NAVA BHARAT VENTURES LIMITED

Transcription

1 VENTURES LIMITED POWER DIVISION, DHENKANAL, ODISHA B J Rao DGM (Mech) Girija Prasad Sarangi N SK S Kameswara Rao Certified Energy Manager Manager -Operations Manager -Electrical

2 NBVL Global footprints India Singapore Laos Zambia Tanzania Company profile : Ferro Alloy, Power & Sugar, Corporate Office : International Office : Development of hydro-electric power project : Coal Mining & 300 MW Thermal Power Plant : Identifying opportunities for mining and setting up agri projects

3 Captive Power Division Dhenkanal, Odisha Boilers 2 X 65 TPH AFBC Boilers 2 X 125 TPH AFBC Turbine Condensing Extraction Turbine Condensing Extraction Cooling Tower Counter flow Induced Draft Cooling Tower Counter flow Induced Draft Ash Handling Pneumatic dry ash conveying Ash Handling Pneumatic dry ash conveying Compressors Reciprocating type Compressors Reciprocating type Fuel Domestic Coal from MCL Fuel Domestic Coal from MCL 30 MW Coal Based CPP 60 MW Coal Based CPP

4 Accreditations / Certifications ISO 9001 The operating facility of Nava Bharat group have been certified with following Accreditations & Certificates for it s constant endeavor as an Environmentally responsible corporate citizen & Strong believer of Corporate Social Responsibility ISO 9001 for adhering to stringent international quality norms ISO for adhering to environmental management standards OHSAS for adhering to stringent Occupational health and safety management system ISO for adhering to stringent Energy management system ISO 9001 ISO ISO ISO 50001

5 Process Flow Coal Based TPP Raw Water From Brahmani River Coal From Washeries Coal From Mines Coal Yard RW Pump House Economizer Reservoir CHP DRUM SSH Bunker DM Plant IBSH Bed Comp Flue Gas MWPH APH PSH Clarifier Cooling Tower ESP Compressor house FLY ash Bed Ash UCFT STEAM TURBINE GEN SILO HP HEATERS SILO Condenser Deareator Dry ash to Brick plants Ash pond etc. through closed trucks LP HEATERS SWITCH YARD AUX LOAD

6 Energy Conservation Methodology NBVL follows PDCA methodology : Identifying the Legal and Other Requirements Conducting energy Review / Audit (Internal / External) Ensuring the Competency of People & creating awareness Establishing and Communicating the Operational Criteria Identifying & prioritizing the Opportunities for Improvement for effective and efficient plant operation Establishing the Baseline, Identifying the EnPI Procurement of Energy Efficient Products Establishing the Objectives and Targets Maintaining The required Documents Establishing the Action Plans Ongoing Energy Review by functional chiefs EnMS Review by management representative Taking decisions for Energy performance improvement Continual Improvement Monitoring the Key characteristics Evaluation Of Legal Compliances Conducting regular Internal Audits Identifying potential non conformities & taking C-CAPA

7 Plant Heat Rate % % MW CPP Net Heat Rate (kcal / kwh) MW CPP Gross Heat Rate (kcal / kwh) Remarks : The Heat rates in are slightly increased in comparison with the previous year due to outage of one HP heater in Unit-2.

8 Specific Energy Consumption % % MW CPP % Auxiliary Consumption MW CPP Specific Coal Consumption (Kg / kwh) Remarks : The % Auxiliary in is low due to high individual Plant Load Factor of 30 MW CPP (Unit-1) in that particular year.

