BEST PRACTICES ON ENERGY SAVINGS - Knowledge … · Aluminium & Power, Jharsuguda SESA STERLITE LTD...

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Aluminium & Power, Jharsuguda SESA STERLITE LTD JHARSUGUDA , ODISHA BEST PRACTICES ON ENERGY SAVINGS

Transcript of BEST PRACTICES ON ENERGY SAVINGS - Knowledge … · Aluminium & Power, Jharsuguda SESA STERLITE LTD...

Page 1: BEST PRACTICES ON ENERGY SAVINGS - Knowledge … · Aluminium & Power, Jharsuguda SESA STERLITE LTD JHARSUGUDA , ODISHA BEST PRACTICES ON ENERGY SAVINGS

Aluminium & Power, Jharsuguda

SESA STERLITE LTD

JHARSUGUDA , ODISHA

BEST PRACTICES ON ENERGY SAVINGS

Page 2: BEST PRACTICES ON ENERGY SAVINGS - Knowledge … · Aluminium & Power, Jharsuguda SESA STERLITE LTD JHARSUGUDA , ODISHA BEST PRACTICES ON ENERGY SAVINGS

Aluminium & Power, Jharsuguda

GROUP PHILOSOPHY

Humble

Smart Hungry

Our DNA

Our Vision

“We will be the world’s

most admired company that

consistently defines the

leading standards in our

businesses, making our

stakeholders proud to be

associated with us.”

Our Values Our Mission

“Our mission is to be a

world-class metals and

mining group and generate

superior financial returns.”

Growth

Trust

Sustainability

Excellence

Entrepreneurship

4/29/2015 KEP WORKSHOP

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Aluminium & Power, Jharsuguda

BUSINESS DIVERSIFIED

→ Sesa Sterlite, a Vedanta

Group company is one of the

world‘ largest global diversified

natural resource company.

→ FTSE 100 London Stock

Exchange listed company.

→ Operations span across India,

Sri Lanka, Africa, South Africa,

Europe and Australia.

4/29/2015 KEP WORKSHOP

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Aluminium & Power, Jharsuguda

PLANT LOCATION

INDIA

PLANT

SITE

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ODISHA

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Aluminium & Power, Jharsuguda

PLANT PROFILE

Capacity of 3615 MW

ISO 9001,14001,50001 & OHSAS 18001 Certified

Water Source – Hirakud Reservoir

Coal Source- Mahanadi Coal Fields

High Concentration Slurry Disposal

Hybrid ESP with SPM level < 40mg/Nm3

4/29/2015 KEP WORKSHOP

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Aluminium & Power, Jharsuguda

IMPLEMENTATION & LEARNINGS

ISO 50001 ENERGY MANAGEMENT SYSTEMS

4/29/2015 KEP WORKSHOP

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Aluminium & Power, Jharsuguda

ENERGY MANAGEMENT TEAM- POWER

4/29/2015 KEP WORKSHOP

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Aluminium & Power, Jharsuguda

CPP :

Kick-off ISO 50001:2011 30th Jan 2012

Stage-2 Audit (Certification Audit) 12th - 15th Sept 2012

IPP :

Kick off ISO 50001:2011 30th Jun 2012

Certification Audit 26th Feb 2013 to 1st Mar 2013

MILESTONES ISO 50001

4/29/2015 KEP WORKSHOP

Page 9: BEST PRACTICES ON ENERGY SAVINGS - Knowledge … · Aluminium & Power, Jharsuguda SESA STERLITE LTD JHARSUGUDA , ODISHA BEST PRACTICES ON ENERGY SAVINGS

Aluminium & Power, Jharsuguda

ENCON EFFORTS & BENEFITS

Implementation of Total Quality Mngt. Culture

Implementation of New Technologies

Implementation of IT Enablement in procuring Energy Efficient Equipments

Improvement in Process & Operational Practices

Development and Implementation of Innovative and Breakthrough Energy Efficiency Improvement Projects.

