240 1212
Graph-2. 1180 0
13:00 13:15 13:30 13:45
Time
Speed (RPM) Power consumption (KWH)
6. Innovative Project Implemented
Reduction in power consumption of CEP by reduction in its discharge pressure
PDCA-1
Speed Vs Vibration
1340 100
78
Speed (RPM)
Graph-1
1260 40
Balancing by 1240
weight addition 20
1220 1321 1304 1290 1274 1251 1247
on motor cooling 1200 0
fan
16:00 17:00 18:00 19:00 20:00 21:00
Motor Time
Speed (RPM)
Shim plates provided at discharge
pipe support. Speed Vs Power consumption
1340 610 650
1320 583
564 600
1300 550
Wedges
Power (KWH)
Stiffness Pump 1280 523 518 550
Speed (RPM)
Graph-2
improveme Installed
nt point at 1260 500
Pump Sole at CEP 1240
Plate 450
1220
Base 1321 1304 1290 1274 1251 1247
1200 400
Frame 16:00 17:00 18:00 19:00 20:00 21:00
Time
Stiffness improvement point
at Discharge pipe support Speed (RPM)
6. Innovative Project Implemented
Reduction in power consumption of CEP by reduction in its discharge pressure
PDCA-2 Replicability : Yes
Electrical
Rating Total annual
lights
(Watt) saving (kWh)
(No.)
400 12 21024
170 8 5957 Biodegradable wastes are utilized for producing bio-
Number of electrical gas and being utilized at plant & associate canteen
26981
units saved annually
Bio gas production > 14 m3 / day
Ash generated Tons 425415 378352 264689 Ash handled (Dry method) % 99.8
Ash utilized in fly ash bricks % 13.5 23.29 33.35 100 % Ash utilization by
supplying ash on FOR basis
Ash utilized in RMC % 77 56.7 37.33
8. Environment Management – Ash Utilization
Upcoming Project (November-21) : Bulk Export of Fly Ash
About the Project :
• Fly ash from plant will be stored in a 45000 MT RC silo by means of
pneumatic conveying pipe lines
• The ash stored in the silo shall be pneumatically conveyed to Marine Vessels
and will be exported to various locations in Gulf & European countries
140 4
112 117 pressure air was used along with water by fabricating in house cleaning
120
device.
100
80 1. Automation of make up water to all the tanks in plant viz. service water
tank, CCW make up tank, Potable water tank, etc so as to avoid overflowing of
60
water
40
5 2. Installation of RTD in high pressure steam drain line so as to quickly
20 identify passing of valve & attend the same
0 3. Drain temperature survey & thermography on regular intervals. Ensuring
2018-19 2019-20 2020-21 proper functioning of steam traps
8. Environment Management – Water
Water Contamination Control Check dams to store rain water Sewage Treatment
Qty of water in m3
2490
2500
2441
2450
2400
2350
2018-19 2019-20 2020-21
FY
CW ARV Pit
9. Best Practices in the Plant
Analytics Dash board in Qlick Sense for KPI monitoring
Digitization
Salient Features:
• All the management as well as plant level KPIs are tracked
• The data is SAP linked, hence no manual intervention
Dash board for sales, revenue, contribution
required
• Analytics helps for projections and corrections of KPIs
9. Best Practices in the Plant
Digitization
• Cross functional teams formed at • Energy Management Cell – Core • Identified & trained 27-J2
plant level to work for improvement team along with Support team candidates & 8-J3 candidates to
in performance parameters viz. GHR, formed with objective of work for a cross functional
APC, Coal Loss & UI. improvement projects for energy project involving high end
• Review meetings chaired by HoP & conservation. statistical tools & analysis
HoT • 24 QC teams for continuous • The projects adopts our unique
improvement projects under KAIZEN 4i improvement methodology
(One KAIZEN/month) (Identify, Ideate, Implement,
Institutionalize)
10. Team Work & Employee Involvement
FY 2020-21
Sr. No Description
No. of Duration
Program
participants (Mandays) Variation in quality of coal in different lots of same shipment
1
(marine vessel)
Internal 140 140
Variety of imported coal based on the price & availability as the plant is
External 66 99 2
designed for 100% imported coal
Monthly review is
conducted by 10th of
every month where
• Energy Conservation Week is celebrated
plant performance is
every year in the form of various competitions reviewed under
and activities with involvement of company various areas viz.
employees, associate employees. Safety, Productivity,
• Active participation & involvement of Students Quality, Cost, Morale
from near by schools and employee families & Environ.
at townships
10. Monitoring
Real Time Monitoring System
ABT : To maintain load schedule OSI PI : Real time plant performance monitoring system
De-staging of Boiler Feed Pump for reduction in power consumption Status – Under Implementation
Dipak.patil@jsw.in
9552577031