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© Confederation of Indian Industry

JSW Energy Limited, Ratnagiri

Sh. Dipak Patil AGM Sh. Vijaykumar Likhitkar Sr. Manager


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.


1. Sp. Energy Consumption in last 3 years


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


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


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


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


3b. Energy Saving projects implemented in FY 2016-17


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




Annual Thermal Cost

Savings

Total Annual Savings

Investment Made


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




Annual Electrical

Cost Savings

Annual Thermal

Cost Savings

Investment Made


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


3c. Energy Saving projects implemented in FY 2017-18

Sr. No. Title of ProjectAnnual Electrical

Cost Savings

Annual Thermal Cost

Savings

Investment Made


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



Sr. No. Title of project

Annual Electrical Savings


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





Savings

Annual Thermal Cost

Savings

Investment Made


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


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.



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.



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.


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..


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.


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


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


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).


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.



•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



•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.


9. Team work, Employee Involvement & Monitoring



Prize distribution of‘Ignite’ Competition

Energy Conservation Quiz competition

for Employees

Energy ConservationAwareness programmefor JVM School Children



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


◻ List of some of projects implemented through Kaizen FY 17-18

31


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



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.



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.


10. Implementation of ISO 50001

Received ISO 50001 certification from July 2015


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%


AWARDS & ACCOLADES

36

FY 2016-17


AWARDS & ACCOLADES

37

FY 2016-17

IPPAIInnovatio


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.


AWARDS & ACCOLADES

39

FY 2017-18


Thank You

Committed for “Better Tomorrow”

11.JSW Energy Limited, Ratnagiri...&RQIHGHUDWLRQ RI ,QGLDQ ,QGXVWU\ 7KDQN

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