Energy Efficiency Management TATA POWER Trombay Unit-7 18 th National Energy Efficient Management Award th Aug 1 st Sept 2017, CII- Hyderabad

Transcription

1 Energy Efficiency Management TATA POWER Trombay Unit-7 18 th National Energy Efficient Management Award th Aug 1 st Sept 2017, CII- Hyderabad 1

2 Vision of our founder Mr. Jamsetji Tata Mr. Jamsetji Nusserwanji Tata ( 3 rd March th May 1904 ) "Cheap and abundant electric power is one of the basic ingredients for the economic progress of a city, a state or a country" 2

3 The Tata Power Company Limited Completed Centenary Year India's largest integrated power company with presence across the entire value chain fuel sourcing, fuel logistics, generation, transmission, distribution, power trading, power services (O & M), solar panel manufacturing. Founded in 1906 to supply power to Mumbai»First hydro plant commissioned in 1915 at Khopoli»Set up thermal power plants in Mumbai in 1950s Expanded in India after private sector reforms in 1990s 30 % of the total installed Generation Thrust on renewable including hydro, wind, capacity solar and geothermal Successful Public Private Partnerships in generation, transmission and distribution Total Installed Generation Capacity MW Solar Wind Hydro a Thermal Generation Capacity 7322 MW Green Generation Capacity 3144 MW Waste Heat 936 MW 1140 MW 693 MW 375 MW 3

4 Technology Pioneers in Indian Power Industry First 150 MW thermal unit Electricity to Mumbai, way back in 1915 First 500 MW thermal unit Trombay Flue Gas Desulphurisation plant using sea water 220 kv Computerized grid control and energy management system transmi ssion lines in four circuit towers 220 kv Cable Transmission Network SCADA and Fiber Optic ground wire communication First gas insulated switch gear First 800 MW Pump thermal unit storage unit in the country of 150 MW Capacity 4

5 Trombay Thermal Power Station Trombay Operations & Specific Energy Consumption 5

6 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, Oil Total Generation Capacity : 1430 MW 6

7 Technology Adopters in Energy Management Key Energy Management Initiatives At Trombay 7

8 GHR & NHR Kcal/kwh Loading Factor % Specific Energy Consumption for last Four Years 2400 Unit Gross Heat Rate Unit Net Heat Rate Loading Factor 100% % 94% Open Cycle operation 1023 Hrs. 80% % 90% 80% % % 50% % 8

9 Benchmarking 9

10 Benchmarking Parameters ( 180 MW UNIT 7) HEAT RATE UoM NTPC (Faridabad) Best Performance Tata Power Trombay Unit 7 Actual Heat Rate Kcal/kwh Deviation in Heat rate Kcal/kwh 45 On Monthly Basis best achieved Heat Rate Kcal/KWH- Jan 12 Auxiliary Power Consumption UoM NTPC (Faridabad) Best Performance Tata Power Trombay Unit 7 Actual Auxiliary Consumption % Deviation in Auxiliary Consumption % - 10

11 Energy Saving Projects 11

12 Energy Saving Projects : FY14 and FY 15 Energy Saving Projects Implemented Annual Savings Rs Million Investment. Rs Million Replacement of Fencing Lights with LED lights Attending Flue gas leakages in HRSG Replacement of OTC thermocouple Coro coating of CW Pumps Total

13 Energy Saving Projects : FY16 and FY 17 Energy Saving Projects Implemented Achieving higher generation on Diffusion mode at low gas supply pressure (Instead of lower generation on Premix mode) Modification in Gas Turbine SADC & subsequently increasing the GT exhaust temperature (OTC) set point Installation of VFD for LP BFP (13 Days Saving) Energy monitoring system of lighting and ACs Savings Rs Million Investment. Rs Million 7.60 Nil 2.84 Nil Nil Total

14 Energy Saving Projects Planned In Next Three Years Energy Saving Projects Planned Savings Rs Million Investment. Rs Million Reduction of HRSG Exhaust Loss by Diverter Seal replacement HRSG Insulation repair Installation of VFD for CEP Installation of VFD for HMP Overhauling of HPBFP ARC valve Total

