JSW Energy Limited, Toranagallu -...
Transcript of JSW Energy Limited, Toranagallu -...
JSW Energy Limited, Toranagallu
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Workshop on "Best Practices in Energy Efficiency in Thermal Power Sector"
Reliance Dahanu Thermal Power Station Dahanu
VIJAYANAGAR PLANT
860 MW RATNAGIRI
PLANT 1200 MW
BARMER PLANT 1080 MW
HYDRO POWER PLANT
1391 MW
JSW ENERGY POWER GENERATION BUSINESS IN INDIA
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
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98.46
95.66
97.17
Availibility (%)
7.72 7.64
7.16
APC (%)
101
94.75
97.36
PLF (%)
30%
32%
34%
36%
38%
40%
INDIA AUSTRALIA CHINA US JSWEL,TORANAGALLU
32.8% 33.3%
35.7% 35.8%
38.0%
ENERGY EFFICIENCY %
* Source: Heat & Power, CSE
SPECIFIC ENERGY CONSUMPTION
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2245
2253
2251
2012-13 2013-14 2014-15
Station GHR, Kcal/KWH
0.14
0.09
0.13
2012-13 2013-14 2014-15
SOC,ml/KWH
0.36
0.33
0.34
2012-13 2013-14 2014-15
Sp. Coal Consumption, Kg/KWH
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.
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ENERGY MONITORING
ONLINE ENERGY MONITORING SYSTEM
TOTAL – 254 NEW METERS INSTALLED (HT + LT)
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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.
EMS - UNIQUE FEATURES
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DASH BOARDS
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Sl No Monitoring and Review Chaired by Participants Frequency
1 Daily Monitoring of Generation, APC, SFOC, SHR, Water , Environment, & safety
Head of Plant Section In
charges,SCE and HOD's
Daily
2 MOPR (Monthly operation performance review)
Head of Plant Section In
charges,SCE and HOD's
Monthly
3 Performance Optimization Group (POG) APC, HEAT RATE & WATER
Head of Plant POG (cross
functional team), HOD,s
Monthly
4 Internal Audit of IMS ISO 9001,14001 and ISO 50001:2011
Management Representative
All Employees Half yearly
ENERGY REPORTING & MONITORING
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ENERGY CONSERVATION PROJECTS
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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 Title of the Project
1 SBU-1 Installation of VFD for ID Fans
2 SBU-1 Installation of VFD for PA Fans
3 SBU-1 & 2 Installation of energy efficient fan blade in cooling tower (40 nos)
4 SBU-2 Unit 2
ID fan- Replacement of Hydraulic coupling with Direct shaft to save coupling losses
5 SBU-1 & 2 Installation LED lights phase wise
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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
SAVINGS ACHIEVED 210 KWH AT FULL LOAD OPERATION PER FAN
ID FAN
DESCRIPTION UOM BEFORE VFD AFTER VFD
MOTOR SPEED RPM 745 610
FAN SPEED RPM 550 550
HYDRAULIC COUPLING % 55 63
POWER CONSUMED KW 1430 1210
ENCON PROJECTS
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SAVINGS ACHIEVED 190 kWh AT FULL LOAD OPERATION
CEP
DESCRIPTION UOM BEFORE VFD AFTER VFD
DEAERATOR LEVEL CONTROL VALVE OPEN
% 42 - 45 53 - 55
DP ACROSS CV MPa 1.61 0.76
POWER CONSUMED KW 950 750
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PROJECT -2 REDUCTION OF CEP POWER BY INTRODUCTION OF VFD
ENCON PROJECTS
ID fan energy saving enhanced by eliminating hydraulic coupling with Hollow Flexible spacer Coupling resulting in Energy Saving of 100 kW.
PROJECT -3 REPLACEMENT OF HYDRAULIC COUPLING WITH SPACER COUPLING
ID FAN - VFD WITH SPACER COUPLING ID FAN - VFD WITH HC
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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
RESULTS
Saving in coal consumption - 5.0 Lac tons/annum
(15tph/boiler)
Utilisation of Waste gas - 2,00,000 Nm3/Hr
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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PROJECT -4 RETROFITTING BOILERS TO ACCOMMODATE WASTE GAS (Contd…)
ENCON PROJECTS
OTHER ENERGY CONSERVATION PROJECTS
GHG Reduction Project
Year of Implement
Savings Investment Payback
Million (Rs.)
Million (Rs.)
Months
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
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GHG Reduction Project
Year of Implement
Savings Investme
nt Payback
Million (Rs.)
Million (Rs.)
Months
Installation of LED lighting in control rooms, VFD and Training hall
2013-14 0.0005 0.70 Within
5 Years
Optimized ESP Rapping motors 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 2
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OTHER ENERGY CONSERVATION PROJECTS
GHG Reduction Project
Year of Implement
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 with modified impellers
2012-13 1.01 0.0025 -
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OTHER ENERGY CONSERVATION PROJECTS
B V SRINIVAS
KUMAR IVATURI
VISHAL SANKAR SONI
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“You can’t change the past but you can change the future, It's Upon you what you Want!”-Go Green