Energy Efficiency Management TATA POWER Trombay Unit-7 18 th National Energy Efficient Management Award 2017 30 th Aug 1 st Sept 2017, CII- Hyderabad 1
Vision of our founder Mr. Jamsetji Tata Mr. Jamsetji Nusserwanji Tata ( 3 rd March 1839-19 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
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 10466 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
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
Trombay Thermal Power Station Trombay Operations & Specific Energy Consumption 5
Trombay: Present Generation Capacity Established in 1956 Unit Year Capacity (MW) Fuel Used Unit 5 1984 500 Coal, Oil & Gas Unit 6 1990 500 Oil & Gas Unit 7 (CCPP) 1993-94 120+60 = 180 Gas Unit 8 2009 250 Coal, Oil Total Generation Capacity : 1430 MW 6
Technology Adopters in Energy Management Key Energy Management Initiatives At Trombay 7
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% 2300 2200 94% 94% Open Cycle operation 1023 Hrs. 80% 2194 91% 90% 80% 2100 2136 70% 2000 1900 1998 2052 1968 2019 1996 2056 60% 50% 1800 2013-2014 2014-2015 2015-2016 2016-2017 40% 8
Benchmarking 9
Benchmarking Parameters ( 180 MW UNIT 7) HEAT RATE UoM NTPC (Faridabad) Best Performance Tata Power Trombay Unit 7 Actual Heat Rate Kcal/kwh 1915 1960 Deviation in Heat rate Kcal/kwh 45 On Monthly Basis best achieved Heat Rate- 1922.3 Kcal/KWH- Jan 12 Auxiliary Power Consumption UoM NTPC (Faridabad) Best Performance Tata Power Trombay Unit 7 Actual Auxiliary Consumption % 2.3 2.3 Deviation in Auxiliary Consumption % - 10
Energy Saving Projects 11
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 1.4 0.5 Attending Flue gas leakages in HRSG 0.3 1.3 Replacement of OTC thermocouple Coro coating of CW Pumps 38.4 2.5 5.1 20 Total 45.2 24.3 12
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 0.008 3.12 - Nil Total 10.448 3.12 13
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 4.75 1.5 1.41 5.86 Installation of VFD for HMP 0.07 0.1 Overhauling of HPBFP ARC valve 3.34 9.0 Total 9.57 16.46 14
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
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
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 24-09-14 2.237 1.443 3.68 85.2% 561.9 13.098 7359.5 1999.9 152.68 0.09 26-09-14 2.480 1.517 3.997 92.5% 603.5 13.102 7907.9 1978.5 151.00 0.086 27-09-14 2.411 1.503 3.914 90.6% 591.8 13.101 7753.9 1981.1 151.21 0.085 Excess Gen Excess Heat HR Saved Mkcal SGC reduction 0.317 548.39 21.41 85.562 1.69 0.234 394.47 18.78 73.501 1.47 For 1 Day 20.29 79.594 1.60 UOM FY 16 FY 17 Total Running Hrs on Diffusion Mode 70 116 No of Days on Diffusion Mode 1681 2785 Total Mkcal Saved 5575 9236 Calorific Value of Gas for FY 16 13 13.17 Total MT saved 425 702 Rs/Mkcal for FY16 1201 822 Total Saving in Rs Million 6.69 7.60 FY16 Gross Gen 1180 1413 Annual GHR Reduction 4.73 6.54 17
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 0.229 0.312 16 KPI impact Auxiliary Consumption 18
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 65 2959 50.0 47% 27 423 83.2 57.7 POST 65 2700 45.8 60% 23.5 415 65.0 46.6 Calculations Power Saving 11.1 KW per hr. FY 17 Saving period 365 Days Energy saved in FY17 97236 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
Trombay Unit 7 Innovative Project Modification in Gas Turbine SADC & subsequent increase of GT exhaust temp (OTC) set point 20
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
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