15 Energy Saving Project :Achieving higher generation on Diffusion mode at low gas supply pressure Idea description : Heat rate Saving during low fuel gas supply pressure, by higher Operating at higher Load on diffusion mode instead of reduced generation on Premix mode. Before: Unit was operated on lower load during low gas supply Pressure. After : Unit was operated on higher load during low gas supply Pressure on diffusion load. KPI impacted Savings (Rs. Million) Investment (Rs. Million) Payback Gross Heat Rate 14.29* *- Saving Calculated for FY16 & FY17 NIL NA KPI impact Low Operating Load & High Heat Rate 15

16 Energy Saving Project :Achieving higher generation on Diffusion mode at low gas supply pressure High Gen due to Premix to Low Generation on Premix Mode Diffusion Changeover with low gas Press Premix mode of Operation with low gas Press 16

17 1 Energy Saving Project :Achieving higher generation on Diffusion mode at low gas supply pressure UoM MU MU MU % MT Mkcal/MT Mkcal Kcal/Kwh Kg/MWH MU DATE GTG Gen STG Gen TOTAL PLF GAS Cons CV Heat HR SGC APC % % % Excess Gen Excess Heat HR Saved Mkcal SGC reduction For 1 Day UOM FY 16 FY 17 Total Running Hrs on Diffusion Mode No of Days on Diffusion Mode Total Mkcal Saved Calorific Value of Gas for FY Total MT saved Rs/Mkcal for FY Total Saving in Rs Million FY16 Gross Gen Annual GHR Reduction

18 Energy Saving Project : Installation of VFD for LP BFP Idea description : Auxiliary Consumption Saving by Installing VFD for LP BFP. Before: LPBFP was running with constant speed motor with Current 83.2 Amp (415 Volt) After : LPBFP was running with VFD which drawing current 65 Amp (415 Volt) KPI impacted Savings (Rs. Million) Investment (Rs. Million) Payback Period Months Auxiliary Consumption KPI impact Auxiliary Consumption 18

19 Energy Saving Project : Installation of VFD for LP BFP Load STG (MW) RPM Frequency (Hz) (MP under ISO 50001) Project Results CV Opening (%) Pressure (bar) I/P Voltage (Volts) I/P Current (Amp) I/P KW PRE % POST % Calculations Power Saving 11.1 KW per hr. FY 17 Saving period 365 Days Energy saved in FY Kwh Energy Rate as per Tariff Order 2.36 Rs/Kwh Total Savings/Annum 2.29 Rs. Lakhs Investment 3.12 Lakhs Payback Period 16 Months This project got implemented in the month of March-17 19

20 Trombay Unit 7 Innovative Project Modification in Gas Turbine SADC & subsequent increase of GT exhaust temp (OTC) set point 20

21 Energy Saving Project :Modification in Gas Turbine SADC & subsequent increase of GT exhaust temp (OTC) set point Idea description : 1) Reducing NOx emission and 2) Subsequently Increasing GT exhaust temperature (OTC) set point resulting in increased STG generation. Before: 1) Oil firing circuits were de-commissioned in 2013 but SADC was still in operation which contributing to bypass air flow. 2) Outlet temperature calculation for OTC was derived from MBA thermocouples. After : 1) Bypass air openings were closed and locked. 2) Outlet temperature calculation for OTC is derived from mainly MBR thermocouples with minor correction from MBA T/C s. KPI impacted Savings (Rs. Million) Investment (Rs. Million) Payback Gross Heat Rate 3.04* NIL NA KPI impact *Saving Calculated for FY16 & FY17 Heat Rate & APC Low Operating Load & High Heat Rate 21

22 Energy Saving Project : Modification in Gas Turbine SADC & subsequent increase of GT exhaust temp (OTC) set point BYPASS AIR PATH BELOW EACH BURNER SADC WINDOWS BLANKED (CC- INT VIEW) Lowered NOx emissions NOx not to exceed 150 ppm (MPCB Norm) Premix mode Diffusion mode Before: 117MW--> 27 ppm. Before: 115MW--> 140 ppm. After 117MW--> 13ppm After 115MW--> 125ppm 22

