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Transcript of 11.JSW Energy Limited, Ratnagiri...&RQIHGHUDWLRQ RI ,QGLDQ ,QGXVWU\ 7KDQN
© Confederation of Indian Industry
JSW Energy Limited, Ratnagiri
Sh. Dipak Patil AGM Sh. Vijaykumar Likhitkar Sr. Manager
© Confederation of Indian Industry2
© Confederation of Indian Industry
Brief introduction on Company/Unit
➢ JSW Energy Limited (JSWEL) was formed in theyear 1994 as the power generating company of O.PJindal Group of Industries.
➢ JSWEL is an integrated power producer havingpresence in the states of Karnataka, Maharashtra,Rajasthan and Himachal Pradesh.
➢ JSWEL has operational capacity of 4531 MW, withthe vision to achieve 10,000 MW in powergeneration by 2020.
➢ JSW Energy Limited, Ratnagiri is a part of JSWELand having a capacity of 4x300 MW at Jaigad inRatnagiri district of Maharashtra.
➢ Plant is designed to run on Imported Coal.➢ India’s largest covered coal shed with stacking
capacity of 3 Lac MT of coal.➢ Sea water is used for condenser and other
auxiliaries cooling. FRP based IDCT are used forcooling of CW.
➢ Plant is having FGD to reduce SOx from Flue Gas.
© Confederation of Indian Industry
1. Sp. Energy Consumption in last 3 years
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1. Sp. Energy Consumption in last 3 years
Reasons for Variation:
1.In FY 16-17 and FY 17-18, due to lessdemand in market compared to FY 15-16,PLF is low. Also units run on partial loadingnumber of times, contributing to higher APCand Heatrate.
2.To be competitive in power sales/market,the higher blend of LCV having high moistureand Low GCV coal is preferred, whichresulted in increase in Aux. Power andHeatrate.
3.However implementation of Encon Projectsrestricted further affect on Aux. power andHeatrate.
Parameter UOM 2015-16 2016-17 2017-18
Plant Load Factor % 79.6 63.6 64.0
Plant availability % 91.4 78.4 77.3
Utilization Factor % 87.1 81.1 82.8
Aux. Power Cons. % 8.91 9.26 9.23
Station GHR kCal/kWh 2337 2342 2361
Average GCV of coal kCal/kg 5847 5801 5006
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2. Information on Competitors, National & Global benchmark
Competitor-1 Competitor-2
NameJSW Energy
RatnagiriVIPL, Butiburi GMR Warora
JSW Energy, Vijaynagar
Capacity 4x300 MW 2x300 MW 2x300 MW 4x300 MWAux Power Con. % 9.23 8.30 8.23 7.72
G. Heat RatekCal
/kWh2361 2345 2297 2332
PLF % 64.03 63.92 71.30 53.27
➢ JSW Energy Ltd., Ratnagiri plant has closed cooling water cycle system and uses sea water for cooling purpose. Additional power requirement around 1% due to sea water IDCT and FGD compared to competitor plants.
© Confederation of Indian Industry7
2. Road Map to achieve National & Global benchmark
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3a. Energy Saving projects implemented in FY 2015-16
Sr. No. Title of ProjectAnnual Electrical
Cost SavingsAnnual Thermal
Cost SavingsInvestment
MadeRs. million Rs. million Rs. million
1Installation of VFD's at CEP & ID Fan (One spacer for 4 Fans) –Saving of 18080 MWh/Yr
63.28 0 90
2Modification in Cooling Tower Hot Water Duct of Unit-3-Saving of 3121 MT of Coal/Yr
0 16.08 22.1
3Installation of Condenser on load Tube Cleaning. Saving of 6306 MT of coal/Yr
0 32.49 6
4Replacement of Conventional lighting system with LED lights-Saving of 420 MWh/Yr
1.47 0 3.9
5 Pyrolysis System- Saving of 10 kL Oil 0.00 0.55 0.5
6Unit-3 Capital Overhauling to improve Turbine efficiency. Saving of 15974 MT of Coal/Yr.
0 82.30 20
7Parting Plane Inspection and repair of Feed water Heaters of Unit-2&3 and Unit#2 Condenser - Saving of 8278 MT Coal/Yr.