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
Energy Saving Project : Modification in Gas Turbine SADC & subsequent increase of GT exhaust temp (OTC) set point BEFORE MBR Correction AFTER 24
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 20-10-16 2.837 1.610 4.447 656 13.175 8638 1943 PRE 29-05-13 2.838 1.596 4.434 658 13.157 8659 1953 Excess Gen -0.001 0.014 Heat Rate Improvement 10 Mkcal Saved for the day 46.16 POST 15-10-16 2.800 1.610 4.409 651 13.18 8575 1945 PRE 18-05-13 2.800 1.565 4.365 649 13.16 8532 1955 Excess Gen 0.000 0.045 Heat Rate Improvement 10 Mkcal Saved for the day 43.55 POST 19-10-16 2.856 1.622 4.478 658 13.18 8673 1937 PRE 13-05-13 2.856 1.585 4.441 660 13.13 8662 1950 Excess Gen 0.000 0.037 Heat Rate Improvement 13 Mkcal Saved for the day 60.34 FY 17 Wt. Avg MkCal Saved per day 50.06 Mkcal Saved per day 50.06 No of days having PLF greater than 102% 69 Total Mkcal Saved 3454 Calorific Value of Gas for FY 17 13.17 Total MT saved 262 Rs/Mkcal for FY17 822 Total Saving in Rs Million 2.84 FY17 Gross Gen 1413 Annual GHR Reduction 2.44 Zero Investment Innovative Project
ENCON Methodology & Involvement of All 26
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
How it all fits together. Logic Emotions Vision Result 28
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** 2013-14 2013-14 Extent of Manpower Involved* 02 Engineers, 01 Supervisor 02 Workmen 02 Engineers 01 Supervisor 08 Workmen 2015-16 04 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 2015-16 02 Engineers 01 Supervisor 02 Workmen Successfully Implemented 5 Installation of VFD for LP BFP MP ISO 50001 under Project Sankalp 2016-17 6 Energy monitoring system of lighting and ACs MP ISO 50001 2016-17 02 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
ISO 50001:2011 Certification 30
Certificate Completed first Surveillance Audit in month of July-17 31
UNIT-7 Monitoring & Analysis 32
Online Monitoring : Auxiliary Power Consumption-(Replication from other Units) IN House Prepared Mus % of APC Date : 20-Jul-17 Mus % of APC CWP 0.0282 25.06% Major Auxiliaries CEP 0.0083 7.38% UNIT 7 Auxiliary Consumption 0.113 2.57% Generation (Mus) 0.070 62.09% HP BFP 0.0334 29.65% FAA 0.00 0.00% Mus 0.000 0.00% % UST 7A 0.0069 6.13% UST 7B 0.0047 4.21% PLF % 0.015 13.26% SST 7A 0.0016 1.45% TOTAL 4.383 101% SST 7B 0.0016 1.46% GTG 2.830 98% STG 1.553 108% 0.088 78.31% Miscellaneous 0.024 21.69% % of Total Aux Consumption Excitation system 0.0033 2.96% Mus "Energy Management System - Unit 7" Environment 415 V Auxiliaries TOTAL 33
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 0 10523 Unit#5 Plant Lighting 4346 Total AC & Lighting Load Unit#6 Plant AC 9 14124 - Unit#6 Plant Lighting 2123 Unit#7 Plant AC 1528 Total AC Load Unit#7 Plant Lighting 455 3601 Unit#8 Plant AC 2064 For Unit-7 Unit#8 Plant Lighting 2095 34
Online Monitoring : Unit-7 Instant Parameters- IN HOUSE PREPARED 21-07-17 12:39 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 121 66 186 ON OFF -0.893 0.121 0.29 40582 29.7 153 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 27.9 37.8 9.9 0.93 98.7 73.4 103.5 43.2 36.1-0.888 BOTTOM 28.3 38.2 9.9 0.89 99.3 68.3 97.0 ON ON -0.893 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 % 61 18.5 15.0 185 101 544 453 283 242 192 112 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 1.89 0.01 CW Pump- 7A Current CW Pump- 7B Current CW Pump- 4A Current CW Pump- 4B Current Pre Filter DP-2 mbar 920.7 28.8 92.0 9.34 340.9 175.8 179.1 10.14 1755 7.94 3.12 2.24 2.91 