9 Comparison with Competitors & National Best figures nd Best nd Best Gross Heat Rate Player-1 Net Heat Rate PAT Target Player-2 National Best Heat Rate NBVL - Dhenkanal

10 Roadmap to achieve National best figures Providing VFD for one of the Condensate Extraction Pump in Unit-2 Replacing the Conventional Lights with LED at Balance areas of Unit-1,2 &3 Optimizing the IAC air consumption by reducing the operating time and pressure reduction Installation of 5 kw Roof top solar PV for Workers colony Utilising day light in TG zero meter floor by Providing extra two windows in Unit-1 & Unit-3 Plugging of damaged tubes in HP Heater-1 for the improvement of heat rate in Unit-2. Replacement of damaged/eroded Air Preheater tubes in both boilers of Unit-2 for the improvement of Boilers performance Major overhauling of the Unit-2 (60 MW)

11 Thermal Energy Conservation Measures ( ) Evaluating the performance of LP Heaters in Unit-2 and replacing of damaged tube bundles Coal Savings : : 1200 MT : 2.92 Rs. Million Normalizing the sp. steam consumption, Vacuum & heat rate of Unit-2 by rectifying the ejector problem and arresting the leakage from Turbine bottom casing Coal Savings : : MT : 23.2 Rs. Million Up gradation of glass wool insulation with ceramic fiber type, at Turbine cross over pipes in Unit-2 and Turbine Steam inlet in Unit-1 Coal Savings : : 32 MT : 0.08 Rs. Million Controlling constant steam venting through startup vent valves by Providing steam trap in startup vent drain of both the Boilers in Unit-1 Coal Savings : : 1318 MT : 3.29 Rs. Million Total Coal Savings: MT Benefits attained by execution of above projects GHG Reduction : 26.6 MT Co2e

12 Lighting Energy Conservation Measures ( ) Replacing the existing 27 W, T5 tube lights in TG-Building, Compressor-House, DMPlant and Raw-water pump House area of Unit-2 with 18W, LED tube-lights Energy Savings : : 2496 Units : Rs. Million Replacing the existing 6 no of 85 W street lights at DM plant to Unit-3 cooling tower road with 45 W LED lights Energy Savings : : 720 Units : Rs. Million Replacing 27 nos. existing 250W, HPSV lights with 45W LED lights at Gate-5 area of Power Plant Energy Savings : : Units : 0.06 Rs. Million Replacing the existing 75 nos. existing 27W, T5 tube lights with 18W LED lights in Unit-1 and 132KV Sub Station area Energy Savings : : 2948 Units : Rs. Million Total Energy Savings: 0.03 MU Benefits attained by execution of above projects GHG Reduction : 49.3 MT Co2e

13 Lighting Energy Conservation Measures ( ) Replacing of 44 nos. 400 W HPSV lamps with 125 W LED flood light and 9 nos. 400 W HPSV lamps with 42 W LED in both the Units Energy Savings : : Units : 0.17 Rs. Million Replacing the remaining 199 nos. of 27 W T5 lights with 18 W LED tube light in both the Units Energy Savings : : Units : 0.03 Rs. Million Replacing the 38 no. of 70 W HPSV lamps with 42 W LED at identified areas in both the Units Energy Savings : : 4660 Units : Rs. Million Replacing of 4 no. of 18 W Gate lamps with 2 no. of 15 W LED at Power Plant Entrance gate Energy Savings : : 123 Units : Rs. Million Total Energy Savings: 0.09 MU Benefits attained by execution of above projects GHG Reduction : 133 MT Co2e

14 Other Energy Conservation Measures ( ) Reducing the consumption of 110 kw VT pump by recycling of DM Plant Filter back wash water in Clarifier and reusing boiler blow down water in Cooling tower Energy Savings : : 1150 Units : Rs. Million Modification and providing thermal insulation around hopper heaters of both the ESPs in Unit-2 Energy Savings : : 9800 Units : 0.02 Rs. Million Application of Friction-reducing, energyefficient protective coating FLUIGLIDE to all the cooling water pumps in Unit-2 Energy Savings : : Units : 0.7 Rs. Million Replacing the 110 kw Horizontal pump and motor with 55 kw, 450 m3 energy efficient pump at River Water Pump House Energy Savings : : Units : Rs. Million Total Energy Savings: 0.34 MU Benefits attained by execution of above projects GHG Reduction : 530 MT Co2e

