JSW Energy Limited, Toranagallu

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Workshop on "Best Practices in Energy Efficiency in Thermal Power Sector"

Reliance Dahanu Thermal Power Station Dahanu

VIJAYANAGAR PLANT

860 MW RATNAGIRI

PLANT 1200 MW

BARMER PLANT 1080 MW

HYDRO POWER PLANT

1391 MW

JSW ENERGY POWER GENERATION BUSINESS IN INDIA

The existing operational capacity of 4,531 MW will be augmented with projects worth 7,269 MW under implementation and development phase identified in several states 2

PLANT PERFORMANCE HIGHLIGHTS

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98.46

95.66

97.17

Availibility (%)

7.72 7.64

7.16

APC (%)

101

94.75

97.36

PLF (%)

30%

32%

34%

36%

38%

40%

INDIA AUSTRALIA CHINA US JSWEL,TORANAGALLU

32.8% 33.3%

35.7% 35.8%

38.0%

ENERGY EFFICIENCY %

* Source: Heat & Power, CSE

SPECIFIC ENERGY CONSUMPTION

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2245

2253

2251

2012-13 2013-14 2014-15

Station GHR, Kcal/KWH

0.14

0.09

0.13

2012-13 2013-14 2014-15

SOC,ml/KWH

0.36

0.33

0.34

2012-13 2013-14 2014-15

Sp. Coal Consumption, Kg/KWH

ENERGY MANAGEMENT SYSTEM AT JSW,VIJAYANAGAR

Energy policy established

Structured Energy Management Cell

Identify, Evaluate and Analyze Energy use &

Consumption ( Coal, Oil, electricity , Water)

Daily energy deviation reporting

Total 25 Energy auditors

E LAN (EMS) System for Energy Consumption Monitoring.

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ENERGY MONITORING

ONLINE ENERGY MONITORING SYSTEM

TOTAL – 254 NEW METERS INSTALLED (HT + LT)

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Time Synchronization of all the meter and Server through EMS software.

Available plant network is being utilized for the metering system.

Meters data is collected in redundant servers for computing &

calculation.

Infinite Web clients developed for viewing & analyzing of data.

Automatic report generation with emailing facility is developed to

eliminate manual intervention

Monitoring real time parameters individual equipment wise

Trending & customizable dashboards are additional advantage.

EMS - UNIQUE FEATURES

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DASH BOARDS

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Sl No Monitoring and Review Chaired by Participants Frequency

1 Daily Monitoring of Generation, APC, SFOC, SHR, Water , Environment, & safety

Head of Plant Section In

charges,SCE and HOD's

Daily

2 MOPR (Monthly operation performance review)

Head of Plant Section In

charges,SCE and HOD's

Monthly

3 Performance Optimization Group (POG) APC, HEAT RATE & WATER

Head of Plant POG (cross

functional team), HOD,s

Monthly

4 Internal Audit of IMS ISO 9001,14001 and ISO 50001:2011

Management Representative

All Employees Half yearly

ENERGY REPORTING & MONITORING

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ENERGY CONSERVATION PROJECTS

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ENERGY CONSERVATION FOR LAST THREE YEARS

Year of Implementati

on

Annual Electrical Savings achieved

Annual thermal savings

Total Annual Savings

Invest. Made

Units Million

Rs Million

Tons of Fuel

Rs Million

Rs Million

Rs Million

2014-2015 5.63 28.12 2238 15.20 43.32 18

2013-2014 4.84 23.47 1883 13.17 36.64 7

2012-2013 0.39 1.98 154 1.06 3.04 0.44

Total 10.89 53.57 4275 29.43 83 25.44

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LIST OF ENCON PROJECTS PLANNED FOR NEXT 3 YEARS

Sl. No

Asset Title of the Project

1 SBU-1 Installation of VFD for ID Fans

2 SBU-1 Installation of VFD for PA Fans

3 SBU-1 & 2 Installation of energy efficient fan blade in cooling tower (40 nos)

4 SBU-2 Unit 2

ID fan- Replacement of Hydraulic coupling with Direct shaft to save coupling losses

5 SBU-1 & 2 Installation LED lights phase wise

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S.No Project Taken

up

Per unit Energy consumed prior to

implementing Encon

Per unit energy consumed after implementation

of Encon

Improvement

(%)