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 % 1055 28 0 0.126 0.044 22.5 49.8 67.5 9.2 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 50.7 164.2 1701 6.4 164.2 5.9 164.2 67.0 283.9 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 2618 68 23.6 32.8 1.7 21.0 21.2 162.4 12.0 5.8 11.7 214.7 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 59.4 0.0 0 71 Fine Filter DP-3 mbar CCWP-4 Status Booster Pump-4 Status HP FCV 30% HP FCV 100% 0 5.0 0.4 130.8 115.7 9.4 115.7 53.3 168.4 110.1 271.3 1 8 90.8% 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 63.9 437.7 416.4 1.4 523.5 62.7 54.2 519.1 519.4 99.5 99.8 55.9 48 35
Online Monitoring : Unit-7 Performance Parameters Comparison-IN HOUSE PREPARED '\\trombaypi\tr U7 GTG MW FINAL'>115 1-7-2017 29-7-2017 1h 22-7-2017 1-8-2017 PARAMETER UOM PRE POST DEVIATION GTG LOAD MW 119.5 119.5 0.0 STG LOAD MW 64.9 67.7 2.8 TOTAL LOAD MW 184 187 2.9 Vaccum BAR -0.890-0.924-0.034 Back Pressure BAR 0.123 0.080 0.043 COMPRESSOR PARAMETER Compressor Inlet Pressure mbar 921 996 75 Compressor Inlet Temperature Deg C 27 28 1.0 Compressor Outlet Pressure Bar 9.16 9.19 0.02 Compressor Outlet Temperature Deg C 338 337-1.07 Pressure Ratio 9.95 9.23-0.72 Compressor Efficiency % 89.7% 86.6% -3.13% Total Air Flow TPH 1740 1702-38 Inlet Guide Vane Position % 86.2 81.6-4.6 Combustion Chamber DP-L mbar 179 179-0.5 Combustion Chamber DP-R mbar 179 183 4.0 Overall Intake DP across Filters mbar 9.43 3.76-5.67 Coalescer Filter DP mbar 3.37 1.62-1.76 Pre Filter DP mbar 2.61 1.05-1.56 Fine Filter DP mbar 3.45 1.63-1.82 '\\trombaypi\tr U7 GTG MW FINAL'>115 1-7-2017 29-7-2017 1h 21-7-2017 1-8-2017 PARAMETER UOM PRE POST DEVIATION CONDENSER TOP SIDE CW Inlet Temp Deg C 28.4 28.8 0.3 CW Outlet Temp Deg C 39.2 38.9-0.3 CW Temp Difference Deg C 10.8 10.1-0.6 Condenser DP MBAR 0.798 0.234-0.6 CW Inlet Valve Position % 98.7 64.8-33.8 CW Outlet Valve Position % 67.8 25.2-42.7 Debris filter DP MBAR 100.6 85.3-15.4 CONDENSER BOTTOM SIDE CW Inlet Temp Deg C 28.9 29.1 0.2 CW Outlet Temp Deg C 38.5 38.6 0.1 CW Temp Difference Deg C 9.67 9.51-0.2 Condenser DP MBAR 0.758 0.550-0.21 CW Inlet Valve Position % 99.3 65.1-34.2 CW Outlet Valve Position % 64.6 31.0-33.6 Debris filter DP MBAR 73.3 77.0 3.7 CW PARAMETER CWP-7A Discharge Pressure Bar 1.72 1.80 0.1 CWP-7ABDischarge Pressure Bar 1.72 1.78 0.1 CWP-7A Motor Current Amp 60.5 60.9 0.4 CWP-7B Motor Current Amp 59.7 60.7 1.0 GAS PARAMETER Gas Flow M3/HR 40295 39370-925 Gas Flow TPH 29.4 28.7-0.7 Specific Gas Consumption Kg/MWH 153 149-3 Fuel Gas Supply Pressure BAR 22.6 18.0-4.7 36
Online Monitoring : Unit-7 Performance Parameters Comparison-IN HOUSE PREPARED '\\trombaypi\tr U7 GTG MW FINAL'>115 1-7-2017 29-7-2017 1h 22-7-2017 1-8-2017 PARAMETER UOM PRE POST DEVIATION HOTWELL TO FWT CEP-A Motor Current AMP 28.0 28.1 0.10 CEP-A Strainer DP mbar 0.126 0.129 0.00 CEP-B Motor Current AMP 23 22-0.59 CEP-B Strainer DP mbar 0.043 0.056 0.01 Condensate Header Temperature Deg C 50.3 43.2-7.02 Condensate Header Pressure Bar 22.5 22.7 0.15 Condensate Flow Kg/S 67.2 66.8-0.44 Condensate Temp at CPH Inlet Deg C 51.1 44.1-6.96 Condensate Temp at CPH Outlet Deg C 163.8 163.6-0.21 Temp Gain Across CPH Deg C 112.7 119.4 6.75 Feed Water Tank Pressure BAR 6.32 6.26-0.07 Feed Water Tank Temperature Deg C 164 163-0.37 LP CIRCUIT LPBFP-A Motor Current Amp 68 67-0.60 LPBFP-A Discharge Pressure Bar 23.3 25.2 1.87 LPBFP-B Motor Current Amp 71 0-71.39 LPBFP-B Discharge Pressure Bar 21.4 24.2 2.83 LP FW Header Temperature Deg C 162.1 