15 Energy Conservation Projects with Zero Material Cost Utilizing existing unused Boiler bed ash cooler fan VFD for 30 kw Clarifier Pump -1 in Power Plant Energy Savings : : Units : 0.28 Rs. Million Switching off the hopper heaters of ESP 1st field during normal operating condition in Both the Units Energy Savings : : Units : 0.29 Rs. Million Redesigning the Ash silo dewatering pumping system near Fly ash silo in Unit-2 by replacing existing 22 kw pump with 15 kw old available pump Energy Savings : : 7000 Units : 0.02 Rs. Million Utilizing existing Unit-1 ID fan Old VFD, for chilled water pump of Vapour Absorption Machine (VAM) Energy Savings : : Units : 0.37 Rs. Million Total Energy Savings: 0.37 MU Benefits attained by execution of above projects GHG Reduction : 618 MT Co2e

16 Compressed Air saving projects with Zero Material Cost Optimising compressed air consumption in Bed Ash System of both the Boilers in U-2 by blocking orifice plate holes and air tapings taken from density stabilizer Energy Savings : : Units : 0.16 Rs. Million Changing the bed ash conveying time from 90 sec to 70 sec and increasing vessel pressure from 0.4 to 0.5 Kg/Cm2 of bed ash conveying system in Unit-2, Energy Savings : : Units : 0.08 Rs. Million Optimising compressed air consumption by changing bed ash conveying system operation to probe mode instead of timer mode in Unit-2 Energy Savings : : Units : 0.05 Rs. Million Optimising compressed air consumption by changing bed ash dome valve opening time from 5 sec to 7 sec in Unit-2 and from 13 sec to 18 sec for system-3 in Unit-1. Energy Savings : : Units : 0.06 Rs. Million Total Energy Savings: 0.13 MU Benefits attained by execution of above projects GHG Reduction : 216 MT Co2e

17 Innovative Project Description of the Project: In order to maintain the temperature of the all control rooms of Power Plants, VAM was installed. Whenever VAM is out of service, the temperature in control rooms was maintained by operating package AC units of respective plants. For operation of package AC unit, the role of cooling water pressure is vital. To maintain the cooling water pressure for U-2 AC unit and U-3 AC unit we are forced to run two Booster Pumps of capacity 37.5 kw and 45 kw Implemented In Annual savings 0.12 MU Action Taken: A team consisting of bottom level supervisors was formed with a objective of running the AC Units with less power. After the study, the team came with an idea that by providing one 0.75 kw booster pump in the U-2 ACW line, the cooling water pressure requirement of both the AC Units can be maintained by running only 37.5 kw ACW pump. The same is implemented after management approval. Investment (Rs.) Million GHG Reduction MTCo2e

18 Solar Power Harnessing The sun provides a tremendous resource for generating clean and sustainable electricity without toxic pollution or global warming emissions Recognizing the importance of solar energy, NBV harnessing solar energy in following ways: Installing solar water heaters at guest house and Bachelor hostel Utilising passive sun lighting at applicable areas in the plant Installation of 2 no of NoriKool double glazed transparent sheet resulted in saving of 960 Units. Construction of office / club building with Eco Friendly lighting

19 Utilization of Waste Utilization of Waste as Energy: % Utilization of Waste as Energy in last five years: Blending the coal washery rejects in high GCV Boiler feed coal Reusing Extracted coal fines from coal yard discharge water settling pit and Ferro Alloy Plant rejected coal fines in Captive Power Plant 6% 94% : Coal : Waste Reduce, Reuse and Recycling Waste: Using slag and fly ash in manufacturing of fly ash brick Vermiculture Programme by using canteen and colony waste Recycling and Reusing the waste water Reusing the bed ash as bed material after sieving Reusing the waste Turbine Lube Oil and Transformer oil for mud gun preparation in Furnace Using the damaged conveyor belts after reconditioning