1 Installation of VFD to ID FAN

&CEP

1430 Kwh

950 Kwh

1210 Kwh

750 Kwh

15.4%

21.0%

2

Installation of Spacer

Coupling For ID fans

1210 Kwh 1110 kwh 8.26%

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ENCON PROJECTS

PROJECT -1 REDUCTION OF ID FAN POWER BY INTRODUCTION OF VFD

SAVINGS ACHIEVED 210 KWH AT FULL LOAD OPERATION PER FAN

ID FAN

DESCRIPTION UOM BEFORE VFD AFTER VFD

MOTOR SPEED RPM 745 610

FAN SPEED RPM 550 550

HYDRAULIC COUPLING % 55 63

POWER CONSUMED KW 1430 1210

ENCON PROJECTS

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SAVINGS ACHIEVED 190 kWh AT FULL LOAD OPERATION

CEP

DESCRIPTION UOM BEFORE VFD AFTER VFD

DEAERATOR LEVEL CONTROL VALVE OPEN

% 42 - 45 53 - 55

DP ACROSS CV MPa 1.61 0.76

POWER CONSUMED KW 950 750

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PROJECT -2 REDUCTION OF CEP POWER BY INTRODUCTION OF VFD

ENCON PROJECTS

ID fan energy saving enhanced by eliminating hydraulic coupling with Hollow Flexible spacer Coupling resulting in Energy Saving of 100 kW.

PROJECT -3 REPLACEMENT OF HYDRAULIC COUPLING WITH SPACER COUPLING

ID FAN - VFD WITH SPACER COUPLING ID FAN - VFD WITH HC

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ENCON PROJECTS

PROJECT -4 RETROFITTING BOILERS TO ACCOMMODATE WASTE GAS

JSW Steel main vertical of JSW group has a integrated steel plant with 14mtpa capacity – furnace with varying size and technology

Excess gas left over is being flared to atmosphere (4-5 lakh Nm3/hr)

Introduced gas burners in all 300MW boilers to accommodate 1,00,000 Nm3/hr of gas so that flaring of waste gas is avoided.

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ENCON PROJECTS

RESULTS

Saving in coal consumption - 5.0 Lac tons/annum

(15tph/boiler)

Utilisation of Waste gas - 2,00,000 Nm3/Hr

Over all Boiler efficiency reduced by- - 1-1.5%

Anticipating the increase in Exit temperatures due to gas firing additional sacrificing baskets were installed at Hot end of Air Heater

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PROJECT -4 RETROFITTING BOILERS TO ACCOMMODATE WASTE GAS (Contd…)

ENCON PROJECTS

OTHER ENERGY CONSERVATION PROJECTS

GHG Reduction Project

Year of Implement

Savings Investment Payback

Million (Rs.)

Million (Rs.)

Months

SBU-1&2: 2 nos. of energy efficient CT fans blades installed saving of 40kwh

2014-15 0.911 1.1 6

Installing bypass chute to transfer coal from conveyor CJ 9C1 to 10C1 eliminating operation of Coal conveyor CJ 9RC1

2014-15 0.544 0.7 17

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GHG Reduction Project

Year of Implement

Savings Investme

nt Payback

Million (Rs.)

Million (Rs.)

Months

Installation of LED lighting in control rooms, VFD and Training hall

2013-14 0.0005 0.70 Within

5 Years

Optimized ESP Rapping motors operation

2013-14 1.8990 -

PA header pressure optimization 2013-14 2.1080 -

Replacement of passing BFP recirculation control valves ( 4 Nos.) in SBU-2 units

2013-14 18.97 3 2

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OTHER ENERGY CONSERVATION PROJECTS

GHG Reduction Project

Year of Implement

Savings Investment Payback

Million (Rs.)

Million (Rs.)

Months

Replacement of passing CEP recirculation control valve

2012-13 1.35 0.44 4

ACW pumps(4 Nos.) casing internal surface applied with ceramic type antifriction coat

2012-13 0.68 0.0017 -

ACW Pumps: Recommissioned with modified impellers

2012-13 1.01 0.0025 -

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OTHER ENERGY CONSERVATION PROJECTS

B V SRINIVAS

KUMAR IVATURI

VISHAL SANKAR SONI

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“You can’t change the past but you can change the future, It's Upon you what you Want!”-Go Green