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Presentation For 14 th CII National Award For “EXCELLENCE IN ENERGY MANAGEMENT” 19-20 Aug 2013,
Presentation For 14 th CII National Award For
“EXCELLENCE IN ENERGY MANAGEMENT”
19-20 Aug 2013, Hyderabad
M K SINGH
A A PRASAD
M S KARTHIK
Introduction BHILAI • A JV of two Maharatnas, NTPC and SAIL, established in March,2001. •

Introduction

BHILAI

• A JV of two Maharatnas, NTPC and SAIL, established in March,2001.

• Company Turnover (2012-13 ) : 1866.8 Cr.

• Total Number of Employees : 817 (as on 30.06.2013).

BHILAI PP-3

2*250MW

500

MW

SAIL &

 

DD/DNH/CSEB

BHILAI PP-II

30*2+14

74 MW

SAIL Captive

ROURKELA

2*60MW

120

MW

SAIL Captive

DURGAPUR

2*60 MW

120

MW

SAIL Captive

NSPCL

814 MW

(500MW captive rest to Grid)

MW 120 MW SAIL Captive NSPCL 814 MW (500MW captive rest to Grid) NTPC-SAIL Power Company

NTPC-SAIL Power Company (Pvt.) Ltd

Our Core Values… BHILAI Sincerity & service orientation People Teamwork CORE VALUES Integrity &
Our Core Values…
BHILAI
Sincerity &
service
orientation
People
Teamwork
CORE
VALUES
Integrity &
Honesty
Innovation
Respect

Vision : To be an Efficient Power producer delivering consistent value to stakeholders

Mission : To be recognized as a reliable power producer in the country.

stakeholders Mission : To be recognized as a reliable power producer in the country. NTPC-SAIL Power

NTPC-SAIL Power Company (Pvt.) Ltd

POWER GENERATION PROCESS

POWER GENERATION PROCESS

PERFORMANCE HighlightsBHILAI • Unit-1 date of Commercial Operation : 22/04/2009 • Unit-2 date of Commercial Operation

BHILAI

Unit-1 date of Commercial Operation : 22/04/2009

Unit-2 date of Commercial Operation : 21/10/2009

6 th rank on All India basis for PLF in 2012-13.

11 stst rankrank on All India basis for PLF 103.5 % in Oct’10

11 stst rankrank on All India basis for PLF 105.07 % in Dec’11.

1st1st rankrank on all India basis for best PLF (103.558%) in June’12 and 1st Quarterly (Apr-June’12) PLF of 101.67%

NTPC-SAIL Power Company (Pvt.) Ltd1st rank rank on all India basis for best PLF (103.558%) in June’12 and 1st Quarterly

Innovation……Culture of NSPCL BHILAI Reduce APC Control Parameters Affecting Heat Rate SEC ENCON NTPC-SAIL Power

Innovation……Culture of NSPCL

BHILAI

Reduce APC

Control Parameters Affecting Heat Rate

SEC
SEC

ENCON

NTPC-SAIL Power Company (Pvt.) LtdInnovation……Culture of NSPCL BHILAI Reduce APC Control Parameters Affecting Heat Rate SEC ENCON

Key Initiatives to Reduce APC B H I L A I Modification Done Investment (

Key Initiatives to Reduce APC

BHILAI

Modification Done

Investment ( in Lacs )

Savings In APC ( Mu)

(2010-11)

Interconnection has been provided between both ESP fluidizing blowers, after which only one Blower is kept in service.

No

0.355

Arresting of Air Ingress in Flue gas duct and APH

12.0

0.769

Condenser Tube cleaning using acid as tubes were very dirty (Poor water quality during initial times)

15.0

11.0

NTPC-SAIL Power Company (Pvt.) LtdCondenser Tube cleaning using acid as tubes were very dirty (Poor water quality during initial times)

BHILAI Modification Done Investment ( in Rs ) Savings In APC (Mu) (2011-12) One of

BHILAI

Modification Done

Investment ( in Rs )

Savings In APC (Mu)

(2011-12)

One of the IAC has been stopped and kept as standby for which a logic is provided for auto start.