0 42.65 6
TOTAL FY 15-16 (With Investment) 64.75 174.07 148.5
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3a. Energy Saving projects implemented in FY 2015-16
Sr. No. Title of Project
Annual Electrical
Cost Savings
Annual Thermal
Cost Savings
Total Annual Savings
Investment Made
Rs million Rs million Rs million Rs million
1Excess Air Optimization. Saving of 4343 MWh and 14016 MT of Coal/Yr
15.20 72.21 87.42 NIL
2Temperature monitoring of High Energy drains. Saving of 3277 MT of coal/Yr
0.00 16.88 16.88 NIL
3Hotwell Makeup pump Interconnection Between U1/2 and U3/4. Saving of 205.8 MWh/Yr
0.72 0.00 0.72 NIL
TOTAL SAVINGS (Without Investment) FY 15-16 15.92 89.09 105.02 NIL
Without investment
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3b. Energy Saving projects implemented in FY 2016-17
Sr. No. Title of Project
Annual Electrical Cost
Savings
Annual Thermal Cost
Savings
Investment Made
Rs million Rs million Rs million
1De-staging of CEP in Unit-2. Saving of 630 MWh/Yr.
2.21 0 0.9
2Modification of Cooling Tower Hot Water Duct in Unit-1. Saving of 1727 MT coal /Yr.
0 10.13 22.1
3Modification of Cooling Tower Hot Water Duct in Unit-2. Saving of 2479 MT coal /Yr.
0 14.54 22.1
4Replacement of conventional lighting with LED lights. Saving of 539 MWh/Yr..
1.89 0 4.22
5Replacement of RH attemperation C.V. to avoid passing. Saving of 292 MT coal /Yr
0 1.71 0.02
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3b. Energy Saving projects implemented in FY 2016-17
Sr. No. Title of Project
Annual Thermal Cost
Savings
Total Annual Savings
Investment Made
Rs million Rs million Rs million
6Improvement in THR of Unit-1 due to changing of turbine insulation from Alumino-silicate to Ceramic MAT. Saving of 20374 MT coal /Yr
119.52 119.52 20
7Condenser cleaning & maintenance of online ball cleaning system during every opportunity to improve THR. Saving of 33332 MT coal /Yr
195.53 195.53 1.44
8
Installation of new weigh bridge at Silo-2 & Shifting of 60T weigh bridge from main gate to Silo-1 due to which savings in truck fuel achieved by reducing vehicle movement.
1.5
TOTAL Saving (With Investment) FY 16-17 319.15 341.43 72.28
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3b. Energy Saving projects implemented in FY 2016-17
Sr. No. Title of Project
Annual Electrical
Cost Savings
Annual Thermal
Cost Savings
Investment Made
Rs million Rs million Rs million
1
Provision of graphic for monitoring of the heat rate impact due to deviation in major parameters so as to take quick actions for any deviation & to monitor accountability of operator. Saving of 4541 MT coal /Yr
0 26.64 NIL
2Optimization of RH Temp Control system by introducing RH platen outlet temp as feed forward input to secondary PID of RH Temp control loop. Saving of 7866 MT coal /Yr
0 46.14 NIL
3Carry out High Energy Drain Survey on regular intervals as well as after every unit start up. Saving of 2500 MT coal /Yr
0 14.66 NIL
4CEP discharge pressure set point optimization. Saving of 2806 MWh/Yr
9.82 0 NIL
TOTAL Saving (Without Investment) FY 16-17 9.82 87.44 0
Without investment
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3c. Energy Saving projects implemented in FY 2017-18
Sr. No. Title of ProjectAnnual Electrical
Cost Savings
Annual Thermal Cost
Savings
Investment Made
Rs million Rs million Rs million
1Modification of Cooling Tower Hot Water Duct in Unit-4. Saving of 1162 MT coal /Yr
0 6.81 22.1
2Replacement of hydraulic coupling by spacer in Unit-2 ID Fan-A, Unit-3 ID Fan-B, Unit-4 ID Fan-A. Saving of 398 MWh/Yr.
1.4 - 1.26
3Replacement of conventional lighting by LED lights. Saving of 271.7 MWh/Yr
0.95 - 2.00
4Replacement of BFP-2A, BFP-3B, BFP-3C, and BFP 4B recirculation control valves. Saving of 557 MWh/Yr.
1.95 - 2.80
Total Saving (With Investment) FY 17-18 4.3 6.81 28.16
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3c. Energy Saving projects implemented in FY 2017-18
Sr. No. Title of project
Annual Electrical Savings
Annual Electrical Cost
Savings
Investment Made
kWh Rs million Rs million
1Optimization of service air pressure by reducing IFC pressure set point from 6.5 ksc to 5.3 ksc.Saving of 398 MWh/Yr
43200 0.15 NIL
2Stopping of one number LDO pump by charging interconnection valve.
7440 0.03 NIL
3Reduction in CEP header pressure from 22 ksc to 18 ksc in Unit-1. Saving of 244.8 MWh/Yr
0.86 0 NIL
4Reduction in CEP header pressure from 22 ksc to 18 ksc in Unit-3. Saving of 432 MWh/Yr
1.51 0 NIL
Without investment
© Confederation of Indian Industry
3c. Energy Saving projects implemented in FY 2017-18
Sr. No. Title of Project
Annual Electrical Cost
Savings
Annual Thermal Cost
Savings
Investment Made
Rs million Rs million Rs million
5Carry out High Energy Drain Survey on regular intervals as well as after every unit start up. Saving of 10548 MT of Coal /Yr
0 61.77 NIL
6
DCS Page display for Monitoring performance affecting controllable parameters shift-wise (SH & RH temperatures & attemperation) so as to take quick actions for any deviation & to monitor accountability of operator. Saving of 3555 MT of Coal /Yr
0 20.82 NIL
Total Saving (Without Investment) FY 17-18 50642.37 82.77 NIL
Without investment
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4. Innovative Projects implemented
1. Installation of VFD in Induced draught fans (ID Fans) and replacement of hydraulic coupling with spacer coupling.
Source of idea:
➢ Higher aux power consumption in ID fan compared to otherunits . Slip losses in ID fan hydraulic coupling increases thepower consumption.
Innovation details:
➢ VFD based ID Fan is a known & proven technology, however,at JSWEL we have installed VFD in ID Fan and to extractmaximum benefits out of it, hydraulic coupling is replaced bydirect spacer shaft keeping other set up unchanged.
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4. Innovative Projects implemented
2. Reduction in CEP header pressure from 22 ksc to 18 ksc in Unit-1 and Unit#3 by balancing of CEP.
Source of idea:
➢ After installation of VFD in CEP and benchmarking with other unit at same load, observed that inunit#1 and 3 CEP taking more current.
Innovation details:
➢ After analysis it observed that with VFD speed reduction CEP Vibration increases.➢ CEP balancing done to shift the high vibration speed range and CEP speed is further reduced to
reduce power consumption.
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4. Innovative Projects implemented
Source of idea:
➢ Suggestions and corrective action based on the daily parameter review.
Innovation details:➢ Efficiency department do the heatrate
calculation based on last day parameters. Sothe loss observed in report can not berecovered. So need for online lossavailability for DCS operator arrived so thatimmediate corrective action can taken.Based on that DCS page developed tomonitor controllable parameter lossesshiftwise in monetary term.
3. DCS Page display for Monitoring & maintaining of unit performance affecting controllable parametersshift-wise (SH & RH temperatures & attemperation) so as to take quick actions for any deviation & tomonitor accountability of operator.
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5. Utilisation of renewable energy sources
UtilizationCheckUtilization of Rain Water for Process use from Water HarvestingCheck Dams:
➢Daily 700 m3 of raw water is utilized for process requirement➢2 no’s of dams having storage capacity of 25000 M3 and 15000 M3each constructed in company owned land.➢Two no’s of pump are installed at dam to pump water to ClarifiedWater Tank through filtration plant.➢About 25 % of process water requirement is fulfilled through thiswater harvesting project.
•Rain water used for year 2016-17: - 78,565 M 3•Rain water used for year 2017-18: - 100,137 M 3..
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5. Utilisation of renewable energy sources
SolarSolar light – To increase the acceptability ofrenewable energy, JSW Energy has provided 125solar lights in the local community. These lights is notonly reducing energy consumption but also reducingan expenditure for power utilization.
BioBio gas unit – 30 bio gas unit have been suppliedand commissioned till now in this localcommunity. Use of wood has drastically reducedby using bio gas.
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Utilization of Plastic waste:➢Waste plastic generated from packing from incoming spare parts.
➢The plastic is processed through plastic pyrolysis machine and thepyrolytic oil generated for the same is used as fuel with LDO duringboiler light up.
➢ 50 kg plastic generate around 25 lit. oil.
▪Quantity of oil generated in year 2016-17- 86 Ltr.
▪Quantity of oil generated in year 2017-18- 104 Ltr
6. Utilisation of waste material as fuel
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6. Utilisation of waste material as fuel
Solid waste generated in canteen :-➢Fed to Bio gas plant. Gas generated is utilized as fuel
for cooking in plant canteen.
Sewage Treatment Plant:-
➢ Capacity 18 m3/day
➢Installed in plant as well as in township fortreatment of sewage. Water generated used forgardening and horticulture purpose.
◻Total fresh water saving FY 2016-17= 2368 M3
◻Total fresh water saving FY 2017-18= 2400 M3
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Main GHG is release of CO2 after coal combustion.
7. GHG Inventorisation
Year Ton of Co2 / Per MW Electricity Generation
2014-15 0.712015-16 0.782016-17 0.732017-18 0.74
Public Disclosure:-
1. GHG data is submitted to Central Electricity Authority(CEA).
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8. Green Supply Chain
•Project-1: Installation of Weighbridge below Ash Silo to reduce turn around time of Ash carrying bulkers
•Description:➢Before installation of Ash bulkers weighing done on weighbridge around
200 mtr distance. ➢With less tonnage of Ash in bulker, bulkers again come to Silo to fill it. More
Turn around time and more fuel consumption for Transportation.➢After installation of weighbridge below the Silo, the turn around time reduced
and saving in fuel for Bulkers.
•Benefits: Reduction in transportation fuel consumption and turn around time of Ash carrying bulkers reduced.
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8. Green Supply Chain
•Project-2: Implementation of use of Cape size vessels (1.5 LakhMT) instead of Panamax (0.75 Lakh MT) for transportation of imported coal.
• Supplier is identified based on the criteria that more number of cape size vessels shall be scheduled for transportation of coal.
• Description: Due to use of higher capacity cape size vessels, number of vessels has reduced which has resulted in reduction in transportation cost along with reliability in coal stock.
• Benefits: Reduction in CO2 emissions in transportation
© Confederation of Indian Industry
8. Green Supply Chain
•Project-3: Procurement of energy efficient lighting & air conditioning ( BEE Star rated)
• Supplier is identified and evaluated as per BEE Certified Rating
• Description: At JSWELR, while purchasing appliances like lighting, air conditioning systems at plant as well as at township, purchasing of BEE Star rated product is made mandatory.
• Benefits: Reduction in power consumption by 14 kWh
•Project-4: Minimum use of printers and print papers
• Description: To minimise e-waste, one central printer at one floor is used.Refilled tonners are used.
• Benefits:- Reduction in e-waste and print papers.
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9. Team work, Employee Involvement & Monitoring
© Confederation of Indian Industry
9. Team work, Employee Involvement & Monitoring
© Confederation of Indian Industry
9. Team work, Employee Involvement & Monitoring
Prize distribution of‘Ignite’ Competition
Energy Conservation Quiz competition
for Employees
Energy ConservationAwareness programmefor JVM School Children
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9. Team work, Employee Involvement & Monitoring
Projects implemented Through Kaizens
YEAR No of Projects/ ideas received
No of Projects Approved
No of Projects Implemented
FY 15-16 97 32 26
FY 16-17 63 32 12
FY 17-18 55 25 8
Number of Small projects implemented based on the suggestion from Employee and Associated Employee
© Confederation of Indian Industry
◻ List of some of projects implemented through Kaizen FY 17-18
31
9. Team work, Employee Involvement & Monitoring
Sr. No
Description
01 Provision of partition in AHP 12 & 34 control rooms & provision of carpet flooring to improve AC efficiency.
02 Logic modification for AHS cooling standby pump pickup on Pr. Low as well as running pump off/trip.
03 Provision of FGD aeration fan trip alarm on DCS
04 Provision of pressure gauge in header of boiler scanner air fan system.
05 Provision of Hotwell makeup pump current on DCS along with high & low current alarm on SOE
06 Provision of design value of total air flow and secondary air flow with respect to generation and total coal flow on DCS page
07 Installation of PVC coated copper tubing's in ash handling system.
08 Interconnection line from Unit-2 AST header to Unit-4 AST header provided
© Confederation of Indian Industry
9. Team work, Employee Involvement & Monitoring
Online monitoring of Aux Consumption of Critical Equipments through EMS (Energy MonitoringSystem): This online monitoring gives an added advantage of identifying individual units aux.performance, trending of efficiencies of significant equipments and optimum schedule distributionamong the units to achieve minimum station net fuel cost.
© Confederation of Indian Industry
9. Team work, Employee Involvement & Monitoring
OSI PI - Real time Power Plant Performance Monitoring System: This online monitoringgives an added advantge of identifying individual units performance, trending of efficiencies andoptimum schedule distribution among the units to achieve minimum station net fuel cost.
© Confederation of Indian Industry
10. Implementation of ISO 50001
Received ISO 50001 certification from July 2015
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10. % investment on Turnover
Year Turnover Rs. In Crores
Investment on ProjectsRs. In Crores.
% Investment on Turnover
FY 15-16 5959.42 1.26 0.02%
FY 16-17 4040.97 12.75 0.31%
FY 17-18 4212.05 2.37 0.05%
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AWARDS & ACCOLADES
36
FY 2016-17
© Confederation of Indian Industry
AWARDS & ACCOLADES
37
FY 2016-17
IPPAIInnovatio
© Confederation of Indian Industry
AWARDS & ACCOLADES
38
FY 2016-17JSW Energy Ltd. Ratnagiri was awarded with first prize for 11th State level award for excellence in Energy Conservation and Management.
Maharashtra Pollution Control Board has awarded 5 star rating to JSW Energy Ltd., Ratnagiri on the basis of the Particulate Matter emission.
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AWARDS & ACCOLADES
39
FY 2017-18
© Confederation of Indian Industry
Thank You
Committed for “Better Tomorrow”