Best Practice case study by JSW Energy Limited

Workshop on "Best Practices in Energy Efficiency in
Thermal Power Sector"
JSW Energy Limited, Toranagallu
Reliance Dahanu Thermal Power Station
Dahanu
1
JSW ENERGY POWER GENERATION BUSINESS IN INDIA
HYDRO POWER
PLANT
1391 MW
BARMER PLANT
1080 MW
RATNAGIRI
PLANT
1200 MW
VIJAYANAGAR
PLANT
860 MW
The existing operational capacity of 4,531 MW will be augmented with projects worth 7,269 MW
under implementation and development phase identified in several states
2
PLANT PERFORMANCE HIGHLIGHTS
ENERGY EFFICIENCY %
40%
38.0%
38%
35.7%
36%
34%
32.8%
35.8%
33.3%
32%
30%
INDIA
AUSTRALIA
CHINA
98.46
101
US
JSWEL,TORANAGALLU
7.72
* Source: Heat & Power, CSE
7.64
97.17
97.36
94.75
95.66
PLF (%)
Availibility (%)
7.16
APC (%)
3
SPECIFIC ENERGY CONSUMPTION
SOC,ml/KWH
0.14
0.13
0.09
2012-13
2013-14
2014-15
Sp. Coal Consumption, Kg/KWH
Station GHR, Kcal/KWH
2253
0.36
2251
0.34
2245
0.33
2012-13
2013-14
2014-15
2012-13
2013-14
2014-15
4
ENERGY MANAGEMENT SYSTEM AT JSW,VIJAYANAGAR
 Energy policy established
 Structured Energy Management Cell
 Identify, Evaluate and Analyze Energy use &
Consumption ( Coal, Oil, electricity , Water)
 Daily energy deviation reporting
 Total 25 Energy auditors
 E LAN (EMS) System for Energy Consumption Monitoring.
5
ENERGY MONITORING
6
ONLINE ENERGY MONITORING SYSTEM
TOTAL – 254 NEW METERS INSTALLED (HT + LT)
7
EMS - UNIQUE FEATURES
 Time Synchronization of all the meter and Server through EMS software.
 Available plant network is being utilized for the metering system.
 Meters data is collected in redundant servers for computing &
calculation.
 Infinite Web clients developed for viewing & analyzing of data.
 Automatic report generation with emailing facility is developed to
eliminate manual intervention
 Monitoring real time parameters individual equipment wise
 Trending & customizable dashboards are additional advantage.
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DASH BOARDS
9
ENERGY REPORTING & MONITORING
Sl No
Monitoring and Review
1
Daily Monitoring of Generation, APC,
SFOC, SHR, Water , Environment, &
safety
2
MOPR (Monthly operation performance
review)
3
Performance Optimization Group (POG)
APC, HEAT RATE & WATER
4
Internal Audit of IMS ISO 9001,14001
and ISO 50001:2011
Chaired by
Participants
Frequency
Head of Plant
Section In
charges,SCE and
HOD's
Daily
Head of Plant
Section In
charges,SCE and
HOD's
Monthly
Head of Plant
POG (cross
functional team),
HOD,s
Monthly
Management
Representative
All Employees
Half yearly
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ENERGY CONSERVATION PROJECTS
11
ENERGY CONSERVATION FOR LAST THREE YEARS
Year of
Implementati
on
Annual Electrical
Savings achieved
Annual thermal
savings
Total
Annual
Savings
Invest.
Made
Units
Million
Rs
Million
Tons
of Fuel
Rs
Million
Rs
Million
Rs
Million
2014-2015
5.63
28.12
2238
15.20
43.32
18
2013-2014
4.84
23.47
1883
13.17
36.64
7
2012-2013
0.39
1.98
154
1.06
3.04
0.44
Total
10.89
53.57
4275
29.43
83
25.44
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LIST OF ENCON PROJECTS PLANNED FOR NEXT 3 YEARS
Sl.