23 Energy Saving Project : Modification in Gas Turbine SADC & subsequent increase of GT exhaust temp (OTC) set point SLOW RESPONSE MBA THERMOCOUPLE FAST RESPONSE MBR THERMOCOUPLE Benefits: Increase in STG Generation with same GTG Generation because of release of higher temperature at GT exhaust in view of fast response T/C s available at MBR plane More stable temperature profile as reading at MBR location as compared to MBA location. Stable operation and Reduction in maintenance 23

24 Energy Saving Project : Modification in Gas Turbine SADC & subsequent increase of GT exhaust temp (OTC) set point BEFORE MBR Correction AFTER 24

25 Energy Saving Project : Modification in Gas Turbine SADC & subsequent increase of GT exhaust temp (OTC) set point UOM MUS MT Mkcal/MT MKCAL Kcal/KWh PARAMETER GTG GEN STG GEN TOTAL Gas cons/day CV Heat Heat Rate POST PRE Excess Gen Heat Rate Improvement 10 Mkcal Saved for the day POST PRE Excess Gen Heat Rate Improvement 10 Mkcal Saved for the day POST PRE Excess Gen Heat Rate Improvement 13 Mkcal Saved for the day FY 17 Wt. Avg MkCal Saved per day Mkcal Saved per day No of days having PLF greater than 102% 69 Total Mkcal Saved 3454 Calorific Value of Gas for FY Total MT saved 262 Rs/Mkcal for FY Total Saving in Rs Million 2.84 FY17 Gross Gen 1413 Annual GHR Reduction 2.44 Zero Investment Innovative Project

26 ENCON Methodology & Involvement of All 26

27 En-Con Methodology Brain Storming Idea Generation Techno- Commercial Feasibility Study Implementation of Idea Procurement Budgeting & Planning Idea Presentation & review by Management Fine Tuning & Optimisation Evaluation of the Results Sharing & Reporting to Management 27

28 How it all fits together. Logic Emotions Vision Result 28

29 Source of Idea Generation & Involvement of All Sr. No. Source of En-con Idea* Source 1 Replacement of OTC thermocouple 2 3 Coro-coating of Unit-7, 6.6 KV Cooling Water pumps at jetty Achieving higher generation on Diffusion mode at low gas supply pressure Discussions with OEM Horizontal Deployment of idea Discussions with OEM Idea Originated in FY** Extent of Manpower Involved* 02 Engineers, 01 Supervisor 02 Workmen 02 Engineers 01 Supervisor 08 Workmen Engineers Progress of Implementation Successfully Implemented Successfully Implemented Successfully Implemented 4 Modification in Gas Turbine SADC & subsequently increasing the GT exhaust temperature (OTC) set point Discussions with OEM Engineers 01 Supervisor 02 Workmen Successfully Implemented 5 Installation of VFD for LP BFP MP ISO under Project Sankalp Energy monitoring system of lighting and ACs MP ISO Engineers, 01 Supervisor 02 Workmen 02 Engineers, 01 Supervisor Contractors Successfully Implemented in FY17 Successfully Implemented in FY17 # Sources of Idea Generation: Audits, Brain Storming, Suggestion schemes/competitions, CFTs, Core Groups, Discussions with OEMs & Periodic Reviews. 29

30 ISO 50001:2011 Certification 30

31 Certificate Completed first Surveillance Audit in month of July-17 31

32 UNIT-7 Monitoring & Analysis 32

33 Online Monitoring : Auxiliary Power Consumption-(Replication from other Units) IN House Prepared Mus % of APC Date : 20-Jul-17 Mus % of APC CWP % Major Auxiliaries CEP % UNIT 7 Auxiliary Consumption % Generation (Mus) % HP BFP % FAA % Mus % % UST 7A % UST 7B % PLF % % SST 7A % TOTAL % SST 7B % GTG % STG % % Miscellaneous % % of Total Aux Consumption Excitation system % Mus "Energy Management System - Unit 7" Environment 415 V Auxiliaries TOTAL 33