20 GHG Management Objectives of Green House Gas Management: Establishing the Baseline, based on activity data Reducing the Intensity of Green House Gas (GHG) Emissions Improving the Gate to Gate energy performance of the Unit Conserving the resources & Utilization of Renewable energy Technology Absorption, Reduce, Reuse and Recycling Waste Including Indirect green house gases in GHG Management Monitoring, Reviewing and real time data transmission of Indirect green house gases to PCB server through RT - DAS Disclosing the emission levels to Employees & Public through awareness programs, seminars and other relevant forums Tree Plantation and green belt development

21 GHG Management Managing Green House Gas (GHG) emissions : Nava Bharat Ventures Ltd, Dhenkanal, Orissa adopted Emission based calculation approach for calculating the Co2e and as base line year : Scope-1 Emissions : Scope-2 Emissions Monitoring Indirect Green House Gas (GHG) emissions : NBVL has installed Stack gas analyzer for monitoring of indirect greenhouse gases and the analyzers are connected to PCB server 1.60 One real time display board is provided at the Plant main gate for the Public 1.00 Yearly Scope-1 and Scope-2 Green House Gas (GHG) emissions: % Baseline X Emission Factor = Tonnes of Emission (t) Green House Gas Emissions Intensity (CO2e / MWh) Green House Gas (GHG) emissions calculation methodology : Activity Data X Global Warming Potential (GWP) = Carbon Dioxide Equivalent (CO2e) of Emissions

22 Supply Chain Management Objectives of Supply Chain Management: Creating Awareness among the Vendors, Associates and Equipment suppliers Evaluating the vendors and suppliers on the basis of Energy and Environmental performance Defining and documenting the purchasing specifications of Energy Efficient and Eco friendly products Procuring the Energy Efficient and Eco friendly Green products and materials Procuring the materials / Equipments which have low environmental impact Providing the required inputs / Services to vendors, associates and suppliers Learning about new energy efficient and Eco friendly green products through external knowledge sharing sessions

23 Supply chain Management Initiatives Projects Implemented Benefits Achieved Replacing of old hired vehicles Reduced emissions with latest version vehicles and fuel consumption Bolero s HSD consumption of Replacing of D-50 dozer with D-80 Dozer was reduced by dozer for coal compacting 4 Liters /day Energy consumption Replacing of Tube lights with EE was reduced by 1402 lights at contract workers colony kwh Energy consumption Replacing welding transformers was reduced by with welding rectifiers kwh / Day HSD consumption of Providing monorail for lifting of PA Hydra was reduced by Fan motor instead of using Hydra 10 Liters/Hour Using cycle rickshaw for collection HSD consumption of of scrap from shop floor in place of Tractor was reduced tractor Type of Inputs Provided: Creating awareness, distributing EE Lamps, quality power and required technical assistance

24 Monitoring and Measurement Installation of Energy meters / Flow meters: Energy meters / Flow meters were installed at preferred points of consumption & for all the identified Significant energy uses Utilizing Portable Measuring Instruments: Utilizing portable instruments like Power Quality analyzer and Thermal imager for condition monitoring of equipments Logging the consumption data in SAP: Energy consumption in plant is logged daily in SAP, reviewed by Section Heads and appropriate action taken Monitoring of Energy performance indicators, Variables & Controls: EnPI, Variables & Control were reviewed by departmental chiefs and appropriate action on significant deviation will be taken Reviewing the Status of Action Plants, Objectives & Targets : Review of area wise Specific energy consumption, status of energy objectives & targets and Energy management action plans