NO

2.102

PAC-1 IAC-1 IAC-2 PAC-2
PAC-1
IAC-1
IAC-2
PAC-2

NTPC-SAIL Power Company (Pvt.) Ltdbeen stopped and kept as standby for which a logic is provided for auto start. NO

BHILAI   Modification Done Investment ( in Rs ) Savings In APC ( Mus )

BHILAI

 

Modification Done

Investment ( in Rs )

Savings In APC ( Mus )

(2011-12)

Interconnection of Ash Handling Compressed air system with that of Main plant Compressed air system, thereby stopping compressors of AHS.

NIL

1.33

Interconnection of Mill Reject conveying air system with Main Plant Service air system thereby stopping Mill Reject conveying Compressors.

NIL

0.164

Reduction of Auto Cut-of and Re-Start pressure of IAC from 7.4/6.8 to 6.4/5.8 Ksc (Reduction by 1 Ksc)

NIL

0.24

NTPC-SAIL Power Company (Pvt.) LtdReduction of Auto Cut-of and Re-Start pressure of IAC from 7.4/6.8 to 6.4/5.8 Ksc (Reduction by

BHILAI Modification Done (2012-13) Tap off has been provided from recovery & effluent discharge header

BHILAI

Modification Done

(2012-13)

Tap off has been provided from recovery & effluent discharge header into mixing chamber directly. Hence, running of waste water holding pump has been stopped.

Investment ( in Rs )

Investment ( in Rs )

NO

Savings In SEC ( Mu)

Savings In SEC ( Mu)

1.17

NTPC-SAIL Power Company (Pvt.) Ltdrunning of waste water holding pump has been stopped. Investment ( in Rs ) NO Savings

BHILAI Modification Done (2012-13) Jockey pump taken in service with provision of pneumatic re-circulation valve.

BHILAI

Modification Done

(2012-13)

Jockey pump taken in service with provision of pneumatic re-circulation valve. System is running in auto with jockey pump in service. Frequent start / stop of jockey pump / compressor / hydrant pump avoided

Investment ( in Rs )

Investment ( in Rs )

NO

Savings In APC ( Mu )

Savings In APC ( Mu )

0.67

Total APC Savings ( in Mu)

17.8

Equivalent Savings in SEC (Kcal/Kwhr)

4.223

NTPC-SAIL Power Company (Pvt.) LtdSavings In APC ( Mu ) 0.67 Total APC Savings ( in Mu) 17.8 Equivalent Savings

Efforts To Control Heat Rate BHILAI • Daily monitoring of Condenser performance and Unit heat

Efforts To Control Heat Rate

BHILAI

Daily monitoring of Condenser performance and Unit heat rate deviation

(24hr avg data).

Timely inspection of Aux. Air Dampers (in every shift) for their

mismatch to have better combustion.

PA flow through mills are maintained as per coal feeding to avoid

secondary combustion, which increases dry flue gas losses.

Operational parameters being maintained near to rated value.

A separate mimic diagram displaying instantaneous Heat Rate Deviation

and helps in keeping vigil on Heat rate deviation due to operating

parameter.

NTPC-SAIL Power Company (Pvt.) Ltddisplaying instantaneous Heat Rate Deviation and helps in keeping vigil on Heat rate deviation due to

BHILAI
BHILAI
ENCON…….A Continuous Process BHILAI Year Of ENCON Annual Thermal Savings Tons of Fuel. Total Savings

ENCON…….A Continuous Process

BHILAI

Year Of

ENCON

Annual Thermal Savings Tons of Fuel.