Daily Monitoring of Specific Consumptions & Deviation Analysis

Energy Improvement Projects is linked to Individual KRA’s

Energy Audit by CII in June’11 & ISO 50001 implementation & certification in the year of 2012

SHR = 2442 Kcal/kwh ; APC= 9.66%; SOC = 0.11 ml/kwh 2014-15

2010-11 SHR = 2678 Kcal ; APC= 10.14%; SOC= 0.80ml/kwh

4/29/2015 KEP WORKSHOP

SHR = 2337 Kcal/kwh; APC= 8.08%; SOC= 0.38 ml/kwh IPP

CPP

SHR= 2430 Kcal/kwh; APC= 9.89%; SOC= 1.12 ml/kwh IPP

CPP

2012-13

Page 10: BEST PRACTICES ON ENERGY SAVINGS - Knowledge … · Aluminium & Power, Jharsuguda SESA STERLITE LTD JHARSUGUDA , ODISHA BEST PRACTICES ON ENERGY SAVINGS

Aluminium & Power, Jharsuguda

1. Selective Soot-blowing:

Optimized need based soot-blowing resulting in flue gas exhaust temperature from

141°C to 137°C and reduction in super-heater spray by 2% that is 8 T/hrs.

Annual saving- 5.82 MTOE

2. Stoppage of purging of HFO guns:

Purging of HFO guns on regular basis are stopped

Annual saving- 35.93 MTOE

3. Optimization of key Process Parameters:

Operational optimization by maintaining the technical parameters like Main-steam

pressure, main-steam temperature , etc. near to design value.

Annual saving- 3.17 MTOE

PROCESS IMPROVEMENT (9X135 MW)

4/29/2015 KEP WORKSHOP

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Aluminium & Power, Jharsuguda

6. Optimized running of Dry Ash conveying system:

Running of Dry-Ash conveying system in level mode from timer mode resulting in

stoppage of 1 compressor.

Annual saving- 188.31 MTOE

5. Optimized use of Compressor:

Stoppage of Dryers in Service Air system (6 nos.)

Arresting of leakages and rectification of intake valve passing resulting in stoppage

of 1 compressor.

Annual saving- 188.31 MTOE

4. Cooling Tower fan door plugging:

Plugging of the holes of Cooling Tower fans, hence reduction in fan loading via

excess air leakage and improvement in vacuum.

Annual saving- 22.14 MTOE

4/29/2015 KEP WORKSHOP

PROCESS IMPROVEMENT (9X135 MW)

Page 12: BEST PRACTICES ON ENERGY SAVINGS - Knowledge … · Aluminium & Power, Jharsuguda SESA STERLITE LTD JHARSUGUDA , ODISHA BEST PRACTICES ON ENERGY SAVINGS

Aluminium & Power, Jharsuguda

7. Optimization in Electrostatic Precipitator :

The 1st Field ESP hopper heaters are switched off during normal running of the

units.

Each hopper consist of 2 heaters of 3Kw each.

Annual saving- 72.31 MTOE

8. Improvement in Belt utilization:

Improvement in Belt utilization by rectifying the track hopper, ILMS (In-line

magnetic separator and replacement of existing conveyor with the new conveyor.

Annual saving- 65.34 MTOE

9. Operational Optimization of Mills Lube-Oil pump:

Stoppage of stand-by Mills Lube-Oil pump

Annual saving- 45.19 MTOE

4/29/2015 KEP WORKSHOP

PROCESS IMPROVEMENT (9X135 MW)

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Aluminium & Power, Jharsuguda

PROCESS IMPROVEMENT (4X600 MW)

4/29/2015 KEP WORKSHOP

1. Increase Reheater temp(528°C to 538°C):

Daily Monitoring HRD sheet

SADC checking(S/D)