34 Online Monitoring : AC & Lighting System of Plant Trombay AC & Lighting Monitoring System Date : 6-Aug-17 CHP 208 Station A Lighting 1296 Total Lighting load Unit#5 AC Plant Unit#5 Plant Lighting 4346 Total AC & Lighting Load Unit#6 Plant AC Unit#6 Plant Lighting 2123 Unit#7 Plant AC 1528 Total AC Load Unit#7 Plant Lighting Unit#8 Plant AC 2064 For Unit-7 Unit#8 Plant Lighting

35 Online Monitoring : Unit-7 Instant Parameters- IN HOUSE PREPARED :39 CONDENSER & CW PUMPS GTG MW STG MW TOTAL MW PREMIX DIFFUSION VACCUM bar Back Gas Make Up Kg/S Pressure Bar Flow M3/Hr Gas Flow TPH ON OFF CW Inlet Temp CW Outlet Temp CW Temp Diff Condenser DP Bar Inlet Valve Position % Outlet Valve Position % Debris Filter DP mbar VP-1 Temp & Status VP-2 Temp & Status Vaccum Bar TOP BOTTOM ON ON GAS & FLUE GAS Compressor CEP FWT, LP Drum & HP Drum LPBFP & LP Steam HPBFP GAS Press CV Position % FG Supply Pressure Bar FG Pressure Bypass Stack After CV Bar Temp Damper Position % FG HRSG Inlet Temp FG HP Evap I/L Temp FG HP Evap O/L Temp FG LP Evap I/L Temp FG LP Evap O/L Temp SGC MT/KWH Compressor Efficiency % Compr Inlet Pressure mbar Compr Inlet Temp IGV Position % Compr Outlet Pressure Bar Compr Outlet Temp DP Comb Chamber-L mbar DP Comb Chamber-R mbar Pressure Ratio Air Flow TPH Intake DP mbar FG HRSG O/L Temp Colascre Filter DP-1 mbar CWP-7A Disc Press CWP-7B Disc Press CW Pump- 7A Current CW Pump- 7B Current CW Pump- 4A Current CW Pump- 4B Current Pre Filter DP-2 mbar Hotwell Level mm CEP 7A Current Amp CEP 7B Current Amp CEP 7A Strainer DP Bar CEP 7B Strainer DP Bar CEP Discharge Pressure Bar CEP Discharge Temp CEP Discharge Flow Kg/S Discharge Pressure After CV % OFF ON OFF ON Temp at CPH I/L Temp at CPH O/L FWT Level mm FWT Pressure Bar FWT Temp LP Drum Pressure Bar LP Drum Sat Temp HP Drum Pressure Bar HP Drum Sat Temp OFF ON OFF ON LP-7A Speed LP-7A Current Amp LP-7A Discharge Pr Bar LP-7B Speed LP-7B Current Amp LP-7B Discharge Pr Bar LP Header Pressure Bar LP Header Temp LP Header Flow Kg/S CCWP-1 Status Booster Pump-1 Status LP Steam Press Ahead ESV Bar CCWP-2 Status Booster Pump-2 Status LP Steam Flow Kg/S HP-7A Current Amp HP-7A Disch Pr Bar HP-7A Leak off Pr Bar HP-7B Current Amp HP-7B Disch Pr Bar HP-7B Leak off Pr Bar HP Header Pressure Bar HP Header Flow Kg/S HP Eco-1 O/L Temp HP ECO-2 O/L Pr Bar HP ECO-2 O/L Temp CCWP-3 Status Booster Pump-3 Status LP Steam Turbine inlet temp Fine Filter DP-3 mbar CCWP-4 Status Booster Pump-4 Status HP FCV 30% HP FCV 100% % CW Pumps HP Steam HP Steam Press before DSH Bar HP Steam Temp before DSH HP Steam Temp after DSH DESH Line Flow Kg/Sec Final SH Temp HP Steam Pressure Ahead ESV Bar HP Steam Flow Kg/S HP steam Temp before Valve-1 HP steam Temp before Valve-2 HP Control Valve-1 Position % HP Control Valve-2 Position % IP Exhaust Temp HP FCV 100% BYPASS