Total Savings

Implementation

Projects

In SEC

Implemented

(Kcal/Kwhr)

2010-11

Attending APH and Flue Gas Duct air ingress

496

0.4188

 

Condenser

Tube

9900

8.3612

Cleaning

Sub Total

 

10396

8.78

Condenser Tube 9900 8.3612 Cleaning Sub Total   10396 8.78 NTPC-SAIL Power Company (Pvt.) Ltd

NTPC-SAIL Power Company (Pvt.) Ltd

BHILAI Year Of ENCON Annual Electrical Savings Units Total Savings Implementation Projects In SEC

BHILAI

Year Of

ENCON

Annual Electrical Savings Units

Total Savings

Implementation

Projects

In SEC

Implemented

(Kcal/Kwhr)

2011-12

Attending APH and Flue Gas Duct air ingress

0.88

0.599

 

Reduction of IAC & PAC air Pressure

0.235

0.161

Sub Total

 

1.115

0.76

NTPC-SAIL Power Company (Pvt.) Ltd0.88 0.599   Reduction of IAC & PAC air Pressure 0.235 0.161 Sub Total   1.115

BHILAI   Year Of ENCON Annual Thermal Savings Tons of Fuel Total Savings Implementation Projects

BHILAI

 

Year Of

ENCON

Annual Thermal Savings Tons of Fuel

Total Savings

Implementation

Projects

In SEC

Implemented

(Kcal/Kwhr)

 

2012-13

Attending APH and Flue Gas Duct air ingress

4000

3.402

 

Insulation

1220

1.038

Survey

 

Condenser

9750

4.44

Tube Cleaning

 

Sub Total

 

14970

8.88

NTPC-SAIL Power Company (Pvt.) Ltd1.038 Survey   Condenser 9750 4.44 Tube Cleaning   Sub Total   14970 8.88

Future ENCON Projects… Impact On CER BHILAI Year Project Investment Savings In Savings of (in
Future ENCON
Projects…
Impact
On CER
BHILAI
Year
Project
Investment
Savings In
Savings of
(in Lacs)
SEC
CO2(tons)
Installing
VFD
in
Condensate
Extraction
230
1.0
2815
Pumps.
2013-14
Avoiding continuous running
of Condensate Make up
Pump
0.25
0.246
410
Providing Orifices in selected
Equipment in cooling water
lines to reduce DM water
flow, thereby reducing
loading of DMCW pump.
0.23
0.141
237
NTPC-SAIL Power Company (Pvt.) Ltd
BHILAI
Year
Project
Investment
Savings
Savings of
(in Lacs)
In SEC
CO2(tons)
2013-14
Replacement of normal
Tube light and Halogen
lamps with LED lamps in
selected areas.
7.5
2.1
6000
Auxiliary power
5.0
NIL
consumption Audit
Replacing
Hydraulic
Scoop
of
ID
fan
with
6250
0.837
2725
VFD.
2014-15
5MW Solar Power Plant
at Daman Diu has been
planned.
(as per CERC
rate)
34065
NTPC-SAIL Power Company (Pvt.) Ltd
BHILAI Year Project Investment Savings In Savings of (in Lacs) SEC CO2(tons)   Addition of

BHILAI

Year

Project

Investment

Savings In

Savings of

(in Lacs)

SEC

CO2(tons)

 

Addition of one layer

of

     

baskets in APH for more heat recovery

7.5lakhs

2.1

6000

2014-15

Helium leak detection test.

     

Optimization of PA fan operation by Installing VFD in PA Fan

     

Attending air ingress in APH and Flue gas duct

     

NTPC-SAIL Power Company (Pvt.) LtdInstalling VFD in PA Fan       Attending air ingress in APH and Flue gas

Performance Highlights B H I L A I Parameter 2010-11 2011-12 2012-13 All India Rank

Performance Highlights

BHILAI

Parameter

2010-11

2011-12

2012-13

All India Rank

16

12

6

Generation (MU)

4019.7

3978

4029.76

PAF %

92.72

92.95*

98.88

PLF %

91.73

90.57 *

92

APC %

8.55

8.456

8.643**

* Lower PAF/PLF in 2011-12 was due to coal shortage

** Backing down of Generation led to Higher APC and SEC.

NTPC-SAIL Power Company (Pvt.) Ltd8.643** * Lower PAF/PLF in 2011-12 was due to coal shortage ** Backing down of Generation

BHILAI NTPC-SAIL Power Company (Pvt.) Ltd Our Target……Benchmark SEC BHILAI Design Station Net Heat Rate
BHILAI
NTPC-SAIL Power Company (Pvt.) Ltd
Our Target……Benchmark SEC
BHILAI
Design Station Net Heat Rate – 2457 Kcal/Kwh
NTPC-SAIL Power Company (Pvt.) Ltd
Implementation Methodology B H I L A I STATION LEVEL NTPC-SAIL Power Company (Pvt.) Ltd