161.2-0.88 LP FW Header Pressure Bar 21.5 23.8 2.25 LP FW Flow Kg/S 12.0 12.0 0.06 LP Drum Pressure Bar 5.8 5.8-0.03 LP Drum Saturation Temp Deg C 163.7 163.5-0.20 LP Steam Flow Kg/S 11.7 11.5-0.19 LP Steam Pressure BAR 5.5 5.5-0.01 LP Steam Temperature Deg C 217.2 221.7 4.55 Temperature Gain Across LP SHtr Deg C 53.5 58.2 4.76 '\\trombaypi\tr U7 GTG MW FINAL'>115 1-7-2017 29-7-2017 1h 22-7-2017 1-8-2017 PARAMETER UOM PRE POST DEVIATION HP CIRCUIT HPBFP-A Motor Current Amp 133 0-133 HPBFP-A Discharge Pressure Bar 111.6 114.8 3.22 HPBFP-B Motor Current Amp 132 134 2.10 HPBFP-B Discharge Pressure Bar 115.6 115.2-0.46 HP FW Header Temperature Deg C 166.9 166.6-0.26 HP FW Header Pressure Bar 115.7 115.5-0.21 HP FW Flow Kg/S 53.4 53.8 0.36 HP FW Temperature at ECO-2 Outlet Deg C 270.5 270.5-0.01 HP FW Pressure at ECO-2 Outlet Deg C 110.0 110.0-0.01 Temperature Gain Across ECO-1 & ECO-2 Deg C 103.6 103.9 0.25 HP Drum Pressure BAR 66.5 66.6 0.13 HP Drum Saturation Temp Deg C 283.4 283.5 0.11 Temperature Gain Across HP Evaporator Deg C 12.9 13.1 0.12 HP Steam Temperature at SH-1 O/L Deg C 437.7 438.2 0.52 Temperature Gain Across HP SH-1 Deg C 154.2 154.6 0.41 HP Steam Temperature at SH-2 I/L Deg C 401.5 404.3 2.82 HP Steam Temperature at SH-2 O/L Deg C 523.0 523.1 0.17 Temperature Gain Across HP SH-2 Deg C 121.5 118.8-2.65 SH Spray Kg/S 1.53 1.46-0.07 Temperature drop at DSH Station Deg C 36.2 33.9-2.30 HP Steam Flow Kg/S 54.0 54.3 0.25 HP Steam Pressure BAR 62.2 62.4 0.15 HP Steam Temperature @ Boiler Outlet Deg C 523.0 523.1 0.2 HP Steam Temperature @ Turbine Inlet Deg C 518.8 519.0 0.2 37
KCAL / KWH Monthly Review 2600 2550 STATION HEAT RATE (KCAL /KWH) 2500 2450 2400 2350 2351 2370 2337 2300 2250 2200 2150 2100 2050 2000 YTD FY18 YTD FY18 2351 ABP FY18 FY 18 (Plan) 2370 Year FY17 FY 17 (Actual) 2337 FY 18 (Actual) 2314 2336 2348 2415 April May June July Aug Sept Oct Nov Dec Jan Feb Mar ABP FY 18 2365 2361 2359 2402 2379 2368 2367 2375 2378 2335 2380 2368 FY 17 2334 2348 2367 2370 2341 2352 2316 2323 2383 2241 2330 2301 38
% 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 FY18 5.38% 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 18 5.75% 5.51% 5.59% 6.33% 6.14% 5.95% 5.77% 5.91% 5.84% 5.99% 6.09% 5.95% FY 17 5.7% 5.5% 5.5% 5.8% 5.7% 5.8% 5.5% 5.5% 5.6% 6.4% 5.9% 5.2% 39
Eco Affection & Carbon Emission Reduction projects 40
Care For Environment- Resource Conservation (Water) Reduction in Unit 7 Specific Make Up Water Consumption Specific Water Consumption M3/MU 35.000 31.387 30.000 25.000 20.000 15.000 21.7 17.4 14.9 19.1 15.4 20.4 20.7 12.0 10.000 5.000 FY09 FY10 FY11 FY12 FY13 FY14 FY15 FY16 FY17 Specific Water Consumption for Trombay Site for FY17: 0.216 M3/MWH 41
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
Care For Environment- Renewable & Energy Conservation Project Usage of Light Pipes in Training Centre Usage of LED Lights in Compound Wall 43
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
Care For Environment- Waste Management Use of Scrap Steel within the plant Before After 45
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 17.15 Lakhs. 46
Care For Environment- Waste Management (Place to Store Oil Drums) 47
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
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
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
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
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
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