25 Review and Reporting of Energy Performance Review Item Frequency Reviewed By Reviewed In Reported to Real time Monitoring and review of Boiler and TG parameters Real time Respective Desk Operator / SIC Real Time Chief-Operation Review of Daily Energy Consumptions & performance Daily Chief-Operation & Plant Head Daily Meeting Top Management Review of Monthly Energy Consumptions & performance Monthly Chief-Operation & Plant Head Monthly Review Meeting Top Management Review of Energy performance, EnPI, Status of Action Plans, SEU and its Variables of Boiler, TG, Utility and Electrical areas Monthly Respective Departmental Departmental Chiefs meeting MR-EnMS Review of status of Obj & Targets, Monthly Effectiveness of Action Plans and status of CAPA taken MR-EnMS & Energy Manager Management Review Top Management Review of Status of PAT Target and legal requirements Monthly PAT (Co-Ordinator) PAT Review Meeting Unit Head Review of Half yearly performance Half yearly Plant Head & Unit Head Half yearly budget Top Management review Review of yearly performance and submitting of Form-1 to BEE Yearly Energy Manager & Unit Head Annual Review meeting Top Management & BEE

26 Monetary Management in RESCON The Opportunities for improving energy performance are identified and Prioritized. High priority opportunities & the opportunities with significant investment are sent for management approval. After obtaining management approval the same is considered under CAPEX works and budget is allotted Year wise % of Investment on Turnover (Rs. Million) Year wise investment per one unit of Energy conserved (Rs / kwh)

27 Awareness on Resource conservation Improving awareness through internal training : Conducting Internal training classes to all employees and contract workers Showing the external presentations to core team: Showing the presentations down loaded from different forums to create the awareness among the core team members Providing Training on SEU and its Variables: Identification of significant energy uses and providing awareness training to the concerned on the variables & controls affecting the SEU Deputing the staff to External Seminars: Improving the knowledge by deputing the employees for external training classes /seminars conducted by BEE, CII,TERI, BSI etc Display of awareness posters: Display of energy policy, resource conservation and GHG awareness posters with in the plant for immediate attention Utilizing the whatsapp for sharing the Tips: Sharing the energy conservation tips and best practices through whatsapp

28 Energy Conservation Day-2017 celebrations Creating awareness among the Future generation by conducting Drawing, Quiz and Debate Competition Creating awareness among the Employees and Contract workmen by Oath taking, Awareness Classes and Quiz Competition Rewarding Employee Contribution and Prize Distribution to Winners Group photo With Winners

29 Extent of team work EnMS Structure: NBVL-CPP has formed a team for implementation of EnMS, the team under the guidance of MR and Designated Energy manager will work for resource conservation, implementation of projects and action plans Y Pattanaik Unit Head V Rama Krishna Head - PP C Thakur Certified Energy Auditor B J Rao Certified Energy Manager M K Patra Certified EnMS lead Auditor / MR N SK SK Rao Certified EnMS lead Auditor S K Nanda Certified Energy Auditor B J Rao Chief-Boiler (O&M) M K Patra Chief- TG (O&M) K Srinivasa Rao Chief-E&I (O&M) N Prabhakar Chief - Utility S K Dash S K Nanda C Pradhan A P Singh B Padhi M B Rao M R Bhutia D B Lalla M Gadnayak N Swain R K Sahoo P Maharana Shop Floor / Workmen Representatives A P Singh Certified Energy Auditor

30 Workers and Employees Involvement Title of the Project Identified By Year of Identification Replacing the 22 kw pump with Mechanical existing old 15 kw pump at Ash Fitter settling pit near silos Providing window opening at BFP area in U-2 for utilizing day light Engineer Changing bed ash conveying system operation from timer mode to probe mode in U-2 Boiler 2nd class operator Modification of ESP Hopper Heater area and providing thermal insulation Supervisor Replacing of 4 nos. 18 W Gate lamps with 2 no of 15 W LED at PP Entrance gate Electrician Providing Booster pump in Unit2 ACW line Supervisor

