Presentation For 14th 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. Company Turnover (2012-13 ) : 1866.8 Cr. Total Number of Employees : 817 (as on 30.06.2013).

BHILAI PP-3 BHILAI PP-II ROURKELA DURGAPUR NSPCL

2*250MW 30*2+14 2*60MW 2*60 MW 814 MW

500 MW 74 MW 120 MW 120 MW

SAIL & DD/DNH/CSEB SAIL Captive SAIL Captive SAIL Captive

(500MW captive rest to Grid)

NTPC-SAIL Power Company (Pvt.) Ltd

Our Core Values..

Sincerity & service orientation Teamwork CORE VALUES Respect

BHILAI

People Integrity & Honesty

Innovation

Vision : To be an Efficient Power producer delivering consistent value to stakeholders Mission : To be recognized as a reliable power producer in the country.
NTPC-SAIL Power Company (Pvt.) Ltd

POWER GENERATION PROCESS

PERFORMANCE Highlights Unit-1 date of Commercial Operation : 22/04/2009 Unit-2 date of Commercial Operation : 21/10/2009 6th rank on All India basis for PLF in 2012-13. 1st rank on All India basis for PLF 103.5 % in Oct10 1st rank on All India basis for PLF 105.07 % in Dec11.

BHILAI

1st rank on all India basis for best PLF (103.558%) in June12 and 1st Quarterly (Apr-June12) PLF of 101.67%

NTPC-SAIL Power Company (Pvt.) Ltd

InnovationCulture of NSPCL

BHILAI

Reduce APC

Control Parameters Affecting Heat Rate

SEC
ENCON

NTPC-SAIL Power Company (Pvt.) Ltd

Key Initiatives to Reduce APC

Modification Done (2010-11)
Interconnection has been provided between both ESP fluidizing blowers, after which only one Blower is kept in service. Arresting of Air Ingress in Flue gas duct and APH Condenser Tube cleaning using acid as tubes were very dirty (Poor water quality during initial times)

BHILAI
Savings In APC ( Mu)

Investment ( in Lacs )

No

0.355

12.0

0.769

15.0

11.0

NTPC-SAIL Power Company (Pvt.) Ltd

BHILAI
Modification Done (2011-12)
One of the IAC has been stopped and kept as standby for which a logic is provided for auto start.

Investment ( in Rs )

Savings In APC (Mu)

NO

2.102

IAC-1

PAC-1 IAC-2 PAC-2

NTPC-SAIL Power Company (Pvt.) Ltd

BHILAI
Modification Done (2011-12)
Interconnection of Ash Handling Compressed air system with that of Main plant Compressed air system, thereby stopping compressors of AHS. Interconnection of Mill Reject conveying air system with Main Plant Service air system thereby stopping Mill Reject conveying Compressors. 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)

Investment ( in Rs )

Savings In APC ( Mus )

NIL

1.33

NIL

0.164

NIL

0.24

NTPC-SAIL Power Company (Pvt.) Ltd

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 )
NO

Savings In SEC ( Mu)

1.17

NTPC-SAIL Power Company (Pvt.) Ltd

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 )

Savings In APC ( Mu )

NO

0.67

Total APC Savings ( in Mu) Equivalent Savings in SEC (Kcal/Kwhr)

NTPC-SAIL Power Company (Pvt.) Ltd

17.8 4.223

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.) Ltd

BHILAI

ENCON.A Continuous Process

Year Of Implementation ENCON Projects Implemented Annual Thermal Savings Tons of Fuel.