Burner tilt operation

Increase in HRH temp from 528 to 538°C

Unit heat rate improved by 2 kcal/kwh

Annual saving- 1653 MTOE

2. Identification and plugging of air ingress points in flue gas ducts

Flue gas, air duct leakage detection resulting in ID FAN Avg. current reduced from 246 A to

234 A. (power reduce by 0.5 MW) &.083 % APC reduction

Annual saving- 376 MTOE

3. PA Fan power reduction by arresting air leakage

Seal air leakage detection and PA hot air and cold air to mill leakage detection in U#2

resulting in PA FAN A- Current reduced from 106 A to 86 A and PA FAN B-108 A to 82 A

(Power reduced by 0.95 MW) APC reduced by 0.158 %.

Annual saving- 715 MTOE

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Aluminium & Power, Jharsuguda

4/29/2015 KEP WORKSHOP

4. Optimization of idle running hours of drives:

Stopping of One CW pump as per circulating water inlet and outlet

temperature.

Annual Saving: 393 MTOE/Unit

Stopping of one Vacuum pump as per condenser Vacuum

Annual Saving : 216 MTOE/Unit

Stopping of DP pump for makeup in condenser.

Annual Saving - 203 MTOE/Unit

Implementation of shutdown checklist to Stop the running equipment

Annual Saving - 144 MTOE/Unit

During Unit Startup use TDBFP instead of MDBFP

Annual Saving - 120 MTOE/Unit

Stopping of 1 seal air fan(250 kw) by arresting seal air leakages

Annual Saving: 41 MTOE/Unit

PROCESS IMPROVEMENT (4X600 MW)

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Aluminium & Power, Jharsuguda

4/29/2015 KEP WORKSHOP

5. Reduction of start up time:

Six Sigma project implemented to reduce very hot startup

Step by step activity/process prepared

Very hot startup time reduced to 1hr 35min to 1hr 10min

saving- 63 MTOE

1.60 1.16

0.00

0.50

1.00

1.50

before after

Very hot Start up

PROCESS IMPROVEMENT (4X600 MW)

6. Reduction of startup time by Deaerator pegging in boiler and turbine preheating

Boiler feed water temp increased to 121°C (earlier 50°C) by deaerator pegging. Which

raised the furnace temp to 97°C (earlier temp was 40°C).Time reduced to 20 min

During turbine preheating ,HP inner /outer casing temp was raised to 204 /192° C instead

of 150°C ,which has reduced the time of heat soak by 2 hrs.

SAVING : reduction in oil consumption during startup to 121 MTOE

Reduction in time by heat soaking 4.5

2.5

1

2

3

4

5

before after

2.29

1.52

0

1

2

3

before after

Reduction in time by increasing furnace temp

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Aluminium & Power, Jharsuguda

4/29/2015 KEP WORKSHOP

8.Reducing the output voltage of lighting transformer

No of taps were reduced in lighting transformer with a reduction in voltage from 432 volts to

415 volts resulted in power saving of 30.2 Kwhr per day

Annual Saving: 1 MTOE

9.Increasing ash utilization by disposing Ash through trucks

Reduction of ash conveying from transfer silo to terminal silo, as D-pump ash conveying

capacity averagely 260tns/hr. Stopped one compressor.

Geho pump dispose 260T of ash per hour. As 4,500T of ash transported through trucks,

per month 18 hours of Geho running hour reduced.

Saving of 10654 kwhr power per month and specific power: 0.05 Kwhr/MT

Annual saving: 7 MTOE

PROCESS IMPROVEMENT (4X600 MW) 7. Reduction of Number of Trips :

Identify the root cause of all unit outages

Implement recommendation of Trip analysis

saving- 150 MTOE/Unit

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Aluminium & Power, Jharsuguda

4/29/2015 KEP WORKSHOP

10.Increasing CHP conveyor belt utilization

Increasing coal conveyor belt utilization from 50 % to 60 % (from 1500 TPH to 1980 TPH)

to minimize the power consumption with saving of 922 MWhr

Annual Saving:97 MTOE

11. Reduction of Rake Turn Around Time

Elimination of idle running time of stream and compressor with a saving of 263 MWhr

