TATA POWER Trombay Unit#8 17 th National Energy Efficient Management Award nd 24th August 2016, CII- Hyderabad

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1 Presentation Title ( Arial, Font size 28 ) Energy Efficiency Management Date, Venue, etc..( Arial, Font size 18 ) TATA POWER Trombay Unit#8 17 th National Energy Efficient Management Award nd 24th August 2016, CII- Hyderabad Technology Adopters in Energy Management LCI drives ( V / F control) for 6.6 KV motors 415 V VFD used for 6.6 KV auxiliary Recommended ISO Certification Energy efficient coating (Coro coating) & Fluid couplings for pumps Pipe Conveyors with VFD s for coal transportation Impeller trimming in HT pumps CFD analysis & its implementation for flue gas ducting Key Energy Management Initiatives AT Trombay Combustion optimization Compressed Air pressure controller, Light Pipes, Turbo ventilators, Micro wind & Hybrid Units In-house developed Energy management system for monitoring using PI

2 Trombay: Present Generation Capacity Established in 1956 Unit Year Capacity (MW) Fuel Used Unit Coal, Oil & Gas Unit Oil & Gas Unit 7 (CCPP) = 180 Gas Unit Coal Total Generation Capacity : 1430 MW 4 Specific Energy Consumption of Last three Years Recovered from major catastrophe

3 Benchmarking Parameters ( 250 MW UNIT 8) HEAT RATE UoM DTPS Dahanu Tata Power Trombay Unit 8 Best Performance Best Performance (FY12) (FY14) Actual Heat Rate Kcal/kwh Deviation in Heat rate Kcal/kwh -22 Auxiliary Power Consumption UoM DTPS (Dahanu) Best Performance (FY11) Tata Power Trombay Unit 8 Best Performance (FY16) Actual Auxiliary Consumption % Deviation in Auxiliary Consumption % Information Sourced from CII Award PPT, MERC tariff order Energy Saving Projects : FY 14 Energy Saving projects implemented in FY 14 Total Annual Savings Rs Million Invest. Made Rs Million Civil Lighting Saving project by transparent roof tops in three cell collectors Additional O2 Transmitters on both sides of RAPH Installation of COC Power supply switch for to ON/OFF COC in running Feeder condition & replacement of Failed Shear pin in running Feeder Combustion Optimisation Replacement of Compound Lights with LED lights Cut-in & cut-out set point revised for Station air compressor saved auxiliary power consumption 0.1 NIL Total

4 Energy Saving Projects : FY 15 & FY 16 Energy Saving projects implemented in FY 15 & 16 Stopping of one CW pump due to sub cooling (22 million saving in FY15) Total Annual Savings Rs Million Invest. Made Rs Million 17.8 Nil Replacement of BFP cartridge Replacing Roof tops of stores with transparent roofs Provision of ON/OFF Push button at various switchgear & unmanned location Combustion optimisation Total Energy Saving Projects Planned In Next Three Years Energy Saving projects Estimated Annual Savings (Rs Million) Estimated Investment (Rs Million) Arresting Air infiltration in Flue gas path Combustion optimisation 0.6 Nil Boiler Skin plate insulation improvement Optimisation of Compressed air pressure Improving Coal conveying system Efficiency using Six Sigma 4 2 Total Installation of measurement and monitoring system for of AC & Lighting load (strengthening of monitoring systems) ISO project

5 Stopping of one CW pump due to sub cooling Idea description : Heat rate & Aux power Saving from condensate system Before:. Unit was operated at higher vacuum with 4 CW Pumps running. Key enablers: Higher Auxiliary power consumption Higher Turbine cycle Heat Rate Syndicated After : Unit operated at rated Vacuum with 3 CW Pump Trigger : Sub Cooling in the Condenser Condensate Hot well Temperature Design Temperature : 45 Deg C, Actual Temperature : 40 Deg C KPI impacted Savings (Rs. Million) Investment (Rs. Million) ROI (%) Auxiliary Consumption Method of KPI impact measurement Auxiliary power consumption of CW Pump NA Final Outcome & Benefits Condensate Temperature (Deg C) Condensate Temperature Design FY 15 FY 16 Sub cooling Reduction Condenser Vacuum Improvement in Heat rate due to reduction in sub cooling Reduction in Auxiliary consumption : 5.9 Mus / Annum Investment : Nil FY 16 Annual Savings : 17.8 Million Rs