BHILAI
Total Savings In SEC (Kcal/Kwhr) 0.4188

2010-11

Attending APH and Flue Gas Duct air ingress Condenser Tube Cleaning

496

9900

8.3612

Sub Total
NTPC-SAIL Power Company (Pvt.) Ltd

10396

8.78

BHILAI
Year Of Implementation ENCON Projects Implemented Annual Electrical Savings Units 0.88 Total Savings In SEC (Kcal/Kwhr) 0.599

2011-12

Attending APH and Flue Gas Duct air ingress Reduction of IAC & PAC air Pressure

0.235

0.161

Sub Total
NTPC-SAIL Power Company (Pvt.) Ltd

1.115

0.76

BHILAI
Year Of Implementation ENCON Projects Implemented Attending APH and Flue Gas Duct air ingress Insulation Survey Condenser Tube Cleaning Sub Total
NTPC-SAIL Power Company (Pvt.) Ltd

Annual Thermal Savings Tons of Fuel 4000

Total Savings In SEC (Kcal/Kwhr) 3.402

2012-13

1220 9750

1.038 4.44

14970

8.88

Future ENCON Projects..Impact On CER

Year Project Installing Condensate Pumps. VFD in Extraction Investment (in Lacs) 230 Savings In SEC 1.0

BHILAI
Savings of CO2(tons) 2815

Avoiding continuous running 2013-14 of Condensate Make up Pump Providing Orifices in selected Equipment in cooling water lines to reduce DM water flow, thereby reducing loading of DMCW pump.

0.25

0.246

410

0.23

0.141

237

NTPC-SAIL Power Company (Pvt.) Ltd

BHILAI
Year Project Replacement of normal Tube light and Halogen lamps with LED lamps in selected areas. Auxiliary power consumption Audit Replacing Hydraulic Scoop of ID fan with VFD. Investment (in Lacs) 7.5 Savings In SEC 2.1 Savings of CO2(tons) 6000

2013-14

5.0

NIL

6250

0.837

2725

2014-15

5MW Solar Power Plant at Daman Diu has been (as per CERC rate) planned.

34065

NTPC-SAIL Power Company (Pvt.) Ltd

BHILAI
Year Project Investment (in Lacs) Savings In SEC Savings of CO2(tons)

Addition of one layer of baskets in APH for more heat recovery Helium leak detection test. Optimization of PA fan operation by Installing VFD in PA Fan Attending air ingress in APH and Flue gas duct

7.5lakhs

2.1

6000

2014-15

NTPC-SAIL Power Company (Pvt.) Ltd

Performance Highlights
Parameter All India Rank Generation (MU) PAF % PLF % APC % 2010-11 16 4019.7 92.72 91.73 8.55 2011-12 12 3978 92.95* 90.57 * 8.456

BHILAI 2012-13 6 4029.76 98.88 92 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.) Ltd

BHILAI

NTPC-SAIL Power Company (Pvt.) Ltd

Our TargetBenchmark SEC

BHILAI

Design Station Net Heat Rate 2457 Kcal/Kwh

NTPC-SAIL Power Company (Pvt.) Ltd

Implementation Methodology
STATION LEVEL

BHILAI

NTPC-SAIL Power Company (Pvt.) Ltd

Employee Involvement Activities Quality Circle Professional Circles Suggestion Schemes Participation in Energy Conservation Campaigns Cost Control Campaigns Water Saving Campaigns.

BHILAI

NTPC-SAIL Power Company (Pvt.) Ltd

MonitoringKey to Energy Management Checklist to compare trends of critical parameters.

BHILAI

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.

NTPC-SAIL Power Company (Pvt.) Ltd

Waste Utilization & Environmental Projects Utilization of Ash

Ash Gen. (MT) (Approx.) Total Utilization (MT) (Apprx.) 28132 229638 325209 697635 179,434 Fly Ash Utilizn %

BHILAI

Fin. Year

Total Utilizn %

09-10 10-11 11-12 12-13 13-14

598593 950307 1144528 994534 229144

4.70 24.16 35.52 88 97.88

3.76 19.33 28.41 70.15 78.31

NTPC-SAIL Power Company (Pvt.) Ltd

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.) Ltd

Awards & Accolades

BHILAI

NSPCL received 10th 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 3rd 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

BHILAI

NTPC-SAIL Power Company (Pvt.) Ltd