Annual Saving: 22 MTOE

PROCESS IMPROVEMENT (4X600 MW)

Page 18: BEST PRACTICES ON ENERGY SAVINGS - Knowledge … · Aluminium & Power, Jharsuguda SESA STERLITE LTD JHARSUGUDA , ODISHA BEST PRACTICES ON ENERGY SAVINGS

Aluminium & Power, Jharsuguda

1. Condenser Cleaning (Jet, bullet & chemical):

Condenser Jet cleaning=1 unit; Bullet cleaning=4 Units; Chemical cleaning=1 unit

Average improvement of 20 kCal/kWh/Unit/Kpa in Heat Rate.

Annual saving- 148.74 MTOE

BEFORE AFTER

TECHNOLOGY IMPROVEMENT (9X135 MW)

4/29/2015 KEP WORKSHOP

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Aluminium & Power, Jharsuguda

2. Air Preheater seal and basket replacement :

Air Preheater Baskets and soft touch seals replaced resulting in Improvement of

boiler efficiency by 0.5%

Reduction in Primary Air Fan (PA) loading of 103 Kwh

Annual Saving: 620.50 MTOE

BEFORE AFTER

4/29/2015 KEP WORKSHOP

TECHNOLOGY IMPROVEMENT (9X135 MW)

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Aluminium & Power, Jharsuguda

3. CT Fans Blades Replacement :

For each unit, 5 CT cells are designed.

Weight of GRP blades is more than FRP blades.

Total 13 nos. of GRP blades replaced with FRP blades.

Average Savings : 234.70 MTOE.

BEFORE AFTER

4/29/2015 KEP WORKSHOP

TECHNOLOGY IMPROVEMENT (9X135 MW)

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Aluminium & Power, Jharsuguda

4. Replacement of Old Chrome rollers with New

Sinter Cast Rollers & Liners

Rollers & Liners are replaced by New Sinter

Cast Rollers

Reduction in Mill power consumption by 30 KW.

Running hours increased from 6000 to 18000

hrs.

Savings : 17.54 MTOE.

BEFORE

4/29/2015 KEP WORKSHOP

TECHNOLOGY IMPROVEMENT (9X135 MW)

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Aluminium & Power, Jharsuguda

5. CW pump Impeller coating:

CW pump impellers coated with

Brush able coating

Reduction in CW pump loading

by 68 kw

Annual Saving: 45.19 MTOE.

4/29/2015 KEP WORKSHOP

TECHNOLOGY IMPROVEMENT (9X135 MW)

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Aluminium & Power, Jharsuguda

6. Ultrafilteration Installation to Reduce DM Water Consumption:

Installation of Ultrafiltration System to reduce the colloidal silica in

Demineralized (DM) water.

Reduction of Blow down losses by 80% & heat losses.

Annual Saving: Rs. 213.62 Million.

Ultra-filtration System

4/29/2015 KEP WORKSHOP

TECHNOLOGY IMPROVEMENT (9X135 MW)

Page 24: BEST PRACTICES ON ENERGY SAVINGS - Knowledge … · Aluminium & Power, Jharsuguda SESA STERLITE LTD JHARSUGUDA , ODISHA BEST PRACTICES ON ENERGY SAVINGS

Aluminium & Power, Jharsuguda

7. Modification of Fly Ash Conveying System:

Due to modification the consumption of compressed service air reduced

resulting in stoppage of 2 compressors.

Each of the units was provided with a separate air vessel to compensate the

fluctuations.

The ash collection vessel size was increased for ESP 3rd field and same was

placed in 4th field

Annual Savings: 376.61 MTOE

BEFORE AFTER

4/29/2015 KEP WORKSHOP

TECHNOLOGY IMPROVEMENT (9X135 MW)

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Aluminium & Power, Jharsuguda

Earlier Turbine hall & compressors house consisted of 72 & 16 electrics fans

respectively.