31 Learning from EnMS (ISO 50001:2011) Minor Non-conformities raised by EnMS External Auditor in last two assessments: Non - Conformity Identified Corrective and Preventive Action Taken An energy monitoring and measurement equipment for Compressors, CHP and other places which are the key characteristics of its operation that determine energy performance have not been put in place Providing suitable measuring instruments and monitoring the energy performance of all identified significant energy uses The findings of the internal audits though are good and focused on the energy performance, the closure of these non conformities are based on corrections and not on corrective action and preventive action for non occurrence is not evident Refresher training was provided on Auditing process, identification NC's/Observation and subsequent actions to be taken for closure & verification of effectiveness Individual Energy Review of Coal Handling Plant not evidenced. (Defined Boilers and CHP as a single energy segment so significant energy uses of CHP has not been identified) Identifying CHP as a separate Energy planning segment and conducting Separate Energy Review, identifying Significant energy Uses Energy performance Indicators, Objective & targets and establishing action plans to achieve objectives.

32 CSR Activities We make constant efforts for development of communities around our plant and our CSR initiatives focus on Education, Health and Livelihood Education: Providing Grant Aid, Library books, Play and Lab equipments to Brahmani Public School Donating Furniture and Distribution Of Blankets to Sibapur sevasram students Construction of boundary wall to Govt. and private schools Development of Play ground and Construction of Toilets in near by schools Health: Conducting Rural Health, Free Diabetic, Eye Checking, Dental and Blood Donation Camps Construction of community health center Providing safe drinking water by construction of RO plant Livelihood: Plantation of Medicinal plants, Installation of Bore well, Providing Street Lights, Construction of Drains and bus shelter, Distributing required aids to differently abled, Supply of Fly Ash Bricks to villagers & Schools

33 Environmental concern Installation of Ambient Air Quality Monitoring Stations and its real time data transmission to PCB server Installation of On-Line Effluent Monitoring System and real time data transmission to PCB server Installation of Ammonia dosing system in both the Units to reduce stack emissions Installation of dust extraction system at Unit-2 CHP secondary crusher house Providing Water Spray System for fugitive dust suppression at applicable areas Providing Atomizing water spray nozzles at fly ash and coarse ash Silos Installation of Oil traps at LDO pump house, coal stacking system (CSS), gate-5 area and Unit-3 GT yard Construction of Silt catch Pits at applicable areas Installation of 100 m3/day Sewage Treatment Plant using Bio-digester and Phytorid Technology Green belt development and tree plantation

34 Tree Plantation NBVL taken a initiative towards plantation & development of green belt in and around the Plant area, Peripheral villages and development of social forestry. No. of trees planted so far : Survival percentage : 94.4 % Sapling Distribution Plantation At Balanda Mine Void Plantation With in the Fence Plantation At Nimidha Ash Pond Plantation Beyond the Fence Plantation in 42 Acres of Land-DKL Plantation By MP at Balanda NBVL Own Nursery

35 Green Belt in and around the Plant

36 Floral Beauty with in the Plant

37 Eco Friendly Environment

38 Park Developed at Balanda Mine Void NBVL developed a park by filling abounded mine void with fly ash at Balanda Village of Angul Dist., Odisha.

39 Excellence Endorsed Resources Management: National Award for Excellence in Energy Management for the years , & from Confederation of Indian Industries. National Award for Excellence in Water Management for the years , & from Confederation of Indian Industries. Environmental Management: Pollution Control Excellence Award for the years 2007, 2013 & 2015 from State Pollution Control Board, Odisha. Prakruthi Mithra award for 2011 from Odisha Forest and Environment Department. Safety: Best Performance in Safety & Environment Management for the years 2011, 2012, 2013 & 2015 from Director of Factories & Boilers, Odisha. State Safety Awards in for the years 2007, 2008,2009, 2011 & 2012 from Director of Factories & Boilers, Odisha. State Safety Awards in different categories for the years 2012, 2013,2014,2016 & 2017 from Director of Factories & Boilers, Odisha.

40 Thank You for your Attention Team- Rescon (CPP)