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

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Hindalco Industries Ltd Hirakud Power 1993-94 2005-06 2004-05 2012-2013 2006-07 Presenters: Mr. Rajeev Kumar - AGM (Technical Services, Energy Manager) Mr. Kailash Pradhan – GM (Operation) Mr. Nimai Mahapatro – AVP (Operation , Energy Auditor)
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Transcript of 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

    1 x 100 MW TG, 3 x 155 TPH COLD CYCLONE CFBC BOILER

    Unit#2

    1 x 100 MW TG, 3 x 155 TPH COLD CYCLONE CFBC BOILER

    Unit#4

    1 x 100 MW TG, 3 x 155 TPH COLD CYCLONE CFBC BOILER

    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

    5Retrofitting of variable frequency drives in Induced Draft Fans 10A & 10B by replacing of existing hydraulic coupling in Boiler-10

    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

    21Retrofitting of variable frequency drives in Induced Draft Fans 13A & 13B by replacing of existing hydraulic coupling in Boiler-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

    Energy saving projects implemented in FY’19

  • 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

    Energy saving projects implemented in FY’18

  • 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

  • Innovative Project 3

    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

    Innovative Project 4

  • 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#4CT#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

    Mayur Kakade, Kshitish Bisi, Akash Bhatter

    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

    Mayur Kakade, Kshitish Bisi, Akash Bhatter

    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

    3 2008-09 25,200 16.0Chakunda, Gambhari, Sisam, Krushna Chuda,

    Radha Chuda, Jammun & Neem

    4 2009-10 31,000 10.0Chakunda, Gambhari, Sisam, Krushna Chuda,

    Radha Chuda, Jammun & Neem

    5 2010-11 30,000 10.0Chakunda, Gambhari, Sisam, Krushna Chuda,

    Radha Chuda, Jammun & Neem

    6 2011-12 25,200 10.0Chakunda, 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]