Each fan rated capacity 3 kw.

Electric fans are replaced by Eco ventilators (224+28) in TG Hall as well as in

Compressor house.

Energy savings : 199.39 MTOE

8. Installation of Eco Ventilators :

4/29/2015 KEP WORKSHOP

TECHNOLOGY IMPROVEMENT (9X135 MW)

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Aluminium & Power, Jharsuguda

Project :

Utilization of Waste Water :Effluent Treatment Plant - 2 (ETP) Commissioning.

Before:

More than 4000m3/day of waste

water was discharged out of the

plant

Specific water consumption was

high

After:

Waste water management by

treatment in ETP

Zero discharge of water out of

plant

Specific water consumption is

reduced

CPP Synergy Office CPP Switchyard CW Pump Area CT Fans Area

4/29/2015 KEP WORKSHOP

TECHNOLOGY IMPROVEMENT (9X135 MW)

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Aluminium & Power, Jharsuguda

Project :

ESP Bag Filter Retrofitting. Before:

Designed ESP had 5 fields

Ammonia dozing was in process

Avg. SPM was more than 100

mg/Nm3

After:

Last 2 fields replaced with Bag filter

Ammonia dozing stopped

Existing Ash Conveying system is

modified

Avg. SPM < 30mg/Nm3

BEFORE

AFTER

BEFORE

4/29/2015 KEP WORKSHOP

TECHNOLOGY IMPROVEMENT (9X135 MW)

Page 28: BEST PRACTICES ON ENERGY SAVINGS - Knowledge … · Aluminium & Power, Jharsuguda SESA STERLITE LTD JHARSUGUDA , ODISHA BEST PRACTICES ON ENERGY SAVINGS

Aluminium & Power, Jharsuguda

TECHNOLOGY IMPROVEMENT (4X600 MW)

AFTER

BEFORE

4/29/2015 KEP WORKSHOP

3. Reduction of power in CEP after removal of one stage

Removal of CEP stage in order to compensate energy loss due to throttling of deaerator

level control valve resulting in CEP Pump-Current reduced from 123A to 92 A. (0.45 MW

power reduced & 0.075 % APC

Annual saving- 167 MTOE

1. Boiler Modification(LTSH,ECO,RH):

Reduced the surface are of LTSH tubes and increase the contact area of economizer

bank which resulted in SH spray reduction and increase in feed water temp.

The modification includes

• LTRH zone curtailment by 120 tubes

• Installation of riffled tubes over exposed furnace water wall tubes

• LTSH tube curtailment by 1 bank

• Economizer zone extension by 1bank.

Annual saving- 4745 MTOE

2. Power reduction in CW pump due to speed reduction

Addition of no of rotor poles from 16 to 18 in CW pump in U#4 for speed reduction saving-

0.233 % APC CWP current reduced from 290 AMPS to 235 AMPS and 1.4 MW saving in

power consumption

Annual Saving: 520 MTOE

Page 29: BEST PRACTICES ON ENERGY SAVINGS - Knowledge … · Aluminium & Power, Jharsuguda SESA STERLITE LTD JHARSUGUDA , ODISHA BEST PRACTICES ON ENERGY SAVINGS

Aluminium & Power, Jharsuguda

AFTER

BEFORE

4/29/2015 KEP WORKSHOP

6. VFD installation in BA slurry pump

Installation of variable frequency drive in bottom ash slurry pump in U#1,U#2 with a saving

of 68 Kwhr

Annual Saving: 45 MTOE

Before After RPM 990 700-750 KW 135.5 67.3 KVA 160.1 68.4 KWH 3313 1152 KVAH 3881 1168

TECHNOLOGY IMPROVEMENT (4X600 MW)

