CII Excellence in Energy Management 2015

A RP-Sanjiv Goenka Group Company in the business of

Generation & Distribution of electricity since 1897
118 year old fully integrated power utility
Subsidiaries in Retail & Real estate
567 sq. km distribution license area
2.9 million consumer base
3 Thermal Power Plants - 1,125 MW capacity
20,400 circuit Km T&D network
40 MW AFBC plant at Asansol (West Bengal)
9 MW Solar power project in Gujarat
50 MW Wind Power Plant in Rajasthan & Gujarat

Coal

Boiler
Turbine & Generator

Steam

(through wagons)

Air
Switchyard
(from atmosphere)

Water

Consumers

(from River Hoogli)

Sl. Projects
No

Investment
(Rs in Lacs)

Benefit

Payback
(months)

519

9 MW-Hr per
day per unit

36

Installation of VFD in Primary Air Fans

of Unit-1 & 2

Modification of BFP Hydraulic

coupling in Unit-1 & 2

170

CEP stage blinding in Unit-1 & 2

14

Reduction of Differential Pressure

across Feed Control Station of Unit- 3

Nil

17 MW-Hr
per day per
unit
3 MW-Hr per
day per unit
6 MW-Hr per
day

7
3

NA

Sl.
No

Projects

Investment
(Rs in Lacs)

Benefit

Payback
(months)

Installation of LT VFDs ( 8 nos)

30

2 MW-Hr per
day

18

Restricted use of Service Air

Compressors

Nil

1 MW-Hr per
day

NA

7
150
Installation of PADO in Unit-1 & 2

Online
immediate
correction of
SHR
deviation

BBGS Specific Energy Consumption Trend- Last Three Years

88.37 % PLF

91.16 % PLF

89.08 % PLF

Benchmarking Figures and Where We Stand Now

Sl.
No.

Plant

Capacity

PLF %
(last 3 Years Avg)

SEC %
(last 3 Years
Avg)

Reliance, Dahanu
2 X 250 MW
(without Cooling Tower)

95.04

7.65
(without FGD)

CESC, Budge Budge

(with Cooling Tower)

3 X 250 MW

89.54

8.28

JPL, Raigarh
(with Cooling Tower)

4 X 250 MW

92.51

8.31

Road map to achieve benchmark/global best

v Engaging consultant of international repute
v Partnering with Foreign institutions
v Formation of a separate cell named Centre of Excellence
v Formation of a centralized Online Performance Optimization
Centre
v Installation of Performance Optimization software (PADO)
v Identification & replacement of inefficient and obsolete
equipments with efficient ones

Project-1 : Speed optimization of Unit-1 & 2 BFP Hydraulic Couplings

Unit-1 & 2 Boiler Feed Pump Specification

q2 X 100 % per unit
qSingle stage Booster pump, make Weir (UK)
qThree stage Pressure stage pump, make Weir (UK)
qMotor rating 8800 KW, make Peebles Electric Ltd (UK)
qGeared variable speed Turbo-coupling for Pressure stage pump, make
Voith (Germany)

Schematic of Boiler Feed Pump

Project-1 : Speed optimization of Unit-1 & 2 BFP Hydraulic Couplings- Contd.

Modification of Hydraulic Coupling
Before Modification
Design
Operating
(47.5 Hz)
(50 Hz)
Input Motor 1406 RPM
1470 RPM
Speed
Max Output 5730 RPM
5150 RPM
Pump Speed
Gear Ratio
143/34
Total Loss in
1148 KW
Coupling

After Modification
Design
Operating
(50 Hz)
(50 Hz)
1470 RPM
1470 RPM
5350 RPM
113/30

5150 RPM
430 KW

Project-1 : Speed optimization of Unit-1 & 2 BFP Hydraulic Couplings- Contd.

Savings
oApprox 17 MW-Hr per day per unit in full load condition with a payback of 7
months
oReduction of Hydraulic oil temperature by 30C which in turn reduced the
cooling water demand for the pump

Project-2 : Installation of VFD in Primary Air Fans of Unit-2

v
v
v
v
v
v

Two number of PA fans in Unit-2 of 772 KW capacity

PA fans are of Centrifugal type
IGVs were operating at 55% throttled condition in full load
VFD drive installed in both PA fans
Savings achieved 9 MW-Hr per day
Pay back period 36 months

Project-3 : Restricted Use Of Service Air Compressors

v
v
v
v
v
v
v
v

No. of installed Service Air Compressors 3

Service air was primarily used for Oil Gun atomization and cleaning
Earlier one Service Air Compressor remained in service for 24 hrs.
Energy audit showed idle running of Compressor throughout the day due
to very low consumption
Later Oil gun atomizing line was connected with Fuel & Ash IA system
Service Air Compressor is now in operation for 8 hrs. for cleaning activity
& remains out of service for 16 hrs. in a day
Savings - 1 MW-Hr per day
Investment - NIL

River Hoogli

Sludge
Pit

Holding Pond
Pump House

Turbine

Condenser

CT Blowdown

Station
Services

Canteen
Hot Water

Cold Water
Cooling Water Forebay

CT Make-up
Cooling Water
Pumps

Cooling Tower
Discharge outside Plant

Revised Scheme

Modifications done

Municipal Drain

Raw Water
Treatment Plant

Fish
Pond

DM
Plant

BBGS is the Globally FIRST Thermal

Power plant to register two of its
Energy saving projects with UNFCCC
as CDM projects & earned 30042
CERs.

v Injection of Ammonia in Flue gas

v Water Fogging inside Flue gas duct using special nozzles

Ammonia Dosing

Water Fogging

Online SPM

Focused approach towards Energy Conservation

Online energy monitoring of all HT drives & boards

Gap analysis & corrective actions on a regular basis by monitoring
format
Extensive training & awareness programs
SEC Targets linked with BBSC & KRA of all executives
Kaizens & Management Programs included in Annual Business plan
Dedicated team for Benchmarking

Management Programme

Energy Monitoring Format

Energy Monitoring Format

Photovoltaic solar panels have

been installed at Garage roof and
Garden area for illumination.
The total installed capacity is
around 4.59 KW-peak

Incorporation of VFD in HT & LT drives

Installation of PADO
CFD analysis of Boiler Flue Path
Installation of LED Lamps
Compressed Air Audit

Thank You