No
Asset
1
SBU-1
Installation of VFD for ID Fans
2
SBU-1
Installation of VFD for PA Fans
3
Title of the Project
Installation of energy efficient fan blade in
SBU-1 & 2
cooling tower (40 nos)
4
SBU-2
Unit 2
5
SBU-1 & 2
ID fan- Replacement of Hydraulic coupling
with Direct shaft to save coupling losses
Installation LED lights phase wise
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ENCON PROJECTS
S.No
Project Taken
up
Per unit Energy
consumed prior to
implementing
Encon
Per unit energy
consumed after
implementation
of Encon
Improvement
(%)
1
Installation of
VFD to ID FAN
&CEP
1430 Kwh
950 Kwh
1210 Kwh
750 Kwh
15.4%
21.0%
2
Installation of
Spacer
Coupling For
ID fans
1210 Kwh
1110 kwh
8.26%
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ENCON PROJECTS
PROJECT -1 REDUCTION OF ID FAN POWER BY INTRODUCTION OF VFD
ID FAN
DESCRIPTION
UOM
BEFORE VFD
AFTER VFD
MOTOR SPEED
RPM
745
610
FAN SPEED
RPM
550
550
%
55
63
KW
1430
1210
HYDRAULIC COUPLING
POWER CONSUMED
SAVINGS ACHIEVED 210 KWH AT FULL LOAD OPERATION PER FAN
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ENCON PROJECTS
PROJECT -2 REDUCTION OF CEP POWER BY INTRODUCTION OF VFD
CEP
DESCRIPTION
DEAERATOR LEVEL
CONTROL VALVE OPEN
UOM BEFORE VFD AFTER VFD
%
42 - 45
53 - 55
DP ACROSS CV
MPa
1.61
0.76
POWER CONSUMED
KW
950
750
SAVINGS ACHIEVED 190 kWh AT FULL LOAD OPERATION
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ENCON PROJECTS
PROJECT -3 REPLACEMENT OF HYDRAULIC COUPLING WITH SPACER COUPLING
ID FAN - VFD WITH HC
ID FAN - VFD WITH SPACER COUPLING
 ID fan energy saving enhanced by eliminating hydraulic coupling with
Hollow Flexible spacer Coupling resulting in Energy Saving of 100 kW.
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ENCON PROJECTS
PROJECT -4 RETROFITTING BOILERS TO ACCOMMODATE WASTE GAS
 JSW Steel main vertical of JSW group has a integrated steel plant with
14mtpa capacity – furnace with varying size and technology
 Excess gas left over is being flared to atmosphere (4-5 lakh Nm3/hr)
 Introduced gas burners in all 300MW boilers to accommodate 1,00,000
Nm3/hr of gas so that flaring of waste gas is avoided.
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ENCON PROJECTS
PROJECT -4 RETROFITTING BOILERS TO ACCOMMODATE WASTE GAS (Contd…)
RESULTS
 Saving in coal consumption
-
5.0 Lac tons/annum
-
2,00,000 Nm3/Hr
(15tph/boiler)
 Utilisation of Waste gas
 Over all Boiler efficiency reduced by- -
1-1.5%
 Anticipating the increase in Exit temperatures due to gas firing additional
sacrificing baskets were installed at Hot end of Air Heater
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OTHER ENERGY CONSERVATION PROJECTS
GHG Reduction Project
Year of
Savings Investment Payback
Implement
Million
Million
Months
(Rs.)
(Rs.)
SBU-1&2: 2 nos. of energy efficient CT fans
blades installed saving of 40kwh
2014-15
0.911
1.1
6
Installing bypass chute to transfer coal from
conveyor CJ 9C1 to 10C1 eliminating
operation of Coal conveyor CJ 9RC1
2014-15
0.544
0.7
17
20
OTHER ENERGY CONSERVATION PROJECTS
Year of
Implement
GHG Reduction Project
Savings
Million
(Rs.)
Investme
Payback
nt
Million
(Rs.)
Installation of LED lighting in control
rooms, VFD and Training hall
2013-14
0.0005
0.70
Optimized
operation
2013-14
1.8990
-
PA header pressure optimization
2013-14
2.1080
-
Replacement of passing BFP
recirculation control valves ( 4 Nos.) in
SBU-2 units
2013-14
18.97
3
ESP
Rapping
motors
Months
Within
5 Years
2
21
OTHER ENERGY CONSERVATION PROJECTS
Year of
Implement
GHG Reduction Project
Savings
Investment Payback
Million
(Rs.)
Million
(Rs.)
Months
Replacement of passing CEP recirculation
control valve
2012-13
1.35
0.44
4
ACW pumps(4 Nos.) casing internal surface
applied with ceramic type antifriction coat
2012-13
0.68
0.0017
-
ACW
Pumps:
Recommissioned
modified impellers
2012-13
1.01
0.0025
-
with
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B V SRINIVAS
KUMAR IVATURI
VISHAL SANKAR SONI
“You can’t change the past but you can change the
future, It's Upon you what you Want!”-Go Green
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