36 Online Monitoring : Unit-7 Performance Parameters Comparison-IN HOUSE PREPARED '\\trombaypi\tr U7 GTG MW FINAL'> h PARAMETER UOM PRE POST DEVIATION GTG LOAD MW STG LOAD MW TOTAL LOAD MW Vaccum BAR Back Pressure BAR COMPRESSOR PARAMETER Compressor Inlet Pressure mbar Compressor Inlet Temperature Deg C Compressor Outlet Pressure Bar Compressor Outlet Temperature Deg C Pressure Ratio Compressor Efficiency % 89.7% 86.6% -3.13% Total Air Flow TPH Inlet Guide Vane Position % Combustion Chamber DP-L mbar Combustion Chamber DP-R mbar Overall Intake DP across Filters mbar Coalescer Filter DP mbar Pre Filter DP mbar Fine Filter DP mbar '\\trombaypi\tr U7 GTG MW FINAL'> h PARAMETER UOM PRE POST DEVIATION CONDENSER TOP SIDE CW Inlet Temp Deg C CW Outlet Temp Deg C CW Temp Difference Deg C Condenser DP MBAR CW Inlet Valve Position % CW Outlet Valve Position % Debris filter DP MBAR CONDENSER BOTTOM SIDE CW Inlet Temp Deg C CW Outlet Temp Deg C CW Temp Difference Deg C Condenser DP MBAR CW Inlet Valve Position % CW Outlet Valve Position % Debris filter DP MBAR CW PARAMETER CWP-7A Discharge Pressure Bar CWP-7ABDischarge Pressure Bar CWP-7A Motor Current Amp CWP-7B Motor Current Amp GAS PARAMETER Gas Flow M3/HR Gas Flow TPH Specific Gas Consumption Kg/MWH Fuel Gas Supply Pressure BAR

37 Online Monitoring : Unit-7 Performance Parameters Comparison-IN HOUSE PREPARED '\\trombaypi\tr U7 GTG MW FINAL'> h PARAMETER UOM PRE POST DEVIATION HOTWELL TO FWT CEP-A Motor Current AMP CEP-A Strainer DP mbar CEP-B Motor Current AMP CEP-B Strainer DP mbar Condensate Header Temperature Deg C Condensate Header Pressure Bar Condensate Flow Kg/S Condensate Temp at CPH Inlet Deg C Condensate Temp at CPH Outlet Deg C Temp Gain Across CPH Deg C Feed Water Tank Pressure BAR Feed Water Tank Temperature Deg C LP CIRCUIT LPBFP-A Motor Current Amp LPBFP-A Discharge Pressure Bar LPBFP-B Motor Current Amp LPBFP-B Discharge Pressure Bar LP FW Header Temperature Deg C LP FW Header Pressure Bar LP FW Flow Kg/S LP Drum Pressure Bar LP Drum Saturation Temp Deg C LP Steam Flow Kg/S LP Steam Pressure BAR LP Steam Temperature Deg C Temperature Gain Across LP SHtr Deg C '\\trombaypi\tr U7 GTG MW FINAL'> h PARAMETER UOM PRE POST DEVIATION HP CIRCUIT HPBFP-A Motor Current Amp HPBFP-A Discharge Pressure Bar HPBFP-B Motor Current Amp HPBFP-B Discharge Pressure Bar HP FW Header Temperature Deg C HP FW Header Pressure Bar HP FW Flow Kg/S HP FW Temperature at ECO-2 Outlet Deg C HP FW Pressure at ECO-2 Outlet Deg C Temperature Gain Across ECO-1 & ECO-2 Deg C HP Drum Pressure BAR HP Drum Saturation Temp Deg C Temperature Gain Across HP Evaporator Deg C HP Steam Temperature at SH-1 O/L Deg C Temperature Gain Across HP SH-1 Deg C HP Steam Temperature at SH-2 I/L Deg C HP Steam Temperature at SH-2 O/L Deg C Temperature Gain Across HP SH-2 Deg C SH Spray Kg/S Temperature drop at DSH Station Deg C HP Steam Flow Kg/S HP Steam Pressure BAR HP Steam Boiler Outlet Deg C HP Steam Turbine Inlet Deg C