Implementation Methodology

BHILAI

STATION LEVEL

Implementation Methodology B H I L A I STATION LEVEL NTPC-SAIL Power Company (Pvt.) Ltd

NTPC-SAIL Power Company (Pvt.) LtdImplementation Methodology B H I L A I STATION LEVEL

Employee Involvement Activities BHILAI • Quality Circle • Professional Circles • Suggestion Schemes •

Employee Involvement Activities

BHILAI

Quality Circle

Professional Circles

Suggestion Schemes

Participation in Energy Conservation Campaigns

Cost Control Campaigns

Water Saving Campaigns.

NTPC-SAIL Power Company (Pvt.) LtdSchemes • Participation in Energy Conservation Campaigns • Cost Control Campaigns • Water Saving Campaigns.

Monitoring……Key to Energy Management BHILAI • Checklist to compare trends of critical parameters. • Timely

Monitoring……Key to Energy Management

BHILAI

Checklist to compare trends of critical parameters.

Timely Energy audit of Equipment to access their performance.

Weekly Review by Senior Management

Real time measurement of Heat Rate Deviation

Preventive Maintenance of Machines to avoid energy loss due to sudden Outage of Machines.

Maintenance of Machines to avoid energy loss due to sudden Outage of Machines. NTPC-SAIL Power Company

NTPC-SAIL Power Company (Pvt.) Ltd

Maintenance of Machines to avoid energy loss due to sudden Outage of Machines. NTPC-SAIL Power Company
Waste Utilization & Environmental Projects • Utilization of Ash BHILAI Fin. Year Ash Gen. (MT)

Waste Utilization & Environmental Projects

Utilization of Ash

BHILAI

Fin. Year

Ash Gen. (MT) (Approx.)

Total

Fly Ash

Total Utilizn

Utilization

Utilizn %

%

 

(MT) (Apprx.)

09-10

598593

28132

4.70

3.76

10-11

950307

229638

24.16

19.33

11-12

1144528

325209

35.52

28.41

12-13

994534

697635

88

70.15

13-14

229144

179,434

97.88

78.31

NTPC-SAIL Power Company (Pvt.) Ltd325209 35.52 28.41 12-13 994534 697635 88 70.15 13-14 229144 179,434 97.88 78.31

BHILAI • Zero Effluent Discharge- ETP and STP has been installed in the plant to

BHILAI

Zero Effluent Discharge- ETP and STP has been installed in the plant to have zero discharge. The water is recycled for use in Ash water system.

120 KLD- STP has been installed in township to avoid ground water contamination & to reduce water consumption by using treated water for gardening purpose.

Rain water harvesting system- 06 nos rain water harvesting pits constructed across township for recharging ground water at a depth of -15m.

Tree Plantation -Total sapling plantation till 2012-13 is 2.20 Lakhs.

NTPC-SAIL Power Company (Pvt.) Ltdrecharging ground water at a depth of -15m. • Tree Plantation -Total sapling plantation till 2012-13

Awards & Accolades BHILAI • NSPCL received 10 t h Best Employer award, and “Best

Awards & Accolades

BHILAI

NSPCL received 10 th Best Employer award, and “Best HR Strategy in Line with Business” from World HRD congress-2013

Great Place to Work-2012 (Top 20 companies in India) and 3 rd in Manufacturing sector.

Edward D Buno HR Innovative practices Award-2012

CEO of NSPCL was conferred with “Exemplary Leader Award” .

NTPC-SAIL Power Company (Pvt.) Ltd• Edward D Buno HR Innovative practices Award-2012 • CEO of NSPCL was conferred with “Exemplary

BHILAI NTPC-SAIL Power Company (Pvt.) Ltd

BHILAI

BHILAI NTPC-SAIL Power Company (Pvt.) Ltd

NTPC-SAIL Power Company (Pvt.) LtdBHILAI