6 Innovative Project : High Velocity Traverse Test Holder Trigger Risk of the Probe getting bend due to CW failure resulting n Unit outage High Temperature Probe Significance: Accurately measure O 2, CO 2, CO at goose-neck Measure furnace exit temperature Detects unbalanced heat transfer and flame propagation Innovatively In-house Designed HVT holder Before What makes it Innovative After Its in-house Design & fabrication of HVT probe holder with pulley arrangement Utilisation of Scrap for fabrication of above probe holder.

7 Benefits & Costing FY 14 Q1 FY 14 Q3 FY 15 Q3 FY 15 Q4 FY 16 Q1 FY 16 Q2 FY 16 Q3 FY 16 Q4 FY 17 Q1 Investment 0.1 Lakhs Annual Savings 5 Lakhs Care For Environment- Renewable & Energy Conservation Project Before After Replacement of OLD AC sheet with new transparent sheet along with turbo ventilators in Materials Department

8 Care For Environment- Renewable & Energy Conservation Project Use of polycarbonate transparent sheets for Natural lighting inside bunker gallery Benefits Illumination with natural Sunlight Improvement in LUX levels Saving in Auxiliary Consumption Lux intensity Before After Reqd Non Monsoon Monsoon Non Monsoon Monsoon Care For Community : Renewable & Energy Conservation Project in the Community Installation of Solar Lights in the Neighbouring Community 70 Solar lights ( MV-3 model- 11 W) have been installed in dark areas of communities of Trombay to address safety of women

9 Care For Environment- Fuel Handling (Eliminating Fugitive emission) Captive Jetty with Screw Unloader to unload coal without any spillage. Pipe Conveyors with VFD ensure transfer of coal without any spillage. 3 Care For Environment : Waste Management (Development of greenbelt Using Bottom Ash) Base formation using bottom ash Covering base level with red soil Planting green carpet grass for landscaping

10 Care For Environment- Waste Management Plasto Silt Use of silt/ash for non structural construction work by filling Ash/Silt in to plastic bottles Alternative to Brick masonry Silt/ash filled in bottle Bricks are replaced with these bottle INNOVATIVE & UNIQUE PROJECT Road side kerbing work with ash/silt filled plastic bottle Care For Environment- Resource Conservation (Water) Reduction in Unit 8 Specific Make Up Water Consumption Further Analysis being done using Six Sigma Recovered from major catastrophe M3/MWH FY10 FY11 FY12 FY13 FY14 FY15 FY16 Specific Water Consumption for Trombay Site for FY16: M3/MWH

11 Care For Community & Customers Energy conservation & Awareness Programme Energy conservation campaign For Schools, Colleges, Employees & Contractors Source of Idea Generation & Involvement of All Sr. No. Source of En-con Idea Source of Idea Generation Year of Idea Origination Extent of Manpower Involved Progress of Implementation 1 HVT holder Brainstorming engineer and 02 workmen 2 3 Stopping of CW pump due to sub cooling Replacing Roof tops of stores with transparent roofs 4 Combustion Optimisation 5 6 Cut-in & cut-out set point revised for Station air compressor. CFD analysis Unit 8 flue gas path. Discussions with OEM Energy Audit Recommendation Energy Audit Recommendation Discussions with OEM #SANKALP (Core Group) engineer including group heads & HOD s 2 Engineers and 10 Workmen along with contractors 08 Engineers and 20 workmen 04 engineer and 04 workmen Engineers in FY13 7 Debris Filter Modification #SANKALP (Core Group) Engineers and 8 workmen

12 Monitoring : Unit 8 PI Dash Board Online Monitoring : Unit 8 Auxiliary Power (M & A)

13 Website: ID: