Hindalco Industries Ltd Hirakud Power Plant_536... · Hindalco Industries Ltd. Novelis Largest...

Hindalco Industries LtdHirakud Power

1993-94 2005-062004-05 2012-20132006-07

Presenters:Mr. Rajeev Kumar - AGM (Technical Services, Energy Manager)Mr. Kailash Pradhan – GM (Operation)Mr. Nimai Mahapatro – AVP (Operation , Energy Auditor)

Agenda

About Hindalco

Hirakud CPP at a Glance

Plant Performance

Energy Conservation Initiatives

Renewable Energy & Environmental Initiatives.

System & Culture

CSR @Hirakud

Awards & Accolades

Our PurposeWhy we exist, why we do it & what we do?

WE MANUFACTURE MATERIAL THAT MAKE THE WORLD

Greener Stronger Smarter

About Hindalco

Integrated Aluminium

Alumina 3.9 Million TPA

Primary Aluminium – 1.3 Million TPA

VAP - 481 KT

Copper Major Player in India

Copper Cathode - 376 KT

DAP - 301 KT

Aluminium Downstream

#1 Rolled Product Supplier Worldwide

Shipments – 3.1 MT

Global leader in aluminium recycler

Focused on premium segment

Hindalco Industries Ltd.

NovelisLargest

aluminium FRP producer globally

Aditya & Mahan1st quartile cost

producer of Aluminium

Utkalamongst the lowest cost

producers of Alumina

One of thelargest custom

copper smelter at single location in

Asia

Global operations across

11 countries

Revenue ofUSD 17 billion

EBITDA ofUSD 2.2 billion

~35,000 employees across

the world

2005

1x 67.5 MW TG, 2 x 145 TPH HOT CYCLONE CFBC BOILER

Unit#1

1 x 100 MW TG, 2 x 165 TPH COLD CYCLONE CFBC BOILER

Unit#5


Unit#2


Unit#4


Unit#3

2008

1993 2006 2013

Journey So Far

6

2874.1

2988.1

2838.0

2500.0

2600.0

2700.0

2800.0

2900.0

3000.0

3100.0

FY18 FY19 FY20

CPP – Generation ( MU )

70.18

72.96

69.11

60.000

62.000

64.000

66.000

68.000

70.000

72.000

74.000

FY18 FY19 FY20

Plant Load Factor (%)

TG Availability (%)

0.071

0.105 0.114

0.000

0.020

0.040

0.060

0.080

0.100

0.120

0.140

FY18 FY19 FY20

Sp.Oil Cons. ( ml / kWh )

92.3 94.9

85.2

70.0

75.0

80.0

85.0

90.0

95.0

100.0

FY18 FY19 FY20

Plant Performance

7

9.39 9.36

9.60

8.800

9.000

9.200

9.400

9.600

9.800

10.000

FY18 FY19 FY20

Auxiliary Energy Cons. ( % ) Plant Heat Rate ( kCal / kWh )

DM Water Cons.( % ) Raw Water Cons ( Lit / kWh )

1.02

0.46

0.62

0.000

0.200

0.400

0.600

0.800

1.000

1.200

FY18 FY19 FY20

26202612

2634

2500

2550

2600

2650

2700

FY18 FY19 FY20

2.53

2.55

2.6

2.48

2.5

2.52

2.54

2.56

2.58

2.6

2.62

FY18 FY19 FY20

Less efficient TG-1 in Operation for

175 Days

Less efficient TG-1 in Operation for

175 Days

Plant Performance

8

Plant Performance

5190

4124

2265

0

1000

2000

3000

4000

5000

6000

FY-18 FY-19 FY-20

Saving (Mtoe )

FYSaving in Electrical

Energy , KwhMtoe

FY-18 19810000 5190

FY-19 15790000 4124

FY-20 8600000 2265

2653

2634

2590

Hindustan Zinc CPP Hirakud FY20 Plan FY21

Plant Heat Rate ( kCal / kWh)

7.5

9.68.8

KPC Limited CPP Hirakud FY20 Plan FY21

Auxiliary Energy Cons (%)

National Bench Mark

Target for FY21

Benchmarking

SlNo

Project DetailsAnnual Electrical Saving

( kWh)Annual Thermal

Saving ( Kcal)Investment

(Rs in Million)

1Installation of Screen in Unit#3 CHP System to control fines and enhance boiler efficiency

15242400 20

2Addition of ECO-1 Coil in Boiler#12/13 for reduction in Back end temp.

732600 25

3 Capital Overhauling of TG-3 37620000 70

4 Capital Overhauling of TG-5 56221200 50

5 Installation of VAM in Unit-4 &5 Cluster 960000 50

6Compressed Air Network Audit and implementation of action plan for reducing aux. power consumption thru Stoppage of Service / Instrument air compressors.

1927200 0.7

7Replacing 2 nos of existing ACW Pump (1500m3/h)with low capacity (1000 m3/h) Pump

2592000 4.2

8 Commissioning of VAM 3rd Phase at CPP 362400 0.7

9Replacement with low energy efficient BFP with high efficiency pump in Unit-4 & 5

2880000 1.6

Totalized Savings: 8721600 (8.72 MU) 109816200 222.2

Major Encon Projects Planned In FY21

Aux. Power Reduction Plan:

Turbine Heat Rate Improvement Plan:

Boiler Efficiency Improvement Plan:

Plant Heat Rate Improvement Plan:

Auxiliary Energy Reduction Initiatives: FY'20

SL.No InitiativesExecution

Month

Annualized Electrical Energy Savings

Annualized Cost Savings

Cost Involved(Cr.)

RemarksMU Rs in Cr.

1 Retrofitting of HT VFD drives in ID Fans of Boiler-12B by replacing the existing hydraulic couplings Apr'19 0.385 0.146 0.60

2Stoppage of 1 CWP in either Units-2,3,4 & 5 as per operation requirements for Partial load operations of TGs

Apr'19 -Dec'19

4.488 1.705 0.00

3 VFDs installed in CCCW Pump of Unit-2 Jul'19 0.051 0.019 0.104 VFDs installed in CCCW Pump of Unit-3 Jul'19 0.034 0.013

5 Retrofitting of HT VFD drives in ID Fans of Boiler-4 by replacing the existing hydraulic couplings Sept'19 0.339 0.129 1.20

6 Retrofitting of HT VFD drives in ID Fans of Boiler-5 by replacing the existing hydraulic couplings Nov'19 0.305 0.116 1.20

7Replacement of Inefficienct M/s - Sulzer Make pump by energy efficient M/s-KSB Make pump with stage reduction in 3 BFP-2

Nov'19 0.141 0.054 0.70

8 Operational Excellence thru Stoppage of 2 nos of CT Fans in Unit-2,3,4 & 5 for seasonal benefit Nov'19 0.426 0.162 0.00

9 Operational Excellence thru Stoppage of CT Fans in Unit-1, 4 & 5 for seasonal benefit Dec - Feb 0.474 0.180 0.00

10Replacement of Inefficienct M/s - Sulzer Make pump by energy efficient M/s-KSB Make pump with stage reduction in 5 BFP 1

Jan'20 0.402 0.158 0.70

11 Retrofitting of HT VFD drives in ID Fans of Boiler-3 by replacing the existing hydraulic couplings Jan'20 1.548 0.588 1.20

12 "Providing Clarified return from unit - 2 & 3 bed ash coolers as make up for unit - 1 cooling tower.“ Feb'20 0.010 0.004 0.00

Totalized Summary 8.60 3.27 5.70

Energy saving projects implemented in FY’20

Auxiliary Energy Improvement Initiatives: FY'19

SL.No Initiatives Execution MonthAnnualized Electrical

Energy SavingsAnnualized Cost

SavingsCost

Involved(Cr.)Remarks

MU Rs in Cr.1 Retrofitting of HT VFD drive in Unit-3, CEP-1 Mar'18 0.317 0.13 0.452 Stoppage of 3 nos of Cooling Water Pumps for Partial Load operations in TG-2,4 & 5. Apr-May 2.660 1.06 Nil

3 Stoppage of 2 nos of Cooling water pumps for Partial load operations in TG-2 & 4 Jun'18 1.812 0.72 Nil

4Retrofitting of variable frequency drives in Induced Draft Fans 11A & 11B by replacing of existing hydraulic coupling in Boiler-11

Apr'18 1.065 0.43 1.110


May'18 0.534 0.21 1.11

6 Retrofitting of HT VFD Drives in 2 CEP-2 May'18 0.310 0.12 0.457 Retrofitting of HT VFD Drives in 4 CEP-2 May'18 0.504 0.20 0.45

8Replace M/s Sulzer make Unit#3 BFP-1 with M/s KSB make because of low discharge flow and high Aux. Power

ConsumptionMay'18 0.547 0.22 0.80

9 Retrofitting of HT VFD Drives in 5 CEP- 2 Jun'18 0.088 0.04 0.4510 Operation of single BFP (Instead of 2 BFPs) in Unit-3 for Partial Load operations of TG Aug'18 1.123 0.45 Nil11 Installation of small cooling water pump with 3000 m3/hr capacity (2 CWP-1) Dec'17 0.329 0.13 0.500

12Stoppage of 1 no of CWP in TG Side as per Operational requirements & to meet Generation Demand after 5 nos of Boiler failures

Oct'18 1.110 0.443 Nil

13 Stoppage of 1 no of CT fan thru out the day and an additionaal CT fans in night for Unit 235 Nov'18 0.108 0.043 Nil

14 Stoppage of CWP in Unit-2 & 4 for Partial load operations (Before TG-4 SSD) Nov'18 0.310 0.124 Nil15 Stoppage of 2 nos of CT Fans each in Unit-2,3,4,5 for winter impact Dec'18 - Jan'19 0.893 0.357 Nil16 Installation of Small CW Pump of Capacity 3000 m3/hr in 4 CW Pump-1 Dec'18 0.434 0.173 0.5017 Stoppage of 1 CWP in Unit-2,3 & 5 for partial load operations / Winter Impact Dec'18 / Jan'19 2.187 0.874 Nil18 Installation of small capacity pump of capacity 3000 m3.hr in 5 CW Pump-3 Jan-19 0.138 0.055 0.5019 Stoppage of 1 CWP in Unit-2,3,4,5 for partial load operations / winter impact Jan'19 1.044 0.417

20 Modified M/s KSB Make Pump with 11 stages instead of existing 12 stages in 2 BFP-3 Feb'19 0.053 0.021 0.13


Mar'19 0.050 0.020 0.45

22 Installation of small capacity pump of capacity 3000 m3.hr in 3 CW Pump-3 Mar'19 0.170 0.068 0.50

Totalized Savings: 15.79 6.31 7.40


Auxiliary Energy Improvement Initiatives: FY'18

SL.No InitiativesExecution

Month

Annualized Electrical Energy Savings

Annualized Cost Savings

Cost Involved (Rs in Cr.)

Remarks

MU Rs in Cr.

1 Stoppage of 2 nos of Cooling water pumps for part load operation of units. Apr'17-Aug'17 4.70 1.79 Nil

2 Removal of one stage in condensate extraction pump of Unit-5, CEP-1 Apr'17 0.31 0.12 0.00

3Installation & replacement of less efficient M/s Sulzer make pump with M/s KSB make BFP pump in 4 BFP-3 under the supervision of OEM

May'17 0.59 0.22 0.80

4 Installation of Centrifugal compressor having capacity of 105 m3/min 2 nos (Phase-I) May'17 1.15 0.44 1.75

5 Retrofitting VFD in 2 number of ID fans in Blr 6. Jul'17 0.89 0.34 1.11

6 Stoppage of a set of ID fans & SA Fans in Boiler-9 Jul'17 0.15 0.06 Nil

7 1 no.of stage removal (Out of 4 nos) in 4-Condensate Extraction Pump-1 Aug'17 0.37 0.14 0.00

8 Retrofitting VFD in 2 number of ID fans in Blr 8. Aug'17 0.94 0.36 1.11

9 Retrofitting VFD in 2 number of ID fans in Blr 7 Oct'17 0.69 0.26 1.11

10 Stoppage of 4 nos of Cooling Water pump in unit-2, 3,4,5 for winter impact / Part load operations Nov'17- Mar'18 8.62 3.27 Nil

11 Stoppage of 4 nos of Cooling tower fans in Unit-2,3,4 & 5 for winter impact Nov'17- Feb'18 0.72 0.27 Nil

12 Stoppage of a set of ID fans & SA Fans in Boiler-5 Nov'17-Feb'18 0.31 0.12 Nil

13Suction Header of Unit#4 and Unit#5 Raw Water discharge pump modification from 450 NB to 600 NB, resulted in Stoppage of Unit #3 Raw Water Pump

Jan'18 0.12 0.05 0.01

14 Installation of small cooling water pump with 3000 m3/hr capacity (2 CWP-1) Dec'17 0.09 0.03 0.70

15 Retrofitting VFD in 2 number of ID fans in Blr 9 Feb'18 0.09 0.04 1.11

16 Retrofitting of HT VFD drive in Unit-3, CEP-1 Mar'18 0.01 0.00 0.50

17 Installation of Centrifugal compressor having capacity of 105 m3/min 2 nos (Phase-II) Mar'18 0.08 0.03 1.75

Totalized Savings: 19.81 7.53 9.94


Journey Towards Energy Conservation

Journey Towards Energy Conservation:

10.85 9.89 9.28 9.39 9.36 9.6

0.924.22

9.08

18.5815.79

8.6

28.40

36.25

15.48

99.41

88.75

57.02

FY15 FY16 FY17 FY18 FY19 FY20

Aux Annual Electricity Saving (MU) Investment Made (Rs million)

Innovative Project 1

Unit # 5 Boilers Siphon is single chamber with 25 nos. of nozzles with the

fluidization from PA air & Continuous compressed air required for material

flow from Siphon to the bed in Boiler # 12 & 13.

Without the instrument air there was restriction of re-circulating material

flow and subsequent forced stoppage / trip of boilers.

For resolving this perennial problem, In house Team brain stormed and

came up with one idea to reducing the height from 800 mm to 550 mm.

After modification & successful trial of Boiler # 12, same In-house design

replicated in Boiler # 13 in Month of June 2020

Now Both Boiler # 12 & 13 is running smoothly with PA Air only, after

modifications.

Results – energy saving 140 Kw.

Innovation Project 2

Retrofitting of 22 nos of HT Variable Frequency Drives in Induced Draft

Fans of Boiler-4 to 13 by replacing of existing hydraulic couplings.

Tangible Benefits

Total energy saving in all the ID fans of Boiler- 1980 KW

Water Saving of 400 m3/h

Existing 1500 m3/h Pump could be replaced with 1000 m3/h.

This has resulted in saving of 80 KW.

Intangible Benefits-

• Less stress to HT motors due to reduced starting in rush current

• Improvement of power factor from 0.67 to 0.96

Innovation Project 2

Auxiliary Cooling

water Pump

Centrifugal Compressors

75 M3/ Hr

Plate Heat Exchangers

550 M3/Hr

Ash Handling Plant 100 M3/

Hr

GeneratorCooler

Turbine Oil Cooler

Instrument Air Compressors

55 M3/hr

Boilers Bed Ash ,Cyclone Ash , ID Fan

fluid coupling

150 M3/hr

100 M3/Hr

Innovation Project 2Water Quantity (M3/h)

S.N Service Normal Operation DesignFuture Requirement (after

executing all suggested projects)Remarks

1 Turbine Oil Cooler 0 0Unit #4 and Unit#5 Turbine Oil cooler is done through DM Water

(CCW Pump).

2 Generator Cooler 0 0Unit #4 and Unit#5 Turbine Oil cooler is done through DM

Water (CCW Pump).

3Boilers Bed Ash ,Cyclone Ash , ID Fan

fluid coupling150 300 100

Unit#5 has only Two Boilers. Bed Ash Coolers are Air Cooled.ID fan fluid coupling to be replaced with VFDs. Only water

requirement for Cyclone Ash cooling.

4Ash Handling Plant including

Compressors 126 50 100

5 IA Compressors 45 45 45

6 AC Compressors 10 10 10

7 Plate Heat Exchangers 550 550 550

Normal opr: When ACW water will be used in the Generator cooler, then CCW water shall be 550-350=200 m3/hr. With the

same terminal temperature difference, ACW shall be 200m3/hr. Design Condition :Tota CCW flow is 550 m3/hr. This water to be cooled by ACW. With the same terminal temperature difference,

ACW shall be 550 m3/hr.

8 Vapor Absorption Machine 0 0 0Cooling Water will be given from Unit#4 /5 both. In case of

Unit#4 S/D , Bigger pump of Unit#5 will cater to the requirement

9 Centrifugal Compressors 0 0 75

10 Total Water Requirement 881 955 880

11 Total Requirement with 10 % margin 969.1 1050.5 968

12 Existing Pump Capacity (M3/h) 1500 m3/h

13 Suggested Pump (m3/h) 1000 M3/h

14 Design Motor Kw 260 180


Advantages: Heating Surface Area of Eco-1

Coil will increase from 820 m2 to 1025 m2.

Total Boiler Surface Area will increase from 5385 m2 to 5590 m2.

Boiler Capacity will increase from 165 TPH to 170 TPH.

APH O/L Temp will decrease from 155°C to 145°C thereby reducing the dry flue gas losses.

Boiler Efficiency will increase by 0.25 %

Addition of ECO-1 Coil in Boiler#12/13 for reduction in Back End Temp.

6

Energy Efficiency in Boiler Feed Pumping system. Payback : 2 Years

Stage 1

Saving - 24 KW

• Less Feed water pressure & Flow available to Boiler

• Passing of BFP recirculation is arrested by installation of control valve

Reliability issue

• Sulzer make Pump was having issue of frequent failure of profile ‘ O ‘ring

• Cut marks and thick scratches observed on the it’s surface of Barrel

Stage 2

Saving - 124 KW

• High efficient catridge in the existing barrel is retrofitted

• For right sizing the no of Stage reduced from 12 to 11 stages

• Plant reliability Enhanced


ENCON PROJECTS COMPLETED:

Project Title: Installation of VFD on Condensate Extraction Pump in TG - 2,3,4 & 5

Project Title: Boiler Feed Pump Over- Hauling / Replacement with Energy Efficient pumps of Unit 3, 4 & 5

Condensate Extraction Pump Variable Frequency Drives

• 49 kW / Pump

• 1.41 Million kWh / Annum

Energy Savings:

• 124 kW / Pump

• 3.57 Million kWh / Annum

Energy Savings:

OH - Fluid coupling

Pump cartridge

ENCON PROJECTS COMPLETED:

Project Title: Capital Overhauling of TG # 2,3,4 & 1

Project Title: Performance improvement in Condenser & Cooling Tower in Unit-2,3,4 & 5

TG-4 Rotor Thread out Rotor Sand Blasting Guide Blade Carrier HPH-5 Internal

Inspection

Condensers O/HCondensers Opening Cooling Tower O/H V Bars & drift eliminators in CT

Renewable Energy Sources:

30 MW Solar Plant at Aditya Aluminium within Same Cluster

51.70

63.41

86.5989.24

2016-17 2017-18 2018-19 2019-20

Yearly Utilization in %

24.42

100.00 100.00 100.00

Apr -20 May-20 Jun-20 Jul-20

Monthly Utilization in % FY 21

Ash Utilization

Captive Brick Plant @HIL

Environment Management – Ash Utilization:

Ash being placed over

the Geo-synthetic

reinforcement

Strengthening and capacity enhancement of Ash Dyke thru

“State of Art technology”, “Geo Synthetic Polymer Grid”, in phased manner.

Connection of reinforcement

with the wall panel

Geo synthetic

reinforcement

placed against a wall

Environment Management – Emission:

To meet the revised SPM norms, successful Implemented HFTR ( State of Art Technology, 1st time in ABG )

Trigger of the Project

• Notification from MOEF regarding the reduction of emission level of existing ESP to below 50mg/Nm3 , The project conceived through senior level management

Uniqueness of the project; is it a new concept?, is it new application-wise?

• New technology implemented for the 1st time in entire ABG group.

• HFTR removes the complexity of adding extra fields .

• Less maintenance compared to single phase transformer.

• Very fast spark rate response.

• Reliability enhancement of ESP by having a standby transformer with HFTR with an addition of changeover switch

• Operation and monitoring of HFTR performance through MODBUS communication.

• Installation of 2way changeover switch for hopper contact for both conventional transformers and HFTR

We have taken following initiatives to conserve water which ultimately resulted in reduction in specific water consumption -

Modernization of our 2 RO based ETPs of having capacity 250 KLD & 50 KLD

Upgradation of RO stream & UF stream of CPP RO plant of capacity 120 m3/hr

Utilization of blow down water instead of clarified water in Gardening/Dust Supression

Construction of Nalgonda pit for pre treatment of water

Utilization of RO reject in ash quenching/conditioning

Water Rationing concept adapted by internal Task Force

Environment Management – Water Management

34

New flow meters were Installed across plant to maintain ZLD through continuous online real time water balance

DCS Real Time ViewInline Flow Tx Open Channel Measurement

Environment Management – Water Management

Raw water tank

Clarifier#1, (100) Clarifier#2, (206) Clarifier#3, (230) Clarifier#4, (190)Clarifier#5, (200)

DM Plant(18)

Service Water

(12)

Drinking Water (72)

CT#1 CT#2 CT#3 CT#4 CT#5

Neutralization Pit, (1)

Oil Water Separator Pit#2

FRP(2)

Blr#1-13, (12)

From STP 2 ,

(4)

Process cooling & misc. U#4-5

To CTBD Clarifier

(20)

From Dam

To Smelter 235 kA, DC 3,

DC 4 (40)

STP 1 500 KLD

Water Balance Diagram of Hindalco Hirakud CPP (For Dry Season)

FRP (7)

Gardening(55)

Raw Water

Treated Water

Effluent

DM Water

Process Cooling Water & Misc U#1-3

CPP, Smelter, Colony (72)

STP 2 300 KLD

To CT-3 (4)

Reuse CHP dust suppression

(18)

Nalgonda Treatment

Common Monitoring Basin

Ash Conditioning,

(20)

From RO Plant, (57)

Oil Water Separator Pit#1

CTBD Clarifier

From CTBD # 2,3,4,5

(77)RO Plant

From RO Plant

To DM Plant

To CT#4(57)

RO Reject Tank(20)

From CMB

(926)

To CTBD clarifier(20)

To CTBD Clarifier

(18)

Service Water(11)

From Unit 4 CTBD

Brick Plant(4)

Road Spray(10)

To CTBD Clarifier

(19)

* All Figures are in m3/hr

Clarifier#4

TO CGP(4)

BD To RO

BD from CGP

Performance Monitoring & Gap Analysis

Monthly TG, Boiler & equipment's performance monitoring as per standards ASME PTC 4.0 for gap analysis and suggesting improvement plan.

Shutdown / Overhauling Monitoring

Advanced Condition Monitoring

Condition monitoring activities transformed in to many folds, by using ultrasonic technology, thermography.

Maintenance KPI

Monitoring KPIs i.e. EEA, MTBF, PM compliance on monthly basis and tracking and monitoring all major equipment's maintenance with proper review

Review of every major shutdown & overhauling with deviation and gap analysis for better execution.

Best Practices – Maintenance & Reliability

SPM Technology Lube Oil Analysis Thermography HT Side Testing

Vibration Monitoring

Advanced analytics

Dynamic Balancing

Mechanical Impurities

Viscosity Testing

NAS

Hot Spot

Boiler Insulation

Bearing

Tan Delta

DGA

LA 3rd Harmonic

Ultrasonic Technology

Compressed Air Audit

Partial discharge/ arching/tracking

Air Ingress/ Valves & Drains passing

Flow measurement

PID Testing

Contact Resistance measurement

Moisture Motor Current Signature Analysis

Terminal Box

TAN

Best Practices – Maintenance & Reliability

4-SECONDARY CRUSHER MOTOR-A

U#5 DCS AND TCC CHANNEL FAILURE

USE OF INSULATED BEARING IN HT MOTOR HAVING VFD

INSTALLATION OF CARBON BRUSH FOR ROTOR EARTH

PREDICTIVE MAINTENANCE THROUGH MCSA

FREQUENCY OF PM REDUCED TO 03 MONTH FROM 06 MONTH

DEDICATED EARTH FOR DCS AND TCC PANEL

SCHEDULE EARTH CHECKING IN EVERY SIX MONTH

6 ID FAN A MOTOR WITH VFD

CUTTING THE PLATE IN BETWEEN IM-SILO AND EXTENDED NEW SILO.

DV-12 PIPE-IN-PIPE WAS REPLACED AND COMPLETE CHECKING OF COMPONENTS

FILLING TIME IS OPTIMISED ACCORDING TO VESSEL PRESSURE

EXTERNAL BOOSTER LINE WAS CLOSED IN DV 12

RELIABILITY OF UNIT 3 INTERMEDIATE SILO CONVEYING

Reliability Centered Maintenance /CBM :

Vacuum Circuit Test Partial Discharge Checking

Air Leakage Test Flow Measurement

Well Established energy management cell headed by DH-TPP.

Daily monitoring of Heat rate and Aux. power deviation report.

Analysis of equipment performance for deviation.

Identification of energy conservation scope.

Theme base suggestions/Kaizens scheme under “Energy Saving ”.

Feasibility study of suggestions & submit proposal for sanction.

Preparation of detail action plan.

Weekly review to monitor project progress.

Benefits analysis after project implementation.

Sustainability of the project

Energy Monitoring

Energy Monitoring

Energy Monitoring

Implementation of ISO 50001

Energy Monitoring

Energy Campaign @Hirakud Power

Digitalization Initiatives

Digital Twin for Optimization of Plant performance.- Rs 26 Lakhs

Energy Reconciliation by digitalization of Coal Supply Chain Tracking System – Rs 250 Lakhs

In-house Data Analytics through Atom Software for process optimization

Process Historians for our Plant Automations – Rs 94 Lakhs

Digitalization Project List for Hirakud Power

S. No. Project List Status Budget Timeline Accountable Team Coordinator Team Owner Status(Updated)

1Mtell solution for Hirakud ( from Power 18 Nos assets has been taken for the project)

Ongoing (agents deployed for all assets, alerts yet to come and go live is to be done after historian

implementation)60 lacs, FY20 Nov'20

Kailash Pradhan, Ashwini, Kunal Singh Mahapatra, Sushant Jena, Samir

Mahapatra, Vivekanand, Jitendra Dwibedy

Mayur Kakade, Kshitish Bisi, Akash Bhatter

Nimai Mahapatro

1.Data sharing is in progress (Fortnightly) 2.Alerts are coming and disscusion is going on

with EQUINOX team. 3.Knowledge sharing sessions with plant

people is in progress.

2Digital Twin implemenation at unit-4 in

Hirakud PowerPO released , Job to be started after lockdown

26.5 lacs, FY20

Sept'20

Kailash Pradhan, Santosh Gupta, GP Behera, S. Verma, ,Amiya Pradhan,

Parthsarathy, Udayan Chaupattanaik, Jitendra Dwibedy


Nimai Mahapatro Rajeev Ranjan

1.Remote Connection from 15th july. 2.DCS data sharing through OPC from

1st AUG.

3 Coal Supply Chain Tracking SystemHHD is used for driver & vehicle registration, vehicle

inspection,Blend tool run already started. RFIDs to be installed in 5000 trucks.

250 lacs (corp), FY20

June'20Hitendra, Jitendra Patang, Gyanaranjan ,

Saurav Panigrahi, Sasanka Datta, K. Reddy, Mrutyunjaya Panda

Akash Bhatter Nimai MahapatroSystem has been launched, usage and

stakeholders training u/p.

4Data Analytics project by Hirakud Power

plant team on Atoms software In Progress (daily discussion with GDNA happening,

submission of findings in June'2020)

No Inventment (In House

Team)

July'20Phalguni Mahanty,Dipankar Dey, Suraj Suna, Mamta Gupta, Rutuja Bezelwar,

Amit Kumar, Kunal Singh,Akash BhatterMayur Kakade

Rajeev Ranjan Kumar

1.SOP compliance completed. 2.Plots has been drawn for dependent

variables. 3.correlation between dependent variables and efficincy in

progress. 4.Regression model to be make.

5Process Historian implementation for

power plant

Techno-commercial offer received from four vendors- Honeywell, Equinox, OSI PI, AspenTech.

Technical evaluation under progress94 lacs, FY21 Nov'20

Asit Pusty, Suraj Suna, Mrutyunjaya Panda,, Ashwini, Sukumar Patra, Ravindra

Ojha, Sudhanshu Mishra, Vivekanand, Samir Mahapatra, Shambhu Patel


Anshu Babu1.Technical evaluation completed. 2.Vendor approval and technical

specification submitted to purchase.

6Integrated Safety solution for Hirakud

cluster ( Hirakud Smelter, Power and FRP )-POC

Technical Discussion has been done With M/S Hacklab for POC

POC for free of cost

July'20Pranesh Gupta, Amiya Pradhan, Shambhu

Patel, Sunil PatelMayur Kakade, Akash

BhatterAnshu Babu Scope finalization u/p

7VEDA implementation for the Hirakud with

GDNA for Post Covid 19 solutionsTechnical discussion in progress with GDNA

Budget to be finalized

from Corp with GDNA

Dec'20Sunil Patel, Neelabh Sanger,Nihar Ranjan

Rout, AbhayAkash BhatterMayur Kakade

Nimai MahapatroAnshu Babu

1.Camera list of Areas identified has been shared. 2.Videos and photos of concerned areas shared

with GDNA team.

Digitalization Initiatives

Plantation Details

Sr. No Year

No. of Saplings

Planted

Area

Covered

(Acres)

Species Planted

1 Up to 2006- 07 4,19,865 250.12

2 2007-08 33,000 12.0Chakunda, Gambhari, Sisam, Krushna Chuda,

Radha Chuda, Jammun & Neem









7 2012-13 25,000 10.0Neam, Karanja, Sisam, Krushna Chuda, Radha

Chuda, Cassia Fistula, Alstonia & Kadamba

8 2013-14 30,000 13.0Neem, Karanja, Sisam, Cassia Fistula, Alstonia,

Kadamba, Mango, Jamun etc

9 2014-15 12,000 6.0Neem, Karanja, Sisam, Cassia Fistula, Alstonia,

Kadamba, Mango, Jamun etc

10 2015-16 10,000 5.0Bamboo, Sisoo, Karanja, Alstonia, Chhatiana,

Mango, Jamun etc

11 2016-17 21,175 10.6Bamboo, Ficus, Alstonia, Champa, Plumeria

Alva etc

12 2017-18 13,500 6.75Krushnachuda, Radhachuda, Acassia, Ficus,

Jamun, Arjun, Ashok etc

13 2018–19 10,500 5.25Bamboo, Sisam, Cassia Fistula,

Alstonia,Kadamba, Mango, Jamun

Total 6,86,440 364.72

Green Belt Cover @Hindalco

Green Cover @Ash Mound

Google Map Top View Shows Impeccable Green Cover

IMS

WCM

LEGAL & STATUTARY

NORMS

REGULATORY NORMS

COPORATE POLICY

GUIDEINES

REVIEW MECHANISM

SYSTEM

Certification Year

ISO 9001 2008, 2015

ISO 14001 2004, 2015

ISO 18001 2007

ISO 45001 2017

ISO 50001 2015, 2020

Systematic Approach

Warranty card for all the critical equipment's.

Standardization & Development of OPL format / MP Design Formats

Model area Identification, development action plan, criteria, system / process implementation.

Several new equipment of NDT are introduced for better break down analysis & condition monitoring.

03 No of RCM projects has been successfully completed i.e. Boiler Feed pump (2B), Secondary crusher & Intermediate silo

Training on RCM has been given to total 06 person as on day.

10 No of job has been handed over to operation for Autonomous Maintenance.

Asset Criticality Review, Asset Record & Tag no display on every equipment.

Digitalization of all documents & drawings,

Strengthening of PM & CM through On-line (Oracle),

Skill level enhancement on Problem solving tools, Improvement in MTTR & MTBF.

Optimization of Inventory level, Strengthening of Ownership Culture, Model area development, Reliability Centered Maintenance.

Asset Management:

Conversion of municipal solid waste into pallets / LDO to use in Boilers

Conversion of fly ash / bottom ash into sand with help of VNIT ,Nagpur

Use of Bio mass Briquettes/ Natural Husk in Boilers 4. Use of PPF in place of LDO

Reduction of rejects in existing RO plant and installation of mechanical Vapor recompression system for treating RO reject water

100% FO Replacement thru Coal Gasification Project.

Installation of Screen in Coal Handling plant

Air Cooled Bed Ash Cooler to replace water cooled bed ash cooler

ESP Healthiness / Revamping

Controlling of load fluctuations and Maintaining ZERO Import export of Power.

TG Deck Foundation study by CPRI

R&D @Hirakud

CSR Activities

Health

• Immunization coverage for 2561 babies;

• OPD facility for 1630 patients;

• Dental camp for 63 patients & support for family planning

camps;

• Eye camp (Cataract Operation) for 138 poor people;

• First aid box distributed to near by schools; and

• Blood grouping of 783 students.

Livelihood

Vegetable seeds support to 84 farms

Agricultural input to farmers.

Sr.

No

.

Main Area

Propos

ed

Budget

(Rs. in

Lakhs)

1Health and

Hygiene10

2 Education 10

3

Skill Development

& Self

Employment

10

4 Drinking Water 10

5 Infrastructure 10

6

Environment

Protection and

Others

10

Total 60

Beyond The Fence:

• Empowerment through Employability and Entrepreneurship for the youths of Sambalpur and its vicinity Rational: To provide high quality multi skill training to the unemployed youths that are in sink with the local industry demand. The training is focused not only on domain skills but also in the overall grooming of the trainees such as personality development, basic communicative English, digital literacy, financial literacy and social skills. Most of the domain skills are imparted through content partners from the industry so that the curriculum matches with the latest skills in demand by the industry.

Project Details-1 :

• Promote small family by supporting to family planning programmes Rational : More People were not coming for Family planning operation. We have encouraged them by providing necessary supports for attending camps, nutritional food kit for operates and incentives for health workers, also logistic supports provided to Hirakud Hospital for organising camps

Project Details-2 :

• Cataract Screening & operation for community Rational : To reduce blindness & develop a Cataract free community we have taken initiatives by providing necessary supports for organising screening camps and taking care of patients from operation to post operation care along with providing spectacles at free of cost. In cases, special eye transplantation has been done by using the donated eye.

Project Details-3 :

Awards & Accolades

Awards & Accolades

Grow Care CSR Award in GOLD Category

International Golden Globes Tiger Award to HINDALCO HIRAKUD for “ Best training Initiatives in Manufacturing Sector”

Gold Award in NAMC

NCQC (National Convention On Quality Concept) 2019, Varanasi

Thanks!Mr. Rajeev Kumar- AGM (Technical Services) -9090090209 , rajeev.kumar @ adityabirla.comMr. Kailash Pradhan – GM (Operation)-9090064304 , [email protected]. Nimai Mahapatro – AVP (Operation)-9090079516 , [email protected]

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