1-Ntpc Sail Power Company (Pvt) Ltd Bhilai

Presentation For 14th CII National Award For“EXCELLENCE IN ENERGY MANAGEMENT”

19-20 Aug 2013, Hyderabad

M K SINGHA A PRASADM S KARTHIK

• 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).

NTPC-SAIL Power Company (Pvt.) Ltd

Introduction

BHILAI PP-3 2*250MW 500 MW SAIL & DD/DNH/CSEB

BHILAI PP-II 30*2+14 74 MW SAIL Captive

ROURKELA 2*60MW 120 MW SAIL Captive

DURGAPUR 2*60 MW 120 MW SAIL Captive

NSPCL 814 MW (500MW captive rest to Grid)

BHILAI


Teamwork

InnovationRespect

Integrity & Honesty

People

Sincerity & service

orientation

CORE VALUES

Our Core Values…..

Vision : To be an Efficient Power producer delivering consistent valueto stakeholders

Mission : To be recognized as a reliable power producer in the country.

BHILAI

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.

•• 11stst rank rank on All India basis for PLF 103.5 % in Oct’10

•• 11stst rank rank on All India basis for PLF 105.07 % in Dec’11.

•• 1st rank 1st rank on all India basis for best PLF (103.558%) in June’12 and 1st Quarterly (Apr-June’12) PLF of 101.67%

BHILAI


Innovation……Culture of NSPCL

SEC

Reduce APCControl ParametersAffecting Heat Rate

ENCON

BHILAI


Key Initiatives to Reduce APC BHILAI

Modification Done(2010-11)

Investment( in Lacs )

Savings In APC( Mu)

Interconnection has been provided between both ESP fluidizing blowers, after which only one Blower is kept in service.

No 0.355

Arresting of Air Ingress in Flue gas duct and APH

12.0 0.769

Condenser Tube cleaning using acid as tubes were very dirty (Poor water quality during initial times)

15.0 11.0


Investment( in Rs )

Savings In APC(Mu)

One of the IAC has been stopped and kept as standby for which a logic is provided for auto start.

NO 2.102


BHILAI

IAC-1

PAC-2IAC-2

PAC-1


Investment( in Rs )

Savings In APC( Mus )

Interconnection of Ash Handling Compressed air system with that of Main plant Compressed air system, thereby stopping compressors of AHS.

NIL 1.33

Interconnection of Mill Reject conveying air system with Main Plant Service air system thereby stopping Mill Reject conveying Compressors.

NIL 0.164

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)

NIL 0.24


BHILAI


BHILAI


Investment( in Rs )

Savings In SEC( Mu)

Tap off has been provided from recovery & effluent discharge header into mixing chamber directly. Hence, running of waste water holding pump has been stopped.

NO 1.17


BHILAI


Investment( in Rs )

Savings In APC ( Mu )

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

NO 0.67

Total APC Savings ( in Mu) 17.8

Equivalent Savings in SEC (Kcal/Kwhr) 4.223


Efforts To Control Heat Rate

• 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.

BHILAI

BHILAI


ENCON…….A Continuous Process BHILAI

Year Of Implementation

ENCON Projects

Implemented

Annual Thermal Savings

Tons of Fuel.

Total Savings

In SEC

(Kcal/Kwhr)

2010-11 Attending APH and Flue Gas Duct air ingress

496 0.4188

Condenser Tube Cleaning

9900 8.3612

Sub Total 10396 8.78


BHILAI

Year Of Implementation

ENCON Projects

Implemented

Annual Electrical Savings

Units

Total Savings

In SEC

(Kcal/Kwhr)


0.88 0.599

Reduction of IAC & PAC air Pressure

0.235 0.161

Sub Total 1.115 0.76


BHILAIYear Of

ImplementationENCON Projects

Implemented

Annual Thermal Savings

Tons of Fuel

Total Savings

In SEC

(Kcal/Kwhr)


4000 3.402

Insulation Survey

1220 1.038

Condenser Tube Cleaning

9750 4.44

Sub Total 14970 8.88


Future ENCON Projects…..Impact On CER BHILAI

Year Project Investment(in Lacs)

Savings In SEC

Savings of CO2(tons)

2013-14

Installing VFD in Condensate Extraction Pumps.

230 1.0 2815

Avoiding continuous running of Condensate Make up Pump

0.25 0.246 410

Providing Orifices in selected Equipment in cooling water lines to reduce DM water flow, thereby reducing loading of DMCW pump.

0.23 0.141 237


Savings In SEC


2013-14Replacement of normal Tube light and Halogen lamps with LED lamps in selected areas.

7.5 2.1 6000

Auxiliary power consumption Audit

5.0 NIL

2014-15

Replacing Hydraulic Scoop of ID fan with VFD.

6250 0.837 2725

5MW Solar Power Plant at Daman Diu has been planned.

(as per CERC rate)

34065


BHILAI


BHILAI


Savings In SEC


2014-15

Addition of one layer of baskets in APH for more heat recovery

7.5lakhs 2.1 6000

Helium leak detection test.

Optimization of PA fan operation by Installing VFD in PA Fan

Attending air ingress in APH and Flue gas duct


Parameter 2010-11 2011-12 2012-13

All India Rank 16 12 6

Generation (MU) 4019.7 3978 4029.76

PAF % 92.72 92.95* 98.88

PLF % 91.73 90.57 * 92

APC % 8.55 8.456 8.643**

* Lower PAF/PLF in 2011-12 was due to coal shortage

** Backing down of Generation led to Higher APC and SEC.

Performance Highlights BHILAI


BHILAI

Our Target……Benchmark SEC


Design Station Net Heat Rate – 2457 Kcal/Kwh

BHILAI


BHILAIImplementation Methodology

STATION LEVEL


BHILAI

• Quality Circle

• Professional Circles

• Suggestion Schemes

• Participation in Energy Conservation Campaigns

•Cost Control Campaigns

•Water Saving Campaigns.

Employee Involvement Activities


BHILAIMonitoring……Key to Energy Management

• Checklist to compare trends of critical parameters.

• 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.


Waste Utilization & Environmental Projects

• Utilization of Ash

Fin. Year Ash Gen. (MT) (Approx.)

Total Utilization

(MT) (Apprx.)

Fly Ash Utilizn %

Total Utilizn %

09-10 598593 28132 4.70 3.76

10-11 950307 229638 24.16 19.33

11-12 1144528 325209 35.52 28.41

12-13 994534 697635 88 70.15

13-14 229144 179,434 97.88 78.31

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.

BHILAI


Awards & Accolades

• 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” .

BHILAI


BHILAI

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