NINL

POWER PLANT

Cost CONTROL
measures

NINL

POWER PLANT

AREAS IDENTIFED FOR COST CONTROL

Reduction in specific LDO consumption in
Boilers
Reduction in specific heat consumption in Boilers
Scrap despatch
Reduction in Acid/Alkali Consumption
Improvement in output of STG
Retrival of solar oil from GTG effluent
Reduction of LDO consumption of GTG
Mixing of spent solar oil with LDO
2

POWER PLANT

NINL

In Rs Lakhs
Savings w.r.t.
Budget Norms

SN

Heads

Reduction in
specific LDO
1
consumption in
Boilers

Budget
norm

Dept.
Actual Production/Consumption data Expected
Proposal
as per
Actual
Dept
Proposal

Ltr/ T steam
1.16

0.400

Mcal/T Steam

Reduction of
Sp Heat
2
consumption in
boilers

785

765

Steam Generation (tons)

799458

LDO cons. (kl)

57.64

Reduction of Sp Heat
consumption in boilers

0.072

Steam Generation (tons)

BF Gas consumption
(KNm3)
CO Gas consumption
(KNm3)
LDO Cons. (kl)
Total Heat cons. (Mcal)
Specific Heat cons.
(Mcal/ton)

Scrap
Despatch

304

435

145

-113

--

799458
332276
90787
57.64
64010986
0
801

POWER PLANT

NINL

Savings w.r.t.
Budget Norms
SN

Heads

Reduction in
Acid/Alkali
consumption

4a

Reduction in Acid
consumption

4b

Reduction in Alkali
consumption

Improvement in Out
put of STG

Actual
Expecte
Budget
Dept.
Production/Consumption d as per
norm Proposal
data
Dept Actual
Propos
al
kg/t of DM Water

DM water
consumption

237757

Acid consumption 111809

0.485

0.472

Specific acid
consumption

0.470

1.65

Alkali consumption 83191

0.348

0.283

Exit enthalpy of
Steam (Kcal/kg)
625

619

Specific alkali
consumption

0.350

Will be realised after

overhauling of STGs

--

0.08

POWER PLANT

NINL

Savings w.r.t.
Budget Norms
SN

Heads

Retrieval of
spent solar oil
from effluent

Budget
norm

Dept.
Proposal

Actual
Production/Consumption Expected
as per
data
Actual
Dept
Proposal

solar oil recovered

(kl/day)

Solar Oil recovered

(kl)

55.0

0.0

GT Runnung Days

137

LDO cons. (kl)

Solar Oil cons. In

Boilers (kl)

0.6

kl/month
Reduction of
LDO
38
Consumption in
17 KL/Month
KL/Month
GTG

Mixing of Spent
Solar Oil with
LDO

Kl/year
0

140 KL /year

24.7

16.5

266

126

9.9

348

35

104.4

636

456

TOTAL (Rs Lakhs)

POWER PLANT

NINL

STATUS OF COST CONTROL MEASURES & SAVINGS TILL jan2012

(RS LAKHS)

SN

1
2
3
4
5
6

Heads
Reduction in specific LDO
consumption in Boilers
Reduction of Sp Heat consumption in
boilers
Scrap etc. despatch
Reduction in Acid/Alkali
consmuption
Improvement in Out put of STG
Retrieval of spent solar oil from
effluent

Savings w.r.t. Budget

Norms
Expected as
per Dept
Actual
Proposal
303.2

404.9

144.7

-113.1

--

4.0

1.65

0.08

--

--

24.7

6
16.5

POWER PLANT

N I NMISCELLENEOUS
L
COST CONTROL
MESURES

Reduction of Job Contract

Restricted use of Vehicles
Reduction of Telephone expenditure
Judicious use of Impress
expenditure
Indenting only essential spares &
consumables
7

NINL

POWER PLANT

Reward ceremony of SRUJANI of power Plant

was held on 12-12-11

No of suggestions received till date

No of suggestions accepted
No of suggestions rejected
No of suggestions implemented
No of suggestions for cost saving/waste
reduction
No of suggestions for system
improvement
No of suggestions for improvement in
safety
Approximate savings from implemented
suggestions

38
28
10
9
9
15
4
8
250000/
yr

NINL

POWER PLANT
Qc teams and savings

No of Teams working

No of projects completed by SHAKTI QC

10

No of projects completed by BIJLEE QC

06

No of projects completed by KIRAN QC

02

No of projects completed by URJA QC

01

No of projects completed by AKSHYA QC

02

No of projects under progress

Estimated annual Savings of the projects

Completed

Rs 150 lakhs
9

NINL

POWER PLANT
FUTURE COST SAVING PLAN

STGs vacuum improvement

Boiler-3 Air Pre-heater

Replacement
Scrap Disposal ( MS scrap
& Used oil)
Total Savings

15
lakhs/mont
h
10
lakhs/mont
h
10
lakhs/Year
310
lakhs/Year
10

Thank You