7. Indigenization of ID fan motor

U#1 ID FAN 1A motor replaced with CGL make with a net saving per day with a new motor

@ 60kw. In addition to this there is a saving due to stoppage of 1 cooling fan having power

consumption 7.5 kw and one lube oil pump having power consumption 1.1 kw

Annual Saving: 9 MTOE

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Aluminium & Power, Jharsuguda

AFTER

BEFORE

4/29/2015 KEP WORKSHOP

9.Use of induction lamp in mill coal feeder

Incandescent lamp of 40 w were replaced by induction lamp of 18 Watt in all mill coal

feeders of U#1,U#2 and U#3 with a saving of 528 Kwhr per feeder per day

Annual Saving: 1 MTOE

TECHNOLOGY IMPROVEMENT (4X600 MW)

8. Implementation of auto timer in lighting system

Earlier for lighting there is no time limit .We have installed timer for illumination in different

area with a saving of 62 kwhr

Annual Saving: 1.95 MTOE

10.Installation of EPIC-3 controller in ESP field

In U#2 ESP field controller from Dalian Chinese make to EPIC-3 controller with a flexibility

of changing field charge ratio resulted in saving of 240 kwhr per day

Annual Saving: 1 MTOE

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Aluminium & Power, Jharsuguda

AFTER

BEFORE

4/29/2015 KEP WORKSHOP

11. Mill Hot air gate modification and mill lube oil system modification :

Mill Hot air gate modification and mill lube oil system modification in all 4 units resulting in

reduction of oil consumption by increasing equipment availability which is equivalent to

decrease in SOC by 0.2 ml/Kwhr

Annual saving- 159 MTOE

Mill HAG Modification Mill Lub oil system modification

TECHNOLOGY IMPROVEMENT (4X600 MW)

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DAILY MONITORING

4/29/2015 KEP WORKSHOP

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Aluminium & Power, Jharsuguda

DAILY MONITORING

Monitoring system

• Integrated Energy Meters are installed for HT & LT motors and configured in DCS. Meters used for all measurements are calibrated as per ISO Standards

• Related Process parameter are displayed on the DCS screen.

• All relevant energy data is captured from these resources at regular intervals by PDHR data.

4/29/2015 KEP WORKSHOP

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Aluminium & Power, Jharsuguda

TQM CULTURE

5S Certified

• 5S structure, zones created & effective audit is in place.

• 5S Awareness sessions are conducted for direct & indirect employees

• 6 zones and 24 Subzones

• Total employee engagement in 5S is 128 direct & 450 indirect

Quality Circle/ Lean Quality Circles

• Awareness training completed for 360 employees (SSL & Service provider)

• Total 20 QC teams formed Including SSL employee and Service providers

• Total 140 SSL employees and service providers are engaged in this initiative

Sig Sigma

• Wave-3 has 9 top priority projects driven by 55 employees

• 4 Team Leaders qualify for Black Belt Certification and 24 Team Members would qualify for Yellow Belt Certification.

4/29/2015 KEP WORKSHOP

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Aluminium & Power, Jharsuguda

Total Savings: 13077 MTOE

Total Savings:

13077 MTOE

CPP : 2482.82 MTOE

IPP : 10595 MTOE

ENCON SUMMARY IN 3 YEARS

4/29/2015 KEP WORKSHOP

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AWARDS & RECOGNITION

7th India Power Award 2014

Engineering Excellence Awards 2014

Excellent Energy Efficient Unit 2014

Top Plant Award -2014

4/29/2015 KEP WORKSHOP

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Aluminium & Power, Jharsuguda

AWARDS & RECOGNITION

6th India Power Award

2013

Engineering Excellence Awards 2013

Excellent Energy Efficient Unit 2013

National Energy Conservation Award-2012

National Energy Conservation Award-2011

4/29/2015 KEP WORKSHOP

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Aluminium & Power, Jharsuguda

THANK YOU

4/29/2015 KEP WORKSHOP