38 KCAL / KWH Monthly Review STATION HEAT RATE (KCAL /KWH) YTD FY18 YTD FY ABP FY18 FY 18 (Plan) 2370 Year FY17 FY 17 (Actual) 2337 FY 18 (Actual) April May June July Aug Sept Oct Nov Dec Jan Feb Mar ABP FY FY

39 % Monthly Review 6.8% 6.5% STATION AUXILIARY CONSUMPTION (%) 6.3% 6.0% 5.89% 5.8% 5.64% 5.5% 5.3% 5.38% 5.0% 4.8% 4.5% 4.3% 4.0% YTD FY18 YTD FY % ABP FY18 FY 18 (Plan) 5.89% Year FY17 FY 17 (Actual) 5.64% FY 18 (Actual) 5.01% 5.33% 5.60% 5.67% April May June July Aug Sept Oct Nov Dec Jan Feb Mar ABP FY % 5.51% 5.59% 6.33% 6.14% 5.95% 5.77% 5.91% 5.84% 5.99% 6.09% 5.95% FY % 5.5% 5.5% 5.8% 5.7% 5.8% 5.5% 5.5% 5.6% 6.4% 5.9% 5.2% 39

40 Eco Affection & Carbon Emission Reduction projects 40

41 Care For Environment- Resource Conservation (Water) Reduction in Unit 7 Specific Make Up Water Consumption Specific Water Consumption M3/MU FY09 FY10 FY11 FY12 FY13 FY14 FY15 FY16 FY17 Specific Water Consumption for Trombay Site for FY17: M3/MWH 41

42 Care for Environment : Water Management Series of surface aerators are placed in the discharge channel to reduce the temperature of cooling water. Treated sewage is collected in storage tanks from where it is pumped up to coal berth and used for coal dust suppression by using sprinkler system. This has reduced consumption of equivalent amount of fresh water. 42

43 Care For Environment- Renewable & Energy Conservation Project Usage of Light Pipes in Training Centre Usage of LED Lights in Compound Wall 43

44 Care For Environment- Waste Management Recycling of waste papers Use of Bottom Ash in Landscape Garden and Brick Making Oil Filters to Reduce Generation of Waste Oil 44

45 Care For Environment- Waste Management Use of Scrap Steel within the plant Before After 45

46 Care For Environment- Waste Management Construction of 4 Nos. of Beautiful Garden in place of un-used, scraped stored, jungle like area. Material Used-Bottom ash, Ash Clinkers, Old RCC precast slabs / tiles, Old structural steel is used to fix the gate for garden. Saving Lakhs. 46

47 Care For Environment- Waste Management (Place to Store Oil Drums) 47

48 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 48

49 Care For Environment- Renewable & Energy Conservation Project Solar Panels Hybrid Unit 1KW Solar wind mill Wind Turbine Knowledge adopted from FY 15 CII Award Innovative products Located at O & S building terrace Tube lights ( 7 Nos of 40W ) sourced by the hybrid Unit 49

50 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 50

51 Waste Management Re-Use of Bio-degradable Waste Awareness Execution Bio-degradable waste for organic gardening in colony Outcome Awareness and training sessions for organic waste utilization were arranged in colony Organic waste generated at colony was used for growing nutrient rich vegetables Chemical pesticide free vegetables 51

52 Care For Community & Customers Energy conservation Awareness Program Energy conservation campaign are done by Trombay Employees voluntarily at many Schools, Colleges, Housing Societies & Offices in Mumbai. Science Laboratory at Chembur Welfare Marathi School Mobile Medical Van Energy Conservation and Electrical Safety Tree plantation drive Employee Voluntary Program 52

53 Website : ID : rautpv@tatapower